AD-A149 684
RADC-TR-84.16S 3Final Technical Report It
July 1984
MAINTAINABILITY TIME STANDARDS FORELECTRONIC EOUIPMENT
Boeing Commercial Airplane Company *
John Rose, John J. Voytko and Jesse A. Davolt 0
* S
APPROVED FOR PUMIC RELESE; DISTRIIUTION UNLIMITED DTICELECTEJAN 2 1985
L-j
ROME AIR DEVELOPMENT CENTERAir Force Systems Command -
r Griffliss Air Force Base, NY 13441
85 01 16 L 09
• , , -o .- . - • -*_ * -..- . . o..
This report has been reviewed by the RADC Public Affairs Office (PA) and .1is releasable to the National Technical Information Service (NTIS). At NTISit will be releasable to the general public, including foreign nations.
RADC-TR-84-165 has been reviewed and is approved for publication.
0
APPROVED: tz,~~/
THOMAS L. FENNELLProject Engineer
APPROVED:
JOHN J. BART, Acting Technical DirectorReliability & Compatibility Division
FOR THE COMMANDER: , "
JOHN A. RITZ VActing Chief, Plans Office -.
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Boeing Commercial Airplane Rome Air Development Center (RBET)Company________
6c. AOORESS ,City. State and ZIP Code) 7b. ADDRESS fCity. State and ZIP Codeo
;.U. Box 3707 Griffiss AFB MY 13441
Seattle WA 98124
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62702F 2338 02
I I TITLE 'Include Security Cl.uficistiono
M!AINTAINABILITY TIME STANDARDS FOR ELECTRONIC EQUIPMENT
12. PERSONAL AUTHORISI
John Rose, John.J. Voytko, Jesse A. DavoltISPAEVU13a. TYPE OF REPORT 13b. TIME COVERED TO. DATE OP REPORT (Yr., Mo.. Day) .PAEOi.
T-inal FROM ____TOJuly 1984 23416, SUPPLEMENTARY NOTATION
N/A
17 COSATI CODES 1S. SUBJECT TERMS (Continue on reverse it necessary and identify by block Plumber#
FIELD GROUP suB. GA. Maintainability Electronics09 I 03 IMaintenance Time Standards
14 04 - -
19. ABSTRACT rContinue on reuerse it necessary and identify by block number,
-Data have been developed to enable predictions to be made of the time taken for the
maintenance of electronic equipment. The data provided are universal and can be used fox
any type of electronic equipment and for any conditions that are representative of actval
operating maintenance environments.
All standards are derived from General Purpose Data, a system of elemental time standards
for simple sequences of body motions. Four "KV factors have been provided to enable
synthesized task times to be related to actual times. The "V" factors account for pertona1,f~itigue(, and delay allowances, for learning, for skill, and for the error between actual
and predilcted time (or variability). The contractor's experience with the application
of a similar ct of elemental standard L-imes for mechanical system maintenance res'-ilted
in a h igh d(.5.,ree of consistency and accuracy. (otne nrvre
20 0jIS 1ABUT1UN,AVAILA8; ITy OF ABSTRACT 21. ABSTRACT SECURITY CL.ASSIFICATION
,NCLASSIF.EO UN.LIMITED 7SAME AS RPT ::OTIC USERS C3UNCLASSIFIED
22& N.AME OF RESPONS.BLE INDIVIDUAL 221, TELEI,CNE NlUMBER 122c OFFICE SYMBOL
InnV'udq %ea Code I(315) 330-3476 RADC (RBr)rLI
DO FORM 1473.,83 APR EDITION OF 1 IAN 73 IS OBISOLETE UNCLASSIFIEDSECURI1TY CLASSIFICATION OF THIS PA -
- LUNCLASSIFIED
*SECLA.TY Ct.ASS1 FC~r.ON 09 T.IS PAGE
IL [,-Kanpics of tosting and maintenance of an F-15 U1HF set have been providcd as a deronsLr-ition
of thu tYpo caneilsis that car. he made with predetermined time standards at anly stage- Of -
dtesign, manutacturc, or use.
-N1
IN LAS-4 1E
4-4
SUMMARY I
The objective for the work undertaken was to provide maintenance time
standards for use in electronic equipment maintainability predictions. The
standards developed provide the means of predicting times that are
representative of different environ.ents associated with maintenance of
shipboard, ground, and airborne electronic equipment. Data provided
include current state-of-the-art electronics such as surface mounted
devices and therefore update data in MIL-HDBK-472, which cover tube
technology.
The method used to develop the time standards was to synthesize them from
General Purpose Data. General Purpose Data is a system of time standards
previously used by both Air Force and Navy for predicting times for basic
body motions. The standards can be used in conjunction with drawings or
manuals and provide all the information necessary for making a predictionor establishing a work measurement standard satisfying MIL-STD-1567A. Astopwatch or field data are not required.
Study "K" factors have been provided to enable synthesized standard times
to be related to field operational environments. The "K" factors account
for the personal needs of the electronics technician, his workingenvironment, unavoidable interruption, his skill , and his learning ]"capabilities. A "K" factor is also included for prediction error
(variability). While no values are currently available for the prediction
error for electronics, the prediction error is expected to be small , based
on previous experience with mechanical system time standards.AW
Approximately 100 data sheets have been provided covering electronic repair
operations and other operations required to access, remove, and replace
electronir equipment. A mnemonic coding system has been developed to aid
the maintenance analyst in locating appropriate time stdndard:.
Illustrations nave been used to show the type of components or tools being
addressed by the time standards.
O S
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Several examples of the application of standards to predicting times fororganizational , intermediate, and depot level repair are provided in the. --
appendix. The examples are for test and repair of an F-15 UHF set and for
test of an AGM86 missile. From the examples it can be concluded that all -
the time standards needed for analysis of electronic equipment testing and
repair have been provided. However, four items are reconended for future
work:
o Development of a classification and coding system for completed analyses
similar to those in the appendix. A coding system will facilitate
storage and retrieval for a DOD library of equipment-level time
standards.
o Improvement of prediction accuracy by measurement of learning and skill
level in a maintenance environment.
o Measurement of maintenance performance under abnormal conditions such as
battle conditions and weightlessness.
a Establishment of a data bank of failure rates, by mode of failure, to
facilitate the inclusion of fault isolatior in mean time to repair
analysis.
The contractor believes that, with training and practice, the developedstandard times can be used to predict maintenance and fault isolation times
for electronic equipment with an accuracy that satisfies the requirement
for Type 1 standards of MIL-STD-1567 (Reference 1-I).
26
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%
PREFACE
The authors would like to express their appreciation for the help
received from Mr. Harry Dashiell kDOD/DPPO) and Mr. Fred Braun
(NALC, Alemeda). Special thanks go to Nina Clancy for her
patience in typing the manuscript.
The expressed or implied use of ccomnercial products or names of
manufacturers in this report does not constitute official
endorsement of such products or manufacturers by the Air Force or
by the contractor.
Data used to develop the time standards provided in this document
are availaboe from the Defense Industrial Resources Support
Office, Cameron Station, Alexandria, Virginia 22314
'ID TIC Tf, _J
DTICLECTE DttrU1 I0.
SV Ayi1mb C A' ®8
i JAN 2 5 W95 Av.tl a:,d/or8
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3
TABLE OF CONTENTS
PAGE
1.0 INDEX OF STANDARDS 86
2.0 GLOSSARY, ACRONYMS, AND ABBREVIATIONS 12
3.0 INTRODUCTION 15
3.1 Background 15
3.2 Approach and Rationale 18
3.3 Training 21
4.0 THE STANDARD DATA APPLICATION METHOD 22
4.1 Selecting Standards 25
4.2 Case Difficulty 27
4.3 Occurrencin9 31
4.4 Use of Personal, Fatigue, and Delay 32Allowances (PF&D)
4.5 Environment 34
4.6 Shipboard Conditions 35Ki
5.0 ALLOWANCES AND VARIABILITY FACTORS 37
5.1 Personal, Fatigue, and Delay Factors 39
5.2 Skill Level Allowance 45
5.3 Learning 46
5.4 Chemical Warfare Ensemble 47
4
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6.0 RECOMMENDATIONS FOR FUTURE WORK 49
6.1 Classification and Coding 49
6.2 Learning Curves and Skill Level 49
6.3 Abnormal Environments 50 ..
6.4 Failure Mode Rates 51
7.0 CODING, STANDARD DATA, AND ENVIRONMENTS 5354. 4
7.1 Coding of Elemental Standards 54
7.2 Elemental Standard Data 59
7.3 Standard Environments 168
8.0 REFERENCES 172
,APPENDIX Al
A. Application Examples A4
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LIST OF FIGURES
PAGE
3.2-1 A Typical Time Standard 20
4.0-1 Example of Data Appl ication For-mat 224.0-2 Example of an Application Surmnary 24
4.1-1 Standard Times for Disengaging 25
4.1-2 Typical Standard Data Sheet 2
I4. 3-1 Task Analysis for Multiple Workers 31
4.5-1 Groundcre.i Chemnic; Defense Ensemble 34
5.0-1 LRU Removal and Replacement - All Systems 3 3
6.4-1 Fault Isolation Procedures 51
I7.1-1 Mnemonic Classification Code 54
7.3-1 Standard Hangar and Flight O~ne Layout 169
7.3-2 Standard Ship Layout 170
7.3-3 Repair Shop 171
I 6
LIST OF TABLES
PAGE
3.1-1 interchange Times 163. 1-2 El ement Times Based on the Work Fac tor System 17
4.2-1 Examples of Case Variable Percentages 27 -
4.2-2 Level of Difficulty Definitions 28
*4.2-3 Cas2 Variable Multipliers 29
4. 2-4 Combined Case Codes 29-
4.4-1 Typical PF&D for Work on an Airplane 33
5.2-1 Skill Level Factors, K(S) 45
5.4-1 Sa fety All1owances f or Chei cal Warf are Ensembl e 48
7.1-1 Work Category Codes (2nd and 3rd Digit) 56
7.1-2 Work Qualifier Codes ('th and 5th Digit) 57
J
7S
1.0: INDEX OF STANDARDS - ELECTRONIC
ADJUST DEVICE ECA-CM-XX
CALIBRATE COAXIAL CABLE TESTER ECA-TA-XX
CLEANING FLUX ECL-FX-XX
CONFORMAL COATING, EPOXY, AND URETHANES ECL-HC-XX
CLEAN SOLDERING IRON ECL-SE-Dl
COAXIAL CABLE TEST EIT-TA-DI
TRANSISTOR TEST E IT-TA-02
MEGGER TEST, CONTINUITY, AND INSULATION EIT-TH-0I
CURRENT MEASUREMENT, DECADE BOX EIT-TH-D2
RESISTANCE MEASUREMENT, DECADE BOX EIT-TH-D3
RESISTANCE MEASUREMENT, WHEATSTONE BRIDGE EIT-TH-D4
LOGIC CHECK, DIGITAL PULSER PROBE EIT-TH-D5'
VOLT-OHM-MILLIAMMETER CHECK EIT-TH-D6
CURRENT TRACE EIT-TH-D7
STRAP, STATIC CONTROL EJP-SA-XX
PREHEAT PRINTED CIRCUIT BOARD EJP-SE'D1 ?J
PREPARE OR TERMINATE PCB TEST EJP-TA-XX
CURE ADHESIVE, ULTRAVIOLET ENF-BS-D1
CURE ADHESIVE, OVEN ENF-BS-DX
CONNECTOR, ELECTRICAL, MULTIPIN BAYONET ENF-CB-XX
CONNECTOR, WITH JACKSCREW ENF-CE-XX
CONNECTOR, FRICTION LOCKING ENF-CF-XX
EYELET, PCB ENF-ER-XX
SECURE DEVICE WITH ADHESIVE ENF-PO-I 1
SECURE DEVICE WITH SOLDER ENF-SE-Ii
FLUX EST-FX-XX
BLACK BOX EXTRACTOR ETF-BB-XX
CONNECTOR, ELECTRICA', MULTIPIN, THREADED COLLAR ETF-CE-XX
FORM COMPONENT LEADS ETL-MA-D I
4 1.0: INDEX OF STANDARDS (CONTINUED) -ELECTRONIC
PULL PCB ETl-PC-Ri
CLIP-ON HEAT SINK ETL-PO-XX
PROBE TEST POINT ETl.-TA- XXDESODERBRAI ETPDS-R
DESOLDER, BRAID ETP-DS-R1
DESOLDER, PUMP ETP-DS-R2
DESOLDER, VACUUM ETP-DS-R4
TIN WIRE ETP-SE-X1
SOLDER OR UNSOLDER WIRE ETP-SE-X2SOLDER DIP ETP-SE-X3
SOLDER SLEEVE OF SHIELDED WIRE ETP-SE-X4
SMD, SOLDERED LEADLESS CHIP CARRIER ETP-SE-X5
CHANGE BIT OR SLEEVE, WIRE WRAP TOOL ETP-WfW-D1
BUNDLE, LACE EWH-BL-XX
BUNDLE, TIE EWH-BT-XX
CABLE TIE EWH-CT-XX
INSULATION, HEAT-STRIPPING EWH-IH-XX
INSULATION, STRIP EW H-IS-X X
PIN, INSTALL ON WIRE EWH-PN-I 1PIN, INSTALL OR REMOVE IN PLUG EWH-PN-12
WIRE CRIMP, MANUAL TOOLS EWH-WC-XX
WIRE WRAP, HAND TWISTED EWH-WW-Rl
WIRE WRAP, HAND-SQUEEZE GUN EWH-IJW-R2 --
WIRE WRAP, POWER GUN EWH-WW-R3
9
1.0: INDEX OF STANDARDS (CONTINUED) - OTHER THAN ELECTRONIC
CONTROL, MANUALLY ACTUATED OAC-CM-XX
BUrTERFLY LATCH, UNFASTEN, FASTEN OAC-LP-XX
CLIMB OR DESCEND OBM-CD-XX
WALK, OBSTRUCTED OR UNOBSTRUCTED OBM-WO-O1
HAND CLEAN, SIMPLE SHAPE TO 10-FT 2 OBJECT OCL-HS-XX
HOLDING CLAMP, TEMPORARY OCP-HT-XX -
ESTIMATED MANUAL TIME OEL-ET-XX
OTHER DATA OEL-OD-XX
REPEAT SEQUENCE OEL-RS-XX
TIME STUDY OEL-TS-XX
EXAMINE, VISUAL OIT-EV-XX
HINGED PANEL WITH HOLD-OPEN ROD OJP-AC-XX
CORD, ELECTRIC, COIL AND UNCOIL OJP-CC-XX
PROTECTIVE CAP OJP-CF-XX a
CLOCK IN, MANUALLY ACTUATED TIME RECORDER OJP-CL-XX
CORD, ELECTRIC, PLUG IN AND DISCONNECT OJP-CP-XX
DRAWER, OPENi AND CLOSE OJP-DR-XX6
ROPE OR CORD, FASTEN OR UNFASTEN OJP-FT-XX a
GLASSES OR GOGGLES, SAFETY, ON AND OFF OJP-GS-XX
DRILL BIT, INSTALL OJP-MA-DI
PREPARE MICROSCOPE OR MAGNIFIER OJP-MY-DX
ENSEMBLE, CHEMICAL DEFENSE OJP-PA-X a_
SAFETY HARNESS OJP-SA-X 1
GET AND ASIDE OMH-LA-XX
OBTAIN OR RETURN FILED MATERIAL OMH-OF-XX
OBTAIN OR RETURN PART OR MATERIAL OMH-OP-XX 6
FASTENER, 1URNLOCK ONF-FT-XX
PRESSURE LATCH, FASTEN OR UNFASTEN ONF-LP-XX
RING, TRU-ARC UNF-RT-XX
SAFETY WIRE, CONTINUOUS, NONTWISTED ONF-SC-XX
SNAP RING ONF-SR-XX
SAFETY WIRE, TWISTED ONF-ST-XX
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1.0: INDEX OF STANDARDS (CONTINUED) - OTHER THAN ELECTRONIC
OBJECT HANDLING OOH-OB-XX
DISENGAGE OOH-DE-XX
POSITION OBJECT OOH-PO-XXTAG, ROUTING, REMOVE OR FILL OUT AND ATTACH OOH-TR-XX
CAN, SCREW CAP, OPEN AND CLOSE OPK-CS-XXENVELOPE, OPEN AND REMOVE CONTENTS OPK-EO-XX
OBJECT, UNPACK OR PACK OPK-OB-XX -.- EESTIMATED PROCESS TIME OPT-ET-XX
TECHNICAL MANUAL, PROCESS ALLOWANCES OPT-TM-XXREAD TECH DATA ORD-TM-XX
COAT, AEROSOL SPRAY OST-CA-XX 4
BOLT, SCREW, OR NUT, FINGER TIGHT OTF-BF-XX
BOLT, SCREW, OR NUT, NC OR NF, MANUAL TOOLS OTF-BM-XX
BOLT, POWER TOOL OTF-BP-XX
CAP OR PLUG, THREADED, FINGER TIGHT OTF-CF-XX --...CAMLOC HIGH-STRESS PANEL FASTENERS OTF-CH-XX
SCREW, MACHINE, MANUAL TOOLS OTF -SM XXSCREW, MACHINE, POWER TOOLS OTF-SP-XX
PLIERS, DIAGONAL, SIDE OR END CUTTING OTL-PD-XX
VISE, MECHANICS, POSITION OBJECT AND REMOVE OTL-VA-XX .
WRENCH, TORQUE OTL-WT-XX
NUMERIC DATA, TRANSFER OWR-NT-XX
PROSE DATA, TRANSFER OWR-PT-XX - "
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-'* 2.0 GLOSSARY, ACRONYMS, AND ABBREVIATIONS
Elapsed Time: 1) The actual time taken by a worker to complete a task, an
operation, or an element of an operation. 2) The total time interval from -
the neginning to the end of a study.
Elemental Standard Data (ESD): Elements of work that can be traced to
scientifically timed operationsland that are intended for synthesis intohigher level, more complex operations.
General Purpose Data (GPD): Data developed from Method Time Measurement
(MTM) elements using the building block concept to assemble simple body
motion into sequences of several motions.
Idle Time: Time during which a worker is not working.
Labor Hour: A unit of measure representing one person working for one
hour. The combination of "n" people working for "h" hours produces "nh"
labor hours. Frequent qualifications to the definition include: 1)
designation of work effort as normal effort; 2) designation of time spent
as actual clock hours.
Method Time Measurement (MTM): A procedure that analyzes any manual
operation or method into the basic motions required to perform it and -
assigns to each motion a predetermined time standard determined by the
nature of the motion and the conditions under which it is made.
Normal Time: The time for a qualified worker, working at a pace that can
be sustained, to complete a specified operation or sequence of operations.
Personal, Fatigue, and Delay (PF&D): An allowance over and above normal
time to allow a worker to compensate for attending to personal needs, for
fatigue, and for delays occurring due to conditions beyond his control.
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Prediction Error: The difference between an observed time and a normal
time multiplied by appropriate "K" factors fbr PF&O, skill, and learning.
Also known as variability.
Time Standard or Standard Time: The time for a qualified worker, working
at a pace that can be sustained, to complete a specified operation or
operations with allowances for personal comfort, fatigue, and work
interruptions.
Time Measurement Unit (TMU): One hundred-thousandth of an hour, 0.00001 .1
hour. (27.8 ThUs 1 second, 1667 TMUs 1 minute).
Variability: See prediction error.
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ANSI American National Standards Institute
APL Airplane
DHU Decimal Hour Unit (one ten-thousandth of an hour)
DIP Dual Inline Package
DOD Department of Defense
E Electrical and Electronic (time standards)
GPD General Purpose Data
GSE Ground Support Equipment
LRU Line Replaceable Unit
MTM Method Time Measurement
NALC Naval Air Logis'Cics Center
NC National Coarse (screw thread)
NF National Fine (screw thread)
0 Other (time sta;d.drds)
OCC Occurrence
PC8 Printed Circuit Board
POTS Predetermined Time Standards
PF&D Personal, Fatigue, and Delay
QTY Quantity
RADC Rome Air Development Center
SMD Surface Mounted Devices
TDR Time Domain Reflectometer
TMU Time Measurement Unit (one hundred-thousandth of an hour)
UHF Ultrahigh Frequency 4
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3.0 INTRODUCTION
This section of the document provides a guide to understanding the develop-
ment, scope, and limitations of the standards orovided in Section 7.0.
3.1 Background
Maintainability prediction is one of the critical activities in equipment 4
design and development. It impacts the definition and attainment of
mission requirements. It also impacts life cycle costs. Past investiga-
tions and feedback to RADC indicated that current maintainability
predictions were indirect, complex in application, only marginally
accurate, and were not directly taking into account system engineering
design characteristics. Further, techniques for maintainability modeling
;:,a trade-offs were virtually nonexistent. Therefore, RADC developed 4prediction techniques under Contract No. F30602-76-C-0242 that are based on
a time synthesis model. The techniques are documented in a report entitled
"Maintainability Prediction and Analysis Study", report RADC-TR-78-169,
Reference 3-1. A subsequent data validation study under Contract 4
F-30602-81-C-0081 (Reference 3-2) showed that the maintenance time
standards contained in RADC-TR-78-169 were: 1) indicative of conditions
resulting from repetitive performance of tasks and, 2) not characteristic
v; the maintenance environments associated with military systems.
As well as remedying the above criticisms, the objective for the time
standards presented in this document is to use them as a basis for updating
data for maintenance task time analysis presented in MIL-HDBK-472. A
MIL HDBK-472 provides four methods of predicting the maintenance times for
electronic equipment, and Procedure II of MIL-HDBK-472 is also based on a
time synthesis model. However, the tables in the handbook are based on old
state-of-the-art components and are inadequate for present-day design
analysis. Tables 3.1-1 and 3.1-2 show the type of camponents currently
covered by MIL-HDBK-472.
I
15
I A.,.*.**..* -C .• - N "___ ' .. . .°. .: : : : : :
TABLE 3.1-1: INTERCHANGE TIMES (FROM MIL-HDBK-472, TABLE 2-3)
PART TYPE AVERAGE T'IME (HOURS)
Plug-in tubes 0.015
* Wired tubes (4 wires) 0. 149
Wired tubes (more than 4 wires) 0. 149 +0. 034 per wire over 4
All tubes with shield ADD 0.007withclam ADD0.02
with clap ADD 0.027
Plug-in fuses 0.010
Srew-in fuses 0.015
All fuses with screw cap 0.014
PARTS OTHER TH.AN TUBES AND FUSES
PART TYfPE AVERAGE TINIE (HOURS)
Parts with 2 wires or 2 tabsto be soldered 0. 081
Parts with more than 2 wires or2 tabs to be soldered 0.1 03-0. 034 per vare over 2
with ciamp A.DD 0.027,
* Parts attached with screws,nuts, and washers ADD 0.022 for each screwv, nut and
L washer combination
16
4TABLE 3.1-2: ELEMENT TIMES BASED ON THE WORK FACTOR SYSTEM(FROM MIL-HDBK-472, I-ABLE 2-4)
ELEME~NT DESCRIPTION ELEMENT TIME*(Hours)
1. PLUG-INS (including handling)
Pin-type tubes, plug-in parts, etc. 0.0075
Tub cap or shield 0.0035-
FuseInsert into horizontal holder 0.0050Insert into vertical holder 0.0075
2. WIRING AND SOLOERING
j Wire wrapping and splicingBare copper wire (1) End 0.0150
(2) Ends 0.0237Juriper wire and Cable leads (1) End 0.0134
()Ends 0.0265Part with axial leads (includes part handling)(1) End 0.0178(2) Ends 0.0289
Sol derPer joint 0.0058
3. REPLACEMENT WITHI HARDWARE
Replace screw into tapped hole 0,0093Replace screw through clearance hole 0.0023Repl ace washer 0.0018Replace nut 0.0071Replace stop nut 0.0210Replace set screw 0.0075Apply glyptol screw 0.0018
4. PART HANDLING
Pull up part and position in chassis for assembly 0.0025
S. PRINTED CIRCUIT WIRING
Repl ace (insert) 0.0033/EndSol der 0.0056/End
*The intercnange task aboard ship does not involve the repetitive (cyclic)factory type of regularly occurring motions; therefore, those interchangeelement times are based on noncyclic and irregularly occurring motions.
17
.. . . . .
However, irrespective of the need to update MIL-HDBK-472, the primary
objective is to provide time standards for use in synthesis of maintenance
times for contemporary electronic equipment, using the application method
developed in RADC-TR-78-169. The standards are representative of the
nonrepetitive nature of maintenance and the environments in which it is
accomplished.
3.Z Approach and Rationale
.0
Since the contractor had previously developed time standards for
maintenance of mechanical systems based on the use of Predetermined Time
Standards (PDTS) (defined in Reference 3-3 and described in Reference 3-4),
the same approach appeared logical for electronic equipment maintenance.
The POTS system known as Method Time Measurement (MTM) forms the foundation
of the staidards developed for this document. MTM is probably the most '
widely useo time standards system used for industrial applications and
consists of severai .sets of data that are based on 11 basic body motions:
Reach Disengage
Move Eye Travel and Focus
Turn Body, Leg, and Foot Motion
Apply Pressure Position
Grasp Release
Crank
The historical development, verification, and validation of the times
associated with the basic body motions of MTM are described in Chapter 4 of
Engineered Work Measurement, Reference 3-5. The standard motions can
obviously be combined into more complex sets of motions. For instance, the
pick up and position of a part might consist of a reach, grasp, move part, -
regrasp, position, and release. The simple body motions of MTM can thus be
used to form more complex operations, and a system of standards known as
General Purpose Data (GPO) has evolved from Method Time Measurement. In -
practice, the application of standards based on fundamental body motions,
18
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even at a GPD level, is a time-consuming process. Higher level, more
complex standards have therefore been developed that retain most of the
accuracy of the fundamental General Purpose Data standards from which they
are derived. A simple example of the way in which the high level standards
of this document have been developed from GPO is the installation of a
protective plastic cap on the end of a cable. The operation consists of
the following body motions:
o Get the cap. -..
o Get the part to be capped.
o Position the cap.
o Apply pressure to the cap.
The motions correspond to GPO elements for:
o A "get" of a jumbled object with one hand with a reach of 18 inches.
o A "get" of an easily grasped object at a variable location with a reach
of three to nine inches.
o A symmetrical "place" of a closely fitting object at a distance of 18
inches. Io An "apply pressure" case 1. (Case 1 requires orientation or adjustment --
to avoid loss of grip during application of force).
Since standard times exist for each of the above GPD elements, the time for Iinstalling a protective cap can be readily derived and is 96 Time Measurement
Units (TMU).
The removal time can be developed in a similar manner and becomes the
standard shown in Figure 3.2-1.
I
19'""
II
.........................-..--- " " ." - -
OJP-CF-XX PROTECTIVE CAP
REMOVE INSTALL
FIRST TMU FIRST TMU
RI 90 II 96
Remove
Begins with getting capped part. Includes reaching to cap, applying pressureto cap, disengaging cap. Ends with asiding cap.
Install ---
Begins with getting protective cap. Includes getting part to be capped,positioning cap. Ends with applying pressure to caplete cap installation.
Figure 3.2-1: A Typical Time Standard
I-
If it were necessary to use a tool to remove the protective cap then the -
"first" removal would include the body motions to get the tool at the start
of the operation and aside it at the end of the operation. An "additional"
operation time would have been developed that excluded the get and aside of
the tool. A number of standards with "first" and "additional" operations
will be seen in Section 7.0.
Higher level elemental standards such as those of Figure 3.2-1 can still be
used in many different combinations as may be seen from the examples
provided in Appendix A. The examples would have consisted of many . -
thousands of body motions at a GPD level.
An alternative to a system of synthesized elemental standards wculd have
been to observe and time actual maintenance operations. There are several
problems with this procedure. First, there must be a sufficiently large
number of repetitions of the operations to determine an estimate of the _ 1
mean time with a specified confidence. Second, there is a variation in
time taken from one technician to another. Recorded times must therefore
be leveled to those of an average technician. Finally, observation and
timing can not be used for design review and critique because at that early
date the equipment does not yet physically exist.
2'0
. ._O .
Wherever possible, use was made of existing elemental standards, mostly
from DOD 5010.15.1-M, Volume VII (Reference 3-6). Where existing standards
have been used, they have been checked for accuracy and suitability as
electronics maintenance standards and reformatted for compatability with
the new standards developed. A prerequisite for including a standard in .
this document is that it can be traced back to a General Purpose Data
source, thus ensuring the consistency of all standards provided.
3.3 Training S
MTM data on which the standards in this document are ultimately based
carries with it the following warning from the MTM Association: -
Do not attempt to apply Methods TimeMeasurement in any wa. unless you under-stand the proper appli,.ation of the data.This statement is included as a word ofcaution to prevent difficul ies resultingfrom misapplication of the data.
The same caution applies to the application of standard data provided in .
Section 7.0. The development of a maintenance task time analysis involves
a number of analytical skills. The analyst must be capable of defining, in
* detail, the elements of the work to be performed by a mechanic or 21technician. Typical task descriptions are shown in Appendix A. For thedevelopment of fault isolation times, the analyst must also have the
ability to determine the failure modes, their effects on the system,
subsystem, and failed component, and the failure rate associated with each
mode. Examples of fault isolation analyses are also provided in Appendix
A.
The knowledge necessary for time standard data application can be obtained
by taking one or more of the courses detailed in DOD 5010.15.1-M (Appendix
III Basic Volume, Reference 3-7). The purpose of training is to ensure
that standards are uniformly applied and can be used with confidence. ]21"1
211
I -
4.0 THE STANDARD DATA APPLICATION METHOD
The process of making a maintenance analysis consists of five steps and
' assumes thiit the analyst is thoroughly familiar with the elemental
standards ivailble.
The first step is to match the maintenance work to be performed with the
work description for first and additional operations from the standard.
i This step is explained in Section 4.1. -_
The second step is to establish the case difficulty (Section 4.2).
The third step is to determine the number of timnes an operation is
repeated, as well as the probability of occurrence, and the number of
people involved (Section *'
The fourth step is to perform the simple cal cul ations necessary to
determine elapsed time and labor hours.
The final step is to apply "K" factors to cover personal, fatigue, and
delay allowances, and if appropriate, skill, learning, and error factors.
Appendix A provides a series of examples showing the application of tirle
standards to the analysis of organizational, intermediate, and depot level
Maintenance of electronic equi?'ent. Application format is shown in Figure .4.0-1. .::
(1) (2) (3) (4) (5) (6i (7) 18)
*DSC iiCN........H R ~1M COD QTY 0C D UWID WITH 1ST ADD: ELAPSED: TOTAL :
0i . V. '8 HSIL MODULE, P0WER .... ........... . ......SUPPLY 1A8
A RMV MODULE AND COVER 100 536 536I LOOSEN MODULE HOLD DOWN SCREWS OTL-WT-Oz 1 3 108UQ TOT
2 RMV COVER RETAINING SCREWS OTF-SM-RB 1 4 '.28
a !NSTL COVER A MODULE 100 625 6S"1 POSH COVER COM-PO-OB 1 25 -2 INSTIL COVER RETAINING SCREWS OTF-SM-I8 1 4 450SP0S!1 MODULE OCH-PO-OC 1 424 TIGHTEN MODULE MOLD DOWN SCREWS OTL-WT-02 1 5 108
(EQ TO)
Figure 4.0-1: Example of Data Application Format
- . . - . -
The example format consists of eight columns identified in Figure 4.0-1 by
numbers (1) through (8).
(1) The STEP column provides a number reference for the overall task, a
letter ref'rence for the suboperation, and a number for each element
of Lhe suooperation.
(2) A DESCRIPTION is provided for the task, suboperation, and element.
(3) Where more than one worker is required, each is identified by WORKER
I /D.
(4) Work that is simultaneous is cross-referenced under SIMO by the STEP
designator from column (1).
(5) Elemental standards are referenced in the column headed CODE. Thecoding system is explained in Section 7.1.
(6) The quantity of first and additional work elements is entered in
column (6). (First elements include time to get and aside objects
that are then available for additional elements.)
(7) The use of OCC (occurrencing factors) is explained in Section 4.3.
They are entered as a percentage.
(8) Fcr each element, the first and additional times that correspond to
the element referenced in column (5) are multiplied by QTY, column
(6), and sunmed to arrive at the elasped time, columm (8), then
multipl,- by OCC, column (7), to give the total time, column (8).
23
I'- ... .... -.. "- v. .. , - ," ,-*- ... r ," -r - " , , ' '"- 'r- "-
: 'Y *; . ." . .. ..'... . . .. '
In the Data Applications of Appendix A, time units are in Decimal Hour
Units (DHU), which equal ten Time Measurement Units (TMU):
100,000 TMU =1 hour
10,000 DHU I hour
I DHU = .0001 hour
2.78 DHU I second
166.7 DHU 1 minute
Suboperation summaries dnd task summaries are also provided with each of
the tasks analyzed in Appendix A. A typical summary shown in Figure 4.0-2.
TASK CODE: 152314XMOI
PART NAME: UMF RADIO SYSTEMSUMMARY
APL MODEL; F-iS PART NO! ZONE:
TASK DESCRIPTION- CONDUCT FLT LINE TFST TOISOLATE TROUBLES It. UHF RADIO
U SYSTEM
PREPARED BY: J.DAVOLT ORO: B7463 DATE: 1-9-84P
REQUESTED BY; J.ROSE ORO 37463 REV.
REFERENCES: TO 12R2-2ARC1O9-2
REMARKS: THIS ANALYSI. IS FOR USE AS AN EXAMPLE OFMAINTAINABILITY TIME STANDARDS APPLICATION. THEUHF RADIO AN/AR09 IS INSTALLED ON F-IS AIRCRAFT.USING THE TEST SET All/ARM-1 ! AT THE APL ISOPTIONAL TO REMOVItNO THE TRANS EIVER, CONTROLLEROR INTERCOM SET AND PERFORMING THE TESTS ON ABENCH SETUP. IN THIS ANALYSIS IT IS ASSUMED ACCESSTO THE UHF SET IS OPEN AND A WORK PLATFORM ISPOSITIONED PER 112314XMOl. ASSUME THE APL IS IN AHANG0AR. POWER IS CONNECTED TO APL.
---------------------- TASK TIME SUMMARY -----------------------
TOTAL MANHOURSI .93 MRS ...... WITH PFIDO 1.11 MRS
TOTAL ELAPSED: .46 MRS ...... WITH PF&D' .56 MRS
USE REQUIRED; YES PERSONAL, 9x
FATIOUE, 6X
DELAY; S%
Figure 4.0-2: Example of an Application Summary
The total labor hours and total elapsed times without and with PF&D are
provided with the summary. In addition, the labor hours and elapsed times,
without and with PF&D are shown for work at the airplane (APL). Work at
the airplane excludes the primary job preparation and termination so that
several jobs on the aircraft can be readily combined.
24
" " . -" .'. ' . . . .. . . . . "-. .. -.-
4.1 Selecting Standards
Standards are selected by breaking down the overall task Into more and more
detailed elements until a match with the standard job descriptions of
Section 7.0 is found. A prerequisite is that the analyst is familiar with . -
all available standards. For instance, removing a black box from an
airplane can be broken down into:
i) Walking to the airplane [
2) Checking that the power is off
3) Opening an access door
4) Disconnecting the cables
5) Loosening the equipment hold-downs
6) Disengaging the equipment from the airplane
Once the task has been broken into a number of suboperations, a search is
made for existing predetermined times. For example, element 6 above,
matches data element OOH-DE in Section 7.0, also shown in Figure 4.1-1. -.
OOH-OE-XX DISENGAGE
DISENGAGE TMU
OA 7008 120OC 220On 400 .OE 700
Disenag
Begins with reaching to object or tool. Includes obtaining control of objectwith hand(s), or with tool when tool is an extension of the hand(s), andloosening and extracting or removing one object from another. Ends with laying Laside tool and/or object.
Remarks
Tools included are a putty knife, screw driver, pliers, or similar to overcomethe limitations of hand or finger dexterity or access. Strength may be usedwith slight to considerable effort. Use of hammer is not included.
Case variable factors: distance 45%, weight 10%, control 45%.
Figure 4.1-1: Standard Times for Disengaging
25
Having matched the work and the standard, the analyst must next select the
level of difficulty for the work. In the case of DISENGAGE, Figure 4.1-1,
five levels are available from Very Easy (A) to Very Difficult (E). A
typical example is also shown in Figure 4.1-2 for a standard that can be
used for releasing door latches.
FASTENER. TUINLOCK TO 3/B-in. DIA ONF-FT-XX
FIRST TMU ADOITIONAL ThUP6-
Unfasten RA 110 YA 60Unfasten RB 160 YB 80Fasten IA 140 XA 90Fasten I 200 X8 130
Unfasten First Piece
Begins with reaching to tool. Incljdes positioning tool to fastener stud andtwisting to unfasten stud from receptacle. Ends with laying aside tool .
Unfasten Additional Piece
Begins witn moving to fastener stud with tool. Includes positioning tool to studand twisting to unfasten. Ends with unfastening Stud from receptac e.
Fasten First Piece
Begins with reaching to tool. Includes positioning tool to fastener stud andtwisting stud to secure in receptacle. Ends with laying aside tool.
Fasten Additional Piece
Begins with moving to fastener stud with tool. Includes positioning tool to studand twisting to secure. Ends with fastening stud to receptacle.
Rema rks
Applies to DZUS, CAJ4LOC, AIRLOCK and similar fastenars.
Case variable factors: distance 10%, weight 5%, control 85%.
Figure 4.1-2: Typical Standard Data Sheet
For ONF-FT only two levels of difficulty are provided, Very Easy (RA, YA)
and Easy (RB, YB). Once case difficulty has been selected, the analyst can
obtain the corresponding time from the table at the top of the sheet.
However, to remove the subjectiveness of selecting case difficulty the
procedure of Section 4.2 should be used. Units of time in the standard
data sheets are Time Measurement Units or THUs. (One TMU is equal to
.00001 of an hour and there are 27.8 TMUs to a second.)
26-
26i-..
~~~~~..................,. . "" ., -. ..-. ......... . .. ,...... ,....,,..... .. ....
* 4.2 Case Difficulty
Some of the standard data in Section 7.0 have been developed to provide the
analyst with the choice of different levels of difficulty for the operation L__
described.
Table 4.2-1 provides examples of the three case variable percentages by
which distance, weight, and control were judqed to contribute to the work
difficulty.
TABLE 4.2-1: EXAMPLES OF CASE VARIABLE PERCENTAGES
Standard Case Variable Percentage
Distance Weight Control
EN,-CB-XX 10 5 85
OMH-LA-XX 80 20 0
ONF-FT-XX 10 5 85
ONF-SR-XX 10 5 85
The case variable percentages are provided with each elemental standard
data sheet in Section 7.0 to which they apply. The definitions of case
difficulty used in constructing the standards are shown in Table 4.2-2.
When applying a standard, Table 4.2-2 can be used to remove some of the
subjectiveness in selecting a level of difficulty. For example, if a
two-pound object was moved to an exact location 12 inches away it would be
classed is a Very Easy case. The cases for different distances and degrees .-
of control can be determined in a similar manner.
Having decided on levels of difficulty for distance, weight, and control, a
case variable multiplier is obtained from Table 4.2-3.
2-
27
* * ..... . . . . .. .* . ... . . . ..-..f - . A A- .'.- .. . . .. ..- .- .-.-.- L-, . - - ... ~ - . .** . ; . . .'- . ~
• .
TABLE 4.2-2: LEVEL OF DIFFICULTY DEFINITIONS
LEVEL DISTANCE WEIGHT CONTROL - SEE REACH(LB) AND MOVE BELOW*
A WITHIN 18-IN. RADIUS, 0 - 3 A,B,E REACHES - A,B,C MOVES.
NO BENDING, STOOPING, ACCOMPLISHMENT IS UNOBSTRUCTED,VERY OR OTHER BODY ASSISTS. OBJECT CLEARLY VISIBLE, FIT, IF
EASY APPLICABLE, IS LOOSE AND OBJECT IS -EASY TO HANDLE. (CLASS "1"POSITIONS). MAXIMUM 1-IN. RECOILON DISENGAGE.
B SAME AS ABOVE, WITHIN 3 - 10 C,D REACHES - C MOVES. SOME30-IN. RADIUS AND IN- INTERFERENCE, OBJECT WHOLLY
EASY CLUDING BODY ASSIST VISIBLE, OR NO INTERFERENCE,BUT NO BENDING OR OBJECT PARTLY VISIBLE. FIT, IFSTOOPING. APPLICABLE, IS LOOSE AND OBJECT IS
DIFFICULT TO HANDLE. (CLASS "i"POSITIONS). MAXIMUM 1-IN. RECOILON DISENGAGE.
C SAME AS EASY, BUT 10-25 C,D REACHES - C MOVES. INTERFER-
WITHIN 4-FT RADIUS AND ENCE, OBJECT PARTIALLY VISIBLE.MODERATE INCLUDING BENOING AND I FIT, IF APPLICABLE, IS CLOSE,
STOOPING. (CLASS "2" POSITIONS). MAXIMUM5-IN. RECOIL ON DISENGAGE.
D SAME AS MODERATE, BUT 25-50 C,D REACHES - C MOVES. INTERFER-
WITHIN A 6-FT RADIUS. ENCE, OBJECT IS NOT VISIBLE OR
DIFFICULT INTERFERENCE AND PARTIALLY VISI-BLE. FIT, IF APPLICABLE, IS
EXACT. (CLASS "3" POSITIONS).OVER 5-IN. RECOIL ON DISENGAGE.
, -___--___
E SAME AS DIFFICULT BUT OVER 50 C,D REACHES - C MOVES. OB-WITHIN AN 8-FT RADIUS. STRUCTED AND NOT VISIBLE. FIT, IF
VERY APPLICABLE, IS EXACT, ACCOMPLISH-DIFFICULT I MENT BY MULTIPLE AND/OR NON-
] _ SYMMETRICAL, DIFFICULT POSITIONS.OVER 5-IN. RECOIL ON DISENGAGE. "- .
MTM REACH
A - TO OBJECT IN FIXED LOCATION OR TC 0IHER HANDB - TO OBJECT IN LOCATION WHICH VARIES SLIGHTLYE - TO INDEFINITE LOCATION OR A REACH TO BALANCE THE BODYC - TO JUMBLED OBJECTS REQUIRING SEARCH AND SELECTD - TO A SMALL OBJECT REQUIRING AN ACCURATE GRASP
* MTM MOVES
A - MOVE OBJECT TO OTHER HAND OR AGAINST STOP --a
B - TO AN APPROXIMATE OR INDEFINITE LOCATIONC - TO AN EXACT LOCATION
28
t"
TABLE 4.2-3: CASE VARIABLE MULTIPLIERS
Case Multiplier M
Very Easy 0.1
Easy 0.3 -
Moderate 0.5
Difficult 0.7
Very Difficult 0.9
. -
The case variable percentage from Table 4.2-1, or from individual standards
in Section 7.0, multiplied by "M" from Table 4.2-3, gives the case variable
factor "F". The final step is to add the case variable factors togetherand then use Table 4.2-4 to detennine the combined case.
TABLE 4.2-4: COMBINED CASE CODES
Sum of Case To Case
"F" Factors Use Code
0 - 19.9 Very Easy A
20 - 39.9 Easy B40 - 59.9 Moderate C
60 - 79.9 Difficult D
80 -100 Very Difficult E
Example
A black box is to be removed from its mounting through a small accesspanel. Its fasteners and connectors have been released and removed and now
it is to be disengaged and moved 30 inches. It weighs 40 pounds and is
only partially visible.
1) From Table 4.2-2:
30 inches distance is an Easy case
40 pounds weight is a Difficult case
"Partially visible" is a Moderate case
29
2) For Disengage OOH-DE-XX (Figure 4.1-1) -
the case variable factors are:
Distance 45%
Weight 10%
Control 45% -g
3) Using the individual difficulties from (1) above in Table 4.2-3,
case variable multipliers are:
Distance, Easy 0.3
Weight, Difficult 0.7
Control, Moderate 0.5
4) Percentages (2) are multiplied by the results of (3) and added:
Individual Case % x M = F
Distance 45 x 0.3 = 13.5
Weight 10 x 0.7 = 7.0
Control 45 x 0.5 = 22.5
Total 43
5) From Table 4.2-4, the combined case for a sum of F values of 43 is
Moderate (40-59.9). .
6) The disengage operation for the black box is given the code OOH-DE-OC
in accordance with the details of the coding system provided in Section *-£ *
7.1, OC being used for Moderate. A time value of 220 TMUs (or eight *:--
seconds) is now obtained from Figure 4.1-1 for a Moderate case with a
code 'OC".
30'..S
4.3 Occurrenclng
An occurrence factor has two uses. The first, and simpler, of the two uses
* is to represent the relative frequency with which an operatlu'n takes place.
For example, if once in every three soldering operations the solder isregrasped, then the time for regrasping would be given an occurrence factor
of 33%. This technique is usable in both the development and application* of elemental standard data.
The second and more complex use of occurrencing is to account for both thelabor hours and elapsed time for tasks involving more than one person. For
example, imagine two mechanics sharing the same operation, suii;, as the
removal of four bolts, in which each mechanic requires 3070 TMU, with 6140
TMIU for the total task. The reader of an analysis would see 6140 TMU
displayed with a 50% occurrence factor, yielding an elapsed time of 3070
TM U. Labor hours and elapsed time are both important maintainability
* parameters and one method of accounting for them is illustrated by Figure -
* 4.3-1.
TASK CODE- 152Sl14XMD
STANDARD DATA APPLICATION PART NAME, UHF RADIO SYSTEM
I /0 WITH1 I ST ADD- ELAPSED, TOTAL -
:ttL:'~~xx....................................................LUNU4i6 lE IN ES O i 4627 95
ISOLATE TROUBLES IN UHF RADIOSYSTEM
*A JOB PREPARATION 1.2 zoo 562 1124
OBTAIN TECHNICAL INFORMATION 1 2 U-FO 1-02 OBTAIN TEST EQUIPMENT AND TOOLS 2 1 O0DM-- 2 963 FROM SHPTO P . S-lOO 7334 ASIDE TEST EQ( MN N OL 1.2 OON-OB-D2 2 96
I. 6 O r CCPIT 2 5 DOM H-01PHA1OCC' o1 6A -O 9 -7 tOCATEKUHF RADIO SW 2 Olt-EV-Z& 2 20
ITURI O# FF UHF SNITCHR 2 9 OAC-CM:C2 ITURN OFF TEST SET NRSN I a OAC-Ch-Oz 1 -7
S INTL TEST EQUIPMENT I C20 106 22I PO .ITETEST, EQUIPMENT I OON-OB-D1 1 40ADACE71,TO UHF RA DIO2 IIISTL CEST CAILE ASSEMBLIES TO I F-EI 476HOOK TEST EQUIPT PER FIG S-1 -
r 3~~~ RFIV SAFETI WIRE FROM AFIETNIIA I OJ-TP 2COIINEC IC
4 R1IV CONHECTOR FROM ANTENNA I F-ER 212CnNNHCCTION TO R/T U1117
R14V COINECTOR FROM J44. OF R/T I EFC-C 11
C SET CONDIT IONS F OR TFST 2 a 0B61 SELECT AP PR 0C E Si FREQUENCY 2 A-
2SELECT MAIIUAL ON .ODE SEECTOR 2I V OLUJE CON 01l 10 1NAXIIIUN 2
5 ToNEADS DISABLE SHITCIIES 2
Figure 4.3-1: Task Analysis for Multiple Workers
313
In Figure 4.3-1 complete suboperations have been occurrenced. In
suboperations A and B the elapsed time is factored by 200% to give the
labor hours for workers one and two. The convention of a minus sign in the
elapsed time column signifies an element, or suboperation, that takes place
in parae . with another el ement or suboperation. Entries with a minus
sign are ignored, not subtracted, in accumulating elapsed times. For
example, while worker number one is performing suboperation B, for a total
of 1096 OHUs, worker number two completes suboperation C in 60 OHUs.
Worker number two's labor hours and idle time are accounted for with worker 0
number one by the occurrence factor of 200% in suboperation B. (The
analysis of Figure 4.3-1 is part of the series of examples for repair of an
F-15 UHF radio provided in Appendix A.)
4.4 Use of Personal, Fatigue, and Delay Allowances (PF&D)
Since all the elemental standard data provided in Section 7.0 is based on acontinuous series of body motions, it is necessary to add allowances for -.
hygiene and personal comfort needs, for the different factors resulting in
fatigue, and for uncontrollable delays and interruptions.
A comprehensive set of PF&O allowances is provided in Reference 3-7, and .
for convenience, the data are reproduced in Section 5.1. The PF&D
allowances are for such things as working position (sitting, standing,
walking), physical factors such as moving weights in different positions,
heat, lighting, mental concentration, monotony, and so on.
Typical PF&D allowances are:
o Bench or shop work at a normal pace and temperature:
5% personal - -
5% fatigue
* 5% dtlay '
o For work below 40°F or above 90OF:
37. additional fatigue allowance
o Use of heavy protective clothing: ,-N
514 additional fitigue allowance
32
Work on an airplane tnder typical conditions is shown in Table 4.4-1.
TABLE 4.4-1: TYPICAL PF&D FOR WORK ON AN AIRPLANE
Condi tions
Equipnent Inside Aircraft Outside AircraftWork Area Handling
Open Easy 18% (8-5-5) 20% (9-6-5)
Open Difficult 19% (8-6-5) 21% (9-7-5)
Moderate Easy 21% (8-8-5) 23% (9-9-5)
Moderate Difficult 22% (8-9-5) 24% (9-10-5)
113
4.5 Environiment
Environment is the term used to describe the conditions that surround the
area in which maintenance is performed. Examples of natural environments j
are moisture, heat, cold, wave motion, rain, wind, snow, ice, sand, and
dust. Induced environments include vibration, clean-room conditions,
radiation, weightlessness, explosive atmosphere, and noise. Conditions .1such as rain, snow, and cold entail the use of protective clothing orspecial equipment such as heaters. -
Arctic or foul-weather gear may result
!n interference or loss of visibility.Such gear increases the degree of /
control required and the increased /, ' -
degree of control results in higher
levels of difficulty as well asm -higher than normal personal and fatigue .
allowances. A typical example, such as
chemical warfare clothing that includes (i
two layers of gloves, may result in an
easy" job element becoming "moderate" ,,
or "difficult". In addition, the outfit
is hot, cumbersome, and uncomfortable- -
(Fiyure 4.5-1). - -.-
A full table of fatigue allowances is
contained in Section 5.1. - -.21
Figure 4.5-1: Groundcrew Chemical Defense Ensemble
3I,-I-. .. i
From the fatigue tables, the percentages by which the normal time might be
increased under chemical warfare conditions are:
Percent As a Result of
2 Face shield
2 Rubber boots
4 Heavy protective clothing
5 Filter mask
3 Heat factor
2 Standing
8 Concentration and manual dexterity
I Noise
27 Total Fatigue Allowance
Personal allowance for a chemical warfare environment might consist of:
Percent As a Result of
6 Extremely disagreeable conditions
4.2 Preparation and cleanup
4.0 Adjunctive allowance for special clothing -
14.2 Total Personal Allowance
With an allowance of 5% for unavoidable delays, the increase in work time
due to PF&D would be 46% (27 + 14 + 5), compared with 15% for bench work
under normal conditions. The use of a chemical warfare groundcrew ensemble
also causes problems with heat stress. Periodic rest cycles are required
and details are provided in Section 5.3.
4.6 Shipboard Conditions
As well as the environments provided for by the tables of Section 5.1, the -. -
environment for shipboard maintenance has the additional complication of
ship's motion. For example, a destroyer commonly rolls 25 degrees from
vertical and may occasionally roll 40 degrees or more during which time
only vital maintenance is performed. Under such conditions maintenance .- "
includes operations such as clamping equipment (OCP-HT-XX), tieing down
35 -p ." '
- ... .. :.
tools (OJP-FT-XX), or returning tools and equipment not in use to drawers
or cabinets (OMH-OP-XX). Working on superstructure -- an antenna, for
eKample -- involves the use of a safety harness (OJP-SA-Xl). In addition,
linear and angular accelerations during pitch, roll, and yaw add to and
subtract from gravitational acceleration and change the weight of equipment 1-
being handled, thereby changing level of difficulty to a more severe case.
3-6
I° .
. . .
5.0 ALLOWANCES AND VARIABILITY FACTORS
Section 5.0 provides data to enable an analyst to relate time standards
developed using the synthesis technique described in Sections 4.1, 4.2, and -_
4.3 to the times that are experienced in an actual operational environment.
Differences between actual and normal times are accounted for by four "K"
factors. The first factor is the Personal, Fatigue, and Delay allowance,
used to account for differences in times for the same work performed under
different conditions and environments. PF&Ds to cover all environments are
provided in Section 5.1. The second factor is for skill, capability, and
motivation of individual technicians and a method of accounting for this
factor is provided in Section 5.2. The third factor is that associated
with how well an average electronics technician has learned to perform a
given task or a given type of work. Very little data on the "K" factors
for learning are available and the only substantiated data found are
provided in Section 5.2. The fourth factor is an error or variability
factor that accounts for the difference between the actual time taken and
the predicted time.
Normal titne, synthesized from the predetermined standards of Section 7.0,
is thus related tc actual time taken in the field by the expression:
AT(t) = N (K(PF&D) + (K(S) x K(L) ) - 1 + K(e))
Where:
AT(t) Actual time after t hours or units of repetition
N = Normal time
K(PF&U) = Personal, Fatigue, and Delay factor from Section 5.1
K(S) = Skill factor from Section 5.2
K(L) Learning factor from Section 5.3 after t hours or
units of repetition
K(e) = Error or variability factor for the difference
between actual and predicted time for an operation.
Note that K(e) is a function of sample size.
3 4
37"--"
* 4
The accuracy possible with the prediction of mechanical maintenance times
by means of elemental standard data is shown in Figure 5.0-1.
Perfect correlation between predicted and demonstrated times fall on a
45-deg line (for equal times on each axis). Problem equipment that failsto mieet the standard time is also readily observed.
20,000
E 15000 -0
z~U.; l
w u Note: 1 de~cimal hour unitCC 5,00 ecua1s 0001 .
eqal 0 C*L .
0 5,000 10,000 15,000 20,000
DEMONSTRATED TIME(DECIMAL H-OUR UNITS)
Figure 5.0-1: LRU Removal and Replacement -All SystemsW.-
Similar results should be possible with the data provided in Section 7.0
for the mnaintenance of electronics.
38
5.1 Personal, Fatigue, and Delay Factors
The remainder of this section has been abstracted from Appendix Il ofReference 5-1.
PERSONAL, FATIGUE AND DELAY (PF&D) ALLOWANCES
General iij>..pensate for attending to personal needs, for fatigue, and for delay occur-
vring due to conditions beyond his control. This time is additive to thenormal time required to accomplish a job. The inclusion of this allowanceis common practice in the development of a labor standard. Present prac-tices for computing PF&D have resulted in varied interpretation of the -factors being considered and the use of different techniques to establishthem. Variances in application range from an allowance for each elementwithin a standard to the adoption of a fixed or blanket allowance for allstandards in an organization or activity. As a result of these differentpractices, standards for identical work are inconsistent and result indifferent measurement criteria for identical jobs or functions and inco-parable data at the summary levels. In order to minimize these variances,it is necessary to establish a standardized method of computing the PF&Dallowances. The guidelines for developing allowances portrayed in thisappendix have been accepted and used extensively for some time throughoutthe Department of Defense, and are established as the standardized method.
Where appropriate, a fixed PF&D allowance based on the standardized methodmay be developed one time for a specific function or for groups of per-sonnel doing similar work under similar conditions. The fixed allowanceapplies to all standards in the function or group and precludes the need toindividually compute the allowance for each standard. In work situationswhere the guidelines are not applicable, the fixed allowance will be develop-ed through work measurement techniques such as time study or work sampling.
Conditions for Consideration -
The development and application of PF&D allowances requires that the var-Lous conditions under which a job is performed be examined and considered.To insure that all conditions are considered, separate factors are pro-vided for each of the three areas; Personal, Fatigue, and Delay. Analysts/technicians must be completely objective in establishing the allowanceswhich correctly reflect the true situations inherent to the job.
Allowances for Personal Time
Consider the surroundings, working conditions, and job requirementswhich cause the employee to stop work from time to time to attend tonecessary personal needs, (go to restroom, get a drink of water, gee ifresh air, etc). Since most operations allow two breaks of 10mi.nutes each during the 480-minute shift, the basic allowance for
39
L i ,~~~~~~~................... ..----.- . .-----.-..-. -. .-- .- .--..-..- 1
this factor will be 4.2 percent (20.0 minutes). If facilities layoutor management policy dictate that longer break periods are required,it will be necessary to recompute the percentage for the Basic allow- -""
ance subject to approval of higher authority.
Percent - -Basic Allowance 4.2 ,--- U
Add:
a. Normal office conditions 0b, Normal shop, central heat, slightly di-ty or
greasyc. Slightly disagreeable conditions. Exposed to
inclement weather part of time, poor heating,or poor cooling. 3
d. Exposed to extremely disagreeable conditionsmost of time. Proximity to hot objects, con-tinuous exposure to disagreeable odors andfumes, or to excessive temperature ranges. 6
Add the following where applicable:
a. Where time is allowed by manageent at the beginvingof the shift to make ready and/or at the end of theshift to get/put away tools and equipment, clean upwork area, or to don/remove special work clothing(aprons, smocks, etc.) allowances are as follows:
TOTAL MINUTES ALLOWED FORPREPARATION AND CLEANUP 7. ALLOWANCE
5 1.010 2.115 3.120 4.2
NOTE: In "super-clean" room conditions, use (b) below tosupplement these allowances.
b. Adjunctive allowance - allowed for work performed 4.0in "super" clean rooms. Required when operatorsmust utilize special clothing, which includescaps, boots, etc., and remove it when leavingwork area. This includes time to invest or di-vest special clothing at beginning and ending of .shift, at lunch, and for personal requirements.
c. Where the work period is 8 consecutive hours and 4.220 minutes lunch period is allowed at the expenseof the Goverinment.
40
0' "" ' °". .. "" " "' I T """" "i "' "" ".. ' ° "" " " ' ' ' ""'" I°''T ' I"" ' '"'' '''. ' 'I' '
Allowances for Fatiaue
Physical: Consider the average weight handled per man and onlythose elements of time that the man is under load to determine per-centage (total time for under load elements divided by base timeand use the closest percentage on the chart). Also, consider the .
height that load must be manually lifted (average situation).
a. Weight Allowances. The percent allowances given below arebased on the effective net weight being handled in the area between .1knees and chest. Chart also applies to laying weight on floor orlow skid, or to sliding or rolling objects along a plane.
Effuctive Net Percent of tire under loadWeight Handled 1-12 13-25 26-50 51-75 76-1001-10 0 1 2 3 4 .--
11-20 1 3 5 7 1021-30 2 4 9 13 1731-40 3 6 13 19 2541-50 5 9 17 25 3451-60 6 11 22 x x61-70 7 14 28 x x71-80 8 17 34 x x
4i
x Study individual job for improvement considering job enlarge-ment, mechanical aids, worker rotation or other stress re-lieving aids.
Table values will be multiplied by the following factors asdictated by conditions:
For picking up load from floor, multiply basic allow- 1.10ance by
For placing load above chest-height, multiply basicallowance by 1.20
For getting load from above chest-height, multiplybasic allowance by 0.50
The application of the factors from this table in the computationformula on page 37 will normally provide a realistic PF&Dallowance. However, in some instances the use of these factorsresults in an unrealistic, zero or negative denominator in theformula. When this occurs, assuming all factors are definedcorrectly, it will be necessary to combine related elements orstandards into higher levels until a realistic allowance is ob-tained. "Realistic" is defined as an allowance acceptable tothe worker, the supervisor, and the analyst.
b. To determine the effective net weight for sliding or rollingobjects the weight must be multiplied by following coefficients offriction:
41
r. .'.. -,".. _. . .. . . . . .,. ,,/ - ., . . . .• - .. .- ' . "-. ," '. ., i ' .
-, , . .. . - . . -, -. _ .. ..* .-- .,*. , - " . - -- , . .. .- . . . . .. - ...... _ . . . . . ., . . . , -*-. , . .**.
Coefficients of Friction (Average Values)
Surface Friction Coefficient
Wood on Wood 0.4
Wood on Metal 0.4 _
Metal on Metal 0.3
Example: Worker sliding a 40 lb. casting from metal conveyorto wood work bench. ENW - 40 lbs. x .4 a 16 lbs.
Position: Consider the position which the employees must assume
to perform the operation. Select the class which best describes theaverage condition. It is assumed that the job will be less tiresome
if the position can be varied frequently.
Class Percent
a. Sitting or standing 0b. Sitting 1c. Walking 1d. Standing 2e. Climbing or descending ramps, stairs or 4
ladderf. Working in close, cramped position
Mental! Consider the degree of concentration necessary toperform the job and the amount of variety in the tasks. Highlyrepetitive jobs should be low in this factor.
Class Percent
a. Work largely committed to habit; simple cal-culations on paper, reading easily understood
material such as routine or familiar instruc-tions, counting and recording, simple inspec-
cion requiring attention but little discretion,arranging papers by letter or number. 0
b. Work requires full attention; copying numbers,addresses or instructions, memory of part number,name while checking stock or parts list, simpledivision of attention between work at hand andjobs of others, conveyor or time schedule, simplecalculations in head, filing papers by subjectof familiar nature. 2
c. Work requires concentrated attention; reading of
nonroutine instructions, routine calculations onpaper such as long division and four-place multi-plication, checking numbers, parts, papers, etc.,
42
requiring cross check or double check, divisionof attention between three components such asaccounting, inspecting, and grading or drivingover unfamiliar route, watching vehicle, trafficand route signs. 4
d. Work requires deep concentration; swift mental cal- -
culations or calculations on paper, memorizing,inspection work requiring interpretation and dis- 2-,
cretion of unfamiliar nature, as when workingagatnst nonroutine specifications, highly dividedattention betneen phases of work, operations ofothers, hazards, etc. 8
Lighting: Consider the amount of light on the working surfacein relation to the fineness of details upon which the operator works.Consider the amount of glare on the work surface and rapid changingor "hypnotic" effect on the work surface.
Class Percent
Continual glare cn work areas - Workrequiring constant change in lighton work area. Less than 75 footcandle power on work surface fornormal job. Less than 125 foot candlepower on work surface for close work. 2
Noise Factor: Consider the general noise of the work areas aswell as any annoying, sharp, staccato, or intermittent noisesoccurring during more than 50% of the work day. If ear plugs orear muffs are worn, their sound deadening effect must be consideredwhen using this allowance.
Cldas Percent
a. Constant, rather loud noises suchas in machine shops, motor testshops, etc. (over 60 decibels) 1
b. Average constant noise level butwith loud, sharp, intermittent, orstaccato noise such as nearbyriveters, punch presses, etc.(Example: sheet metal shop). 2
Monotony: Consider the fatigue resulting from fast, highlyrepetitive operations. The cycle is the time elapsed from start-ing one element until the same element is started again.
43
~ *. . ..-... '. *.'-,"'.-. °.
Cycle Time Percent
a. 0.00-0.20 minutes 4b. 0.21-0.40 minutes 3c. 0.41-0.80 minutes 2d. 0.81-2.50 minutese. 2.51 minutes or more 0 4
Restrictive Safety Devices and Clothing: Consider those deviceswhich are required by the job and which cause fatigue when worn. Noallowance should be made here unless it io necessary to remove thedevice occasionally for relief, or if wearing them causes fatigue.If more than one device is required, add the allowances.
Class Percent
a. Face shield 2b. Rubber boots 2poeteclhng
Goggles or welding mask 3d. Tight, heavy protective clothing 4 .
e. Filter mask 5f. Safety glasses 0
Allowances for Delay
Consider the job in relation to adjacent jobs--how long can anyadjacent job be shut down before the job being studied is affected?Also, consider other delays inherent in the job, such as supervisory
~ interruptions, moving from one work station to another, waiting forcranes, etc. No delays which can be preventad by the employeeshould be considered here.
Basic Allowance
Class Percent 4
a. Isolated job. Little coordination with ad-jacen% jobs .
b. Fairly close coordination with adjacent jobs 2
Balancing Delay. Where employees are required to move from ,one work station to another to balance adjacent stations, add thefollowing:
a. Move once each 5 minutes 5b. Move once each 30 minutes 3c. Hove once each 60 minutes 2d. Move once each 2 hours 0
44
. . . . . . ..........................................................................................................................
5.2. Skill Level Allowance
In order to predict labor requirements, the normal time, synthesized from
the data in Section 7.0 can be multiplied by K(S), where K(S) is obtainedfrom Table 5.2-1, adapted from Reference 5-2.
TABLE 5.2-1: SKILL LEVEL FACTORS, K(S)
K(S) DESCRIPTION
2.00 Very slow; clumsy, fumbling movements;operator appears half asleep, with nointerest in the job.
1.50 Steady, deliberate, unhurried performance,as of a worker not on piecework but underproper supervision; looks slow, but timeis not being intentionally wasted while -_.under observation.
1.00 Brisk, businesslike performance, as of an(Standard average qual'fied worker on piecework;Rating) necessary standard of quality and accuracy
achieved with confidence.
0.80 Very fast; operator exhibits a high degreeof assurance, dexterity, and coordinationof movement, well above that of an averagetrained worker.
0.67 Exceptionally fast, requires intense effortand concentration, and is unlikely to be .--kept up for long period; a "virtuoso"perfomance only achieved by a few out-standing workers.
The factors in Table 5.2-1 are not a function of the number of times a
specific task has been performed, but represent the range of variability in
456
45""i
*i
' . • - -° • . . - • • . . .. ° . - . . o o .- . -- - °. .- . . .. . •
workers due to differences in skill. The classification does not imply
that workers always remain in a given category. Skill levels can and do
change over time. -
5.3 Learning
The learning process for electronic maintenance technicians involves the
accumulation of cognitive skills by means of repetition of a given task.
The development of manual dexterity is generally a result of highly
repetitive production operations and is probably rot a significant factor
for electronics maintenance. A review of several alternative methods for
defining task time as a function of the cumulative experience of the task
is provided in Reference 5-3. The time constant model advocated is of the
form:
K(L) = (Y(C) + Y(f) x (i-e-t/tau) )-I
T(t) = N x K(L)
Where:
N = Normal time
K(L) = Learning-curve factor
T(t) = Expected task time after "t" hours of repetition
Y(c) Output index for time t = 0
Y(c) + Y(f) = Output index for time t = infinity
tau = Learning time constant
Data presented by Towill and Bevis, Reference 5-4, for eight trainees
perfonning electronic assembly, yield values of:
Y(c) = 33.6%
Y(f) 66.4%
tau = 3045 units x 4.14 minutes/unit
= 210 hours
46
,° -
ExamplIe:
Silorinal time for assembling an electronic unit is 0.2 hr. Determination oilthe expected time for an average trainee who has removed five units isobtained as follows:
N =0.2
Y(c) = 0.336
Y(f) = 0.664
t =) 0.LX x hours
K(L 2 .33 +.664 (1 - e-1/210))
= (33 +.664 (1 - .99525))-
(36+.003)-l
The expected task tine for the fifth unit (t =1 hour) is thus given by:
T(t) =N x K(L)
= 0.2 x 2.95 .
=0.59 hours -0
5.4 Chemical Warfare Ensemble
At elevated temperatures, heat stressi beccmes the overriding factor. Tablep 5.4-1 (Reference 5-5) provides both the maximum time and the recommnendedLiwork and rest cycle times for elevated temperatures, and should be used to
supplement PF&D allowances for normial ambient temper'atures.
47
TABLE 5.4-1: SAFETY ALLOWANCES FOR CHEMICAL WARFARE ENSEMBLE
,;AR N: N; T-'> 12.3LE h lNTENOE9 AS~ A GJIOE ONLY. IF SIGNIFICANT HEkT STRESS OCCURS USING THIS liA),CE.y"PER 'I v)' S-:'t jL') 2)'6JLT 4dl TH LICAL MED)ICAL SERVICE PERSONNEL.
GROUNO SJPPfORT ENSEMBLE
MAXIMUM TIME (MINUTES) WITH MINIMUM HEAT STRESS EFFECTAIR TEMPERATURE RANGES (F)
ENSEMBLE CUNF SJRAT IONS WORKLOAD0 LESS THAN 70 70-79 do-89 90
CHARNC),L 'V;RGAR'IENT L)W xX xx 15 !0 fOVE- F'&tIGli 4ITH MODERATE 200 11; 6S -j
PRU IE-T IlE MASv- HOOD HEAVY 60 50 40 303LOVES, AND gjOOTS.
F4IGjES 41--1 PROTECTI'jE LOW XXY xxx xxx ?MA SK, L4)1:) 4-40 rL1VES. monfERATE xxx XXX 2i)6
HE~dy 300 170 65 4
*F:i 'EMPERATURE 1N EXCESS ')F 90. WORKTIME WILL BE SEVERELY LIMITED.
SlJPERVISR INFORMATION
Wilm,'REST C'YCLE TIME (MINUTES) WITH MINIMAL HEAT STRESS EFFECTSAIR TEMPERATUJRE RANGES 'F.
ENiSEM9LE C )NFI VjATIONS WOARKL-)AO LESS THAN 70 7o-79 130-89 1
CHARCO"AL ')V" GAIRMENT L.OW XXX XXX 40/1.30 20i50)YER FAT:('GOES WI[TH 4MOORATE 40/20 30/25 20/140 10/60P4-.-}T 'P: V ASY +)01), mE A,.Y 20,!25 15/30 13,'50 5.!1 7 oGLOVES' AN) B'01S.
FA 'I fuc 4 I.H PR ) EC-TIV 1 v- LOW XXX XXX XXX SO)/SdMASK, 100,I ANI) GLOVE S. MOWERATE XXX XXX 5,)/ 5 30!60
HEAVY 60:310 45/30 ''o 145
*F~k TEMPERATuRE IN4 EXCESS OF 90. WORKTIME REQURIES RE4:r CYCLES ARE PROHITIVELY RESTRICTED.
L-)w .iRKLJ)Ao: ADMINSPATIVE WORKMIIOERATE -ilqKLoA0: MOST GR')'J0 SUPPO0' OPERATIOINS.
HEAY W~KLAD 0MOB-L-)AD;N46, -iANDLING HEAVY EQUPIENT. C;)NS TIT[N TASKS.
XXX -ANY qEASY)NARLE 40RK.'4EST CYCLE SHOULD PRE VE4T HEAT CASULT IFS.
48~
7]48L'
6.0 RECOMMENDATIONS FOR FUTURE WORK
The project described in the previous sections has been one of development
rather than research. Existing methods and techniques have been used to
develop the time standard data presented in Section 7.0. These data are
the "conclusions" of the work and as the work progressed, several areas -2have come to light that night warrant further investigation.
Reconmendations for future work have therefore been made and constitute the
remainder of Section 6.0.
6.1 Classification and Coding
The data in Section 7.0 have been classified with a mnemonic coding system
that, after sane use, permits rapid location of data without the need to
refer to an index. However, the size of the data set of standards is
approaching the capacity for its mnemonic coding system. Since a large
number of maintenance analyses can be created from the time standards
provided, their retrieval by a code that contains mnemonic fields requires
the careful design of a suitable coding system. A taxonomy of equipment
characteristics or naintenance operation characteristics, or both, is an
alternative to the mnemonic approach. Most importantly, the system must be -
unambiguous if good retrieval capability and duplication of analyses are to
be achieved. The benefit of the well-designed classification and coding
system might be significant if the DO decides to build a data bank of
maintenance task times for specific electronic equipment.
6.2 Learning Curves and Skill Level
The development of 'K" factors based on learning was addressed in Section -
5.3. However, only one set of data was found for electronics and that was
for manufacturing, not for maintenance. It appears that work is required
that will correlate maintenance time For a given task with factors such as:
0 The number of times the worker has performed the tasK
49
' . . . . . . . . . . . . . . . . . . . ..- .. ' ".. " '
o Natural ability
o Duration and specificity of training
o The time between identical maintenance actions
o Years of related experience and age
A knowledge of such factors would enable the results of maintenance task
time analyses to be used for:
0 Development of life-cycle costs
o Design trades between reliability and maintainability
o Spares and manpower planning
0 Determination of cost optimized training and retraining schedules
It is therefore recommended that time standards be developed for some
weapon system not yet in service and that data be collected to enable the
above "K" factors to be calculated. Where possible, variables such as -
training and skill level would be changed in a manner appropriate for a
statistically designed experimenL.
6.3 Abnormal Environments
Alluisi and Fleishman (Reference 6-1) provided more than 200 references ontemporal factors and work rest cycles associated with human perfer-mance andproductivity under abnormal conditions, including some that occur under
military operations. A review of these reports v3s o,tside the scope ofthe current contract but might yield facto'- s rel:vant to planning for
battle or other extenuatinig conditiuns.
No reports were found on conditions of weightlessness that apply to
analysis of space station maintenance. It'is probable that the times for
basic body motions, on which the standards in Section 7.0 are based, are
significantly different for weightless conditions. Of course there may be
some factor of proportionality for the same body motions on the ground and
in space. Consideration should therefore be given to an analysis of
existing records of different astronaut's body motions on the ground and in
space to determine the "K" factor for space maintenance.
50
n [ ................................................. I I"~'~ "(lIl"' "I '' n"'YII
6.4 Failure Mode Rates
Two problems exist in determining fault isolation times. The first problem
is the lack of suitable data on failure rates by mode. The second problem
is the inordinate amount of work that is required to perform an analysis of L
contemporary electronic systems. There appears to be no easy solution to
either of these problems.
For example, Figure 6.4-1 shows a part of a fault isolation procedure for a
flight management computer.
PREREQUISITESFMC NAV DATA ELECTRICAL POWER (MM 24-22-00)
LOADING PROBLEMS CS'S: 11E8,11E9, E29,11E30_.
0D "UNIT FAIL" ANNUNCI- YES _ IFORm DATA LOADINGATOM ON DATA S( LOADER IPITOCIUE .'SING A FFERENT IILLUMINATE AFTER LOADEI POWER- iDATA 0ASE LOADEIR.On SELF-TEST WAS COPL ETED 0
IM: ALL LIGHTS ON DATA SASELOADER ILLUMINATE FORAPPROXIMATELY 6 SECONDSWRAING POER-O4 SILF-TEST 5 IENCE.
PERFORM DATA LOADINGn O PROCEDURE USING A DIFFERENT
I TAPE.DI D "READ FAIL" ANNUNCI- YES IF FAULT PERSISTS, VERIFY
At ON DATA SASE LOADER j DATA SASE LOADER INTIRFACEI LLUINATI AF TERI LOADERt "WvEI- CAKE| IS PROPERTLY CONNECTED
ON SELF-TEST WAS COMPtEISO? TO FMC DATA SASE LOADERCOINNECTOR.
DD "DATA Ki FAIL" ANNU- YES OPEN "FNCS CNPTR" CIRCUIICIATOR ON DATA BASE LOADER BREAKER CORRESPONDING TO SIDE (N133)(PM 34-61-01).ILLUMINATE AFTER LOADER POWER- THAT WAS BEING LOADED AND DIS-on SELF-TEST #AS COMPLETED? CONNICT DATA SASE INTERFACE
CABLE. AfTER 15 SECONDS,On MINIUS, CLOSE "FNCS CNPTR-
CIRCUIT BREAKER.AFTIR DATA LOAD WAS ENSURE "INCS CNPTR" _ DATA LOADING OPfRATION IS
COMPLETED, WAS NAY DATA" OR CIRCUIT BREAKER CORRESPONDING FUNCTIONAL. NO ACTION"ACTIVE" CYCLE DISPLAY ON CDU TO INC THAT IS NOT BEING / EOI:ED."I01T" PAGE BLANK? LOADED IS OPEN AND RECOANECT
DATA BASE LOADER INTERFACENO CABLE.
RIEPEAT DATA LOADING PROCE-DATA LOAD NOmAL. DURE., LODOMADOES
FAULT PERSIST "
Figure 6.4-1. Fault Isolation Procedures
Times for each of the maintenance actions called for in the procedure can
be determined by synthesis from the standard times in Section 7.0.
However, the average time taken for fault isolation is a function of the
probability of following each route through the fault isolation tree. The
probability of following each route is in turn dependent on the probability
of failure of the piece parts of system, on the system architecture, and in
most cases on the modes of failure of the piece parts. To complete the
analysis, MIL-HDBK-217 or its equivalent would have to include failure
rates by mode. A computerized method of analysis might then be developed
to accomplish some of the combined failure mode and effect analysis, and
fault isolation time analysis. Neither of these two tasks is trivial but
the payoff in terms of improved fault isolation methods could be very
significant.
52
7.0 CODING, STANDARO DATA, AND ENVIRONMENTS
This section provides the data required by an electronic system maintenance
analyst for synthesizing maintenance task times. The data consist of:
o Details of the way in which each type standard data has been classified
and coded to permit easy retrieval and referencing.
o Standard data from which times for electronic systems maintenance can be
synthesized.
o Standard environments that can be used to define the conditions under
which maintenance is assumed to be performed.
Section 7.2, which contains the standard times, is indexed by mnemonic code
for easy location. The data used to develop the standards in Section 7.2
have been deposited with the Defense Industrial Resources Supply Office,
Cameron Station, Alexandria, Virginia 22314.
53
7.1 Coding of Elemental Standards
Each elemental standard time is uniquely identified by a seven charactercode that is placed in the upper corner of the data sheet.
F.TP-SE-I TIN WIRE
TIN
FIRST THU ADDITIONAL THU
Ii 95 Xl 482
Tin First
Begins with reaching to soldering iron. Includes cleaning tip, positioningiron in holder, getting wire or solder, tinning wire or terminal. Ends withasiding wire or solder and solderlig iron.
Tin Additional
Begins with cleaning tip. Includes getting wire or solder. Ends with tinningwire or terminal.
Figure 7.1-I Mnemonic Classification Code
The code is mnenonic and is divided into three fields, the first of which
is subdivided. The first character splits the data in two parts, and is
either an "E" for electrical and electronic or an "0" for other. ("Other"
contains the nonelectronic standards required to access or remove and
replace equipment.)
The second and third characters describe the work category. Figure 7.1.1
has a "TP" for a "Tool, Powered" obtained from Table 7.1-1.
The fourth and fifth characters are qualifiers. For exampl e, the SE of
ETP-SE stands for "Solder, Electric" obtained from Table 7.1-2.
54
obtained from the body of the data sheet.
The sixth character, obtained from the body of the data sheet, identifies "
the following attributes:
R remove first piece
I install first piece
Y remove additional piece
X install additional piece
D* first piece, different than remove or install
Z additional piece, different from remove or install
* An "0" is also used in standards other than electronic.
The seventh character, obtained from the body of the data sheet, is either
a number referring to a special case or an
A or F for Very Easy
B or G for Easy
C or H for Moderate
o or I for Difficult
E or J for Very Difficult
5.
55 .
TABLE 7.1-1: WORK CATEGORY CODES (2ND AND 3RD DIGIT)
Major actions being performed, or the type of equipment involved:
AC Actuate
BM Body Motion
CA Calibrate
CL Clea.
CP Clamp
EL Elemental
IT Inspect
JP Job Preparation/Temination
MH Material Handling
NF Nonthreaded Fastening
OH Object Handling
PK Package
PT Process Time
RD Read
ST Surface Treat
TF Threaded Fastner
TL Tool Use, Hand
TP Tool, Powered
WH Wire Handling
WR Write
56
TABLE 7.1-2: WORK QUALIFIER CODES (4TH AND 5TH DIGIT)
AC Access HC Hand, Clean
BB Black Box HS Hand, Simple
BF Bolt, Finger HT Hold, Temporary
BL Bundle Lace IH Insulation, Heat
BM Bolt, Manual IS Insulation, Strip
BP Bolt, Power LA Lay Aside
BS Bond or Seal LP Latch, Pressure
BT Bundle, Tie MA Manual
CA Coat, Aerosol MY Magnify
CB Connector, Bayonet NT Number Transfer
CC Cord, Coil and Uncoil OB Object
CD Climb or Descend OD Other Data
CE Connector Electrical OF Obtain File
CF Cap or Connector, Friction OP Obtain Part
CH Camloc, High-Stress PA Protective Apparel
CL Clock PC Printed Circuit
CM Control, Manual PD Pliers Diagonal
CP Cord, Plug PN Pin
CS Cap, Screw PO Position
CT Cable Tie PT Prose Transfer
DE Disengage RS Repeat Sequence
DR Drawer RT Ring, Tru-Arc
DS Desolder SA Safety
EO Envelope, Open SC Safety, Continuous
ER Eyelet, Replace SE Solder, Electric
ET Estimate SM Screw, Manual
EV Examine, Visual SP Screw, Power
FT Fasten SR Snap Ring
FX Flux ST Safety, Twisted
GS Glasses, Safety TA Test, Automatic
Continued on page 58
57
TH Test, Hand
TM Technical Manual
TR Tag, Routing
TS Time Study
VA Vise, Adjust
VS Video Tape Standard
WC Wire Crimp
WO Walk Obstructed
WL Wire Lock
WT Wrench, Torque
WW Wire Wrap
58
7.2 Elemental Standard Data
The standard data are divided into two data sets. The first set, prefaced
by an "E" code, covers the work elements that apply to electronic equipmentrepair only. The second data set covers the other work elements, prefaced
by an "0", consistinG of elements that apply to other areas of maintenance.
The data are arranged in alphabetical order of mnemonic code.
59
ECA-CM-XX ADJUST DEVICE
FIRST ThU ADDITIONAL T4U
01 1200 Zi 670
First
Begins with reaching to tool. Includes locating adjust point, makingadjustment, checking reading. Ends with asiding tool.
Additional
Begins with locating adjust point. Includes positioning tool. Ends withmaking adjustment.
IIlk
60
CALIBRATE COAXIAL CABLE TESTER ECA-TA-XX
FIRST TMU
D1 7950
02 4790
First (Dl) (Used With 50-ohm cable)
Begins with setting controls on the Time Domain Reflectometer (TOR) tester.Includes adjusting TOR controls, removing dust caps from TOR and precisioncable, connecting the precision cable to the rDR, calibrating TOR andadjusting CRT to obtain zero index with 50-ohm precision cable. Concludes(after test) with removing 50-ohm cable, stowing cable, and replacing dustcaps.
First (02) (Used With Other Than 50-ohm Cable)
Begins after setting-up tester for 50-ohm cable test. Includes gettingappropriate impedance-matching adapter, removing dust caps, connecting adapterto 50-ohm precision cable, and adjusting controls to obtain zero index.Concludes (after test) with removing adapter cable, replacing dust caps, andstowing the adapter.
Remarks
Use with EIT-TA-0l, Coax Cable Test.
6.
6!
ECL-F X-XX CLEANING FLUX
FIRST THU ADDITIONAL TMU
D 229 Zi 84
First (Up to 3-in, stroke)
Begins with reaching to cleaning fluid. Includes removing and asiding cap,getting brush, wetting brush, cleaning flux from connection, asiding brush.Ends with getting and installing cap.
Additional (Up to 3-in. stroke)
Begins with wetting brush. Ends with cleaning flux from connector.
.-..
62
...... ..... o
62"
CONFORMAL COATING, EPOXY, AND URETHANES ECL-HC-XX
REMOVE
FIRST ThU ADDITIONAL TMU
Ri 471 YI 308
Remove First
Begins with reaching to printed circuit board. Includes positioning board,getting heated tool, loosening conformal coating from terminal, asiding tool,getting vacuum, cleaning surface, releasing board. Ends with asiding vacuum.
Remove Additinnal
Begins with applying heated tool to temin.l. Includes loosening conformalcoating from terminal. Ends with cleaning additional area.
63
_ _ _- -g. --- - - i - -: .: _.. "
IECL-SE-01 CLEAN SOLDERING IRON
FIRST ThU
01 38
First
Beings with positioning iron to sponge. Includes wiping tip, regrasping iron,j positioning iron back to sponge. Ends with wiping tip on other side.
I6
COAY.IAL CABLE TEST EIT-TA-01
FIRST TMU
01 2704
Fi rst
Begins with connecting the cable to be tested to adapter. Includes settingfeet/division scale on TDR, checking zero adjustment, adjusting zeroreference, adjusting distance dial to set pulse of graticule line, makingfinal adjustments, actuating test switch, reading fault location indicator.Ends with disconnecting cable tested.
Remarks
Use with ECA-TA-01/D2 Time Domain Reflectometer calibration.
N '
65
*" : " " '; " 'i " ' 'i " -'I ' " ' I ' I ~ ~ ~ ~ ~ ~ ~ ~~.. . . ... . . . . . . . . . . . . . . . . . . . . .."" ' "."T I ". . - -'
-' ' ' ' ' * ' ' ' ' '"
" ' ' " " -' " '
EIT-TA-02 TRANSISTOR TEST
FIRST TMU
02 630
* First
Begins with reaching to test leads. Includes installing test leads,positioning low-drive switch, observing good/bad indication, device polarity,and base lead identification, positioning high-drive switch, observinggood/bad indication, device polarity, and base lead identification, -
positioning switch off. Ends with disconnecting test leads.
66
U
Ui
p -i
S-
66
S
MEGGER TEST, CONTINUITY, AND INSULATION EIT-TH-O1
FIRST TNIJ ADDITIONAL T1U
Dl 1146 Zi 776
First
Begins with getting megger, uncoiling leads. Includes installing test leads,cranking megger, checking meter indication, disconnecting and coiling testleads. Ends with asiding megger.
Additional
Begins with installing test leads, cranking megger. Ends with disconnectingtest leads.
67
.............. ... . . . . . I i ' i " "
D'72
I-
EIT-TH-D2 CURRENT MEASUREMENT, DECADE BOX
FIRST THU ADDITIONAL THU
02 4440 Z2 2600
First
Begins with connecting equipment. Includes loosening binding posts,positioning leads, tightening binding posts, installing and removing leads totest instrument, actuating selector switch, selecting current, settingvoltage, adjusting coarse and fine controls, reading indications, adjustingdecade half scale, turning down coarse and fine controls, adjusting decade,presetting voltage, adjusting coarse and fine controls, comparing readings,turning coarse and fine controls down, decade to zero, selector down. Endswith disconnecting equipment.
Additional
Begins with turning selector to current. Includes selecting voltage,adjusting coarse and fine controls, comparing indications, adjusting decadehalf scale, turning down coarse and fine control, presetting voltage selectorto proper range, adjusting coarse and fine controls, comparing readings.Turning fine and coarse controls down, decade back to zero and selector down.
4
68
4., . . . " : : , r, ". . . . . ' . . -. . . . . . - , . . " . .. .. . . . . . . " " . . - . . " .. '
RESISTANCE MEASUREMENT, DECADE BOX EIT-TH-03
FIRST ThU ADDITIONAL ThU
D3 3040 Z3 990
First
Begins with connecting equipment. Includes loosening binding posts,positioning leads, tightening binding posts, installing and removing leads totest instrument, selecting "ohms", verifying decade is set at zero, turningselector to proper range, adjusting zero control , actuating decade switch asrequired to obtain resistance reading, returning decade to zero. Ends withequipment disconnect which includes loosening binding posts, removing testleads, and tightening binding posts.
Additional
Begins with turning selector to proper range. Includes adjusting zerocontrol, actuating the decade switch as required to obtain resistance reading.Ends with returning decade to zero.
I.
69
............. ......................... ",'i"" i....',............"...".'.'"",",....",..
EIT-TH-04 RESISTANCE MEASUREMENT, WHEATSTONE BRIDGE
FIRST TMU
04 1420
First
Begins with reaching to test leads. Includes positioning leads on testpoints, positioning ratio arm dial, actuating BA and GA switches, adjustingmeasuring arm dial, reading dials, removing and asiding test leads.
Remarks: Wheatstone bridge on a test bench ready for use. --
07 .• ... , .
LOGIC CHECK, DIGITAL PULSER PROBE EIT-TH-D5
FIRST TMU
05 520
First
Begins with reaching to probe. Includes connecting probe leads, actuating plogic family switch or logic pulser switch, positioning probe to test point,observing indicator light. Ends with disconnecting leads and asiding probe.
I
•I
711
'," i , i '" " " .. . " i i *i *, - ' i ,' i . ...... i...~ . . . . . . . .
EIT-TH-06 VOLT-OH-MILLIAMMETER CHECK
FIRST ThU ADDITIONAL ThU
D6 926 Z6 296
First
Begins with reaching to volt/ohm meter. Includes positioning test leads inmeter, selecting scale, zeroing meter, positioning probes to test points,reading meter indication, disengaging probes and leads. Ends with asidingmeter.
Additional
Begins with probes in hand, includes occasional resetting of meter scale,positioning probes to test points, reading meter indication.
r: ... .... .. -.. / .:< > <... '
- - .-.. .. . . ..... . . . . . . . . . . . . . . . . .
72
..... ........ ..............
............ .............. ........ . . ....... ... .. . . . . . . . . .
•~ ~~~~~~~~~~~~~~ -. .... ' "-" - °.- " °
' ' ° "....,~ ~ ~ ~ ~ ~~~~~.. ... .. ......""... , ' ,, , i i i 'i "-" ;
CURRENT TRACE EIT-TH-07
FIRST T14U
07 640
First
Begins with reaching to current tracer. Includes positioning tracer probe,
adjusting light sensitivity and observ' indication. Ends with asiding probe.
73
EJP-SA-XX STRAP, STATIC CONTROL
REMOVE INSTALL
FIRST TMU FIRST T4U
R1 77 I1 104
Install
Begins with reaching to strap and ground cord. Includes all motions forinstalling strap to body and attaching ground cord to reliable ground.
Remove
Begins with reaching to ground cord and strap. Includes all motions fordisengaging ground cord and strap. Ends with laying aside ground cord andst rap.
74
IIIIIII
PREHEAT PRINTED CIRCUIT BOARD EJP-SE-01
FIRST THU
0l 700
Preheating Printed Circuit Board
Begins with getting PCB and positioning it on heater. Includes adjustingheater temperature, turning heater on, allowing board to heat, turning heateroff, and ends with removing board from heater.
Remarks
To be used when installing or removing surface mounted devices on PCB approvedfor preheating.
Analysis based on preheater HG3-2 manufactured by Manix, Division of HenryMann Inc.
/
I .
I-
75
EJP-TA-XX PREPARE OR TERMINATE PCB TEST
JOB PREPARATION TMU JOB TERMINATION TMU
D1 7101 D2 3600
Job Preparation
Begins with getting and installing interface unit, including walking to andfrom interface unit storage, installing power cables to interface display,installing circuit board to be tested, walking to magnetic tape storage,selection of tape, walking to tape drive, installation of tape of drive unit,walking to keyboard. Ends with typing required information on keyboard.
Job Termination
Begins with hand-rewinding of magnetic tape, unlocking tape from drive unit,removing tape, walking with tape to tape storage, asiding tape, walking toprinter, removing printout, walking to interface display unit, remov' ingcircuit board tested, carrying circuit board to work bench and return,removing unit from test set, carrying interface unit to storage unit. Endswith walking to work bench.
/
Remarks
For probe of test points, use ETL-TA-XX.
76
CURE ADHESIVE, ULTRAVIOLET ENF-BS-01
INSTALL THU
01 1510
Install
Begins with positioning device in holder. Includes opening door, positioningdevice and holder under lamp, closing door, setting timer, allowing for curetime, opening door, removing device and holder from chamber, closing door,removing device from holder. Ends with inspecting for proper cure.
Remarks
Ultraviolet lamp, 2kw, 200w per in.Adhesive type MR-8153R, Panasonic Industrial Co.
77
- ".-
ENF-BS-OX CURE ADHESIVE, OVEN
INSTALL THU
02 9570
D3 26270
Install
Begins with positioning device in holder. Includes opening oven door,positioning device and holder in oven, closing oven door, setting timer,allowing for type of adhesive, turning off oven, opening oven door, removing ,device and holder from oven, closing oven door, removing device from holder.Ends with inspecting adhesive for proper cure.
Remarks
Oven is preheated to 150 C.
Adhesive Type:
D2: MR-8153R, Panasonic Industrial Co. or 124-1, Ablestik LabsD3: E-7, Epoxy Technology
78
ENF-CB-XXCONNECTOR, ELECTRICAL, HULTIPIN BAYONET, 1/4 TO 1-1/2-in. OIA E,.-C-..X
REMOVE INSTALL
RA 80 IA 160RB 130 1B 220RC 190 IC 330RD 280 ID 500RE 390 IE 750
Remove
Begins with visually selecting cable-mounted connector to be removed.Includes loosening and removing bayonet-type collar and disengaging cable-mounted connector from fixed connector alone or in a group. Ends withreleasing or laying aside cable-mounted connector. 4
Install
Begins with reaching to cable-mounted connector alone or in group. Includesreading cable number, visually selecting matching fixed connector and engagingcable-mounted connector. Ends with twisting to secure bayonet-type collar. 4
Remarks
Applies to Bendix PT-06 series connectors and similar.
Not applicable to coax connectors (OTF-CE).
Case variable factors: distance 10%, weight 5%, control 85%.
(Identical to NALC code ONF-CB-XX).
79 4
L 79
%,.p "
- .- - * . * i .. - - .,. . * . _ __ - . .
ENF-CE-XX CONNECTOR, WITH JACKSCREW
REMOVE ThU INSTALL ThU
RB 2132 IB 2350RC 3052 IC 3520 -RD 4112 ID 5160
Remove
Begins with selecting cable-mounted connc-tor to be removed. Includes .reaching to tool, loosening jackscrews, disengaging connector from fixedconnector. Ends with capping both fixed and loose connectors and asidingloose connector and tool.
Install
Begins with selecting cable-mounted connector to be installed. Includesremoving caps from both loose and fixed connectors, positioning looseconnector on fixed connector, reaching for tool and tightening jackscrews.Ends with asiding tool.
8
Io. I
" .. -
-- o .
0e
° . I
0- . -
. I-,-
6 '4 -°'
80l6"-
, 4'.' .
S CONNECTOR, FRICTION LOCKING ENF-CF-XX ,
REMOVE TMU INSTALL THU
RB 312 IB 430 L.~RC 412 IC 600RD 592 ID 1010
Remove
Begins with visually selecting cable-mounted connector to be removed.*Includes disengagement of cable-mounted connector fran fixed connector. Ends* with capping both loose and fixed connector and asiding loose connector.
* Install
Begins with selectin~g -.able-rnounted connector to be installed. Includesnromoving caps from both loose and fixed connectors, positioning loose.connector on fixed connector. Ends with applying pressure to mate the
* connectors.
P-
ENF-ER-XX EYELET, PCB
REMOVE THU INSTALL TMU
R1 417 11 2270
Remove
Begins with positioning PCB on drill press, aligning eyelet with drill,actuating handle to lower bit to eyelet, applying pressure to drill througheyelet. Ends with raising drill.
Install
Begins with positioning PCB for work, positioning eyelet in board, moving PCBto arbor press, positioning board in press, securing eyelet by actuating -press. Ends with examining installation and asiding board.
82I
* I
* °- I
82
*. .-
SECURE DEVICE WITH ADHESIVE ENF-PO-I1
INSTALL
FIRST TNU
11 214
First
Begins with reaching to adhesive. Includes removing cap, applying adhesive toPCB, asiding adhesive, replacing cap, getting dual inline package (DIP) orflatpack, getting positioning tool, positioning tool to DIP or flatpack,positioning DIP or flatpack to PCB, releasing tool. Ends with asiding tool.
83.-..
•LL
......... -.
... o.....
ENF-SE-I1 SECURE DEVICE WITH SOLDER
INSTALL
FIRST THU
Ii 433
First
Begins with reaching to DIP or discrete. Includes getting positioning tool,positioning tool to DIP or discrete, positioning DIP or discrete to PCB,releasing and asiding tool, getting, applying, and asiding flux, getting andcleaning iron tip, getting solder, tacking on lead. Ends with asiding solderand iron.
84
I. ".
I .
* ' *, * 4. - :4 ._
FLUX EST-FX-XX
FIRST T14U ADDITIONAL THU -
D 1l 122 Z 1 40
Fi rst
Begins with reaching to open or closed flux bottle. Includes removing cap,positioning flux bottle, applying flux, replacing cap. Ends with asiding flux-bottle.
Additional
*Begins with positioning flux bottle. Ends with applying flux.
a* jj 1Z
85S
ETF-BB-XX BLACK BOX EXTRACTOR
REMOVE T4U INSTALL ThU
RI 497 11 730
Remove
Begins with reaching to latch and releasing latch (Hollingshead), rotatingknob, checking for red band and rotating keeper (Tridair). Ends withdisengaging extractor.
Install
Begins with positioning the hold down/extrator, rotating the keeper (Tridaironly), tightening knob, repositioning LRU, final tightening of knob. Endswith checking red band for proper exposure.
'7I
HOLLINGS HEAD
TRIDAIR
86
.1 ~ ' _____-.*,*-
CONNECTOR, ELECTRICAL, NULTIPIN, THREADED COLLAR ETF-CE-XX,p..
REMOVE TNU INSTALL THU
1/4 to 1 inchRA 470 IA 580RB 570 IB 680RC 710 IC 850RD 880 ID 1130RE 1080 IE 1490
1-1/16 to 1-1/4 inch
RF 530 IF 670RG 640 IG 780RH 830 IH 1000RI 1140 II 1370RJ 1570 Id 1950
Remove First Piece
Begins with visually selecting cable-mounted connector to be removed.Includes loosening and removing threaded collar and disengagement of cable-mounted connector from fixed connector alone or in group. Ends with releasingor laying aside cable-mounted connector.
Install First Piece
Begins with reaching to cable-mounted connector alone or in group. Includesreading cable number, visually selecting matching fixed connector, engagingcable-mounted connector to fixed connector, starting and running down collar.Ends with final tightening of threaded collar.
Remarks .
Does not include use of tools for final tightening or initial loosening ofthreaded collar. Does not include installation or removal of safety wire.
Applies to AN 3100, AN 3106, and similar.
Case variable factor: distance 10%, weight 5%, control 85%.
(Identical to NALC code OTF-CE-XX).
I:I
371 2-
* ETL-.MA-01 FORM COMPONENT LEADS
FIRST THU
01 573
* First Piece
* Begins with measuring PCB eyelet spacing, obtaining component, positioningcoimponent to tool and forming leads. Ends with disengaging canponent from
* tool and asiding component and tool.
88
k7 77 L- 7. ' --
PULL PCB ETL-PC-R1
REMOVE TKU
*R1 116
Remove First Piece
Begins with reaching to PCB puller. [ncludes positioning pullet, actuatingpuller, disengaging PCB, releosing puller. Ends with asiding PC3 and puller. -
I Remarks
Use OOH-PO-XX for Instal I.
IK
89
IETL-PO-XX CLIP-ON HEAT SINK
REMOVE Th4U INSTALL THU
R1 79 11 69
Instal 1
Begins with getting heat sink. Includes opening heat sink and positioning onwork object.
Remove*
Begins with reaching to het sink. includes applying pressure to release heat
j sink. Ends with asiding heat sink.
90
- PROBE TEST POINT ETL-TA-XX
SF IRST T4U ADDITIONAL ThU
01 2060 Zi 830
First
Begins with walking to printer. Includes removing printout, installing aprobe on interface display unit, verifying first check point frcm printout,locating check point on PCB, probing first test point with care. Ends withcalling up test program by input to keyboard.
Additional
Starts with verifying additional test point from printout. Includes locatingpoint on PCB, and probing.
Remarks: Use with EJP-TA-XX.
9.
..........................- . . .. .... .... ....
-. '"'-... -'- ,. .
ETP-DS-R1 DESOLDER, BRAID
REMOVE
FIRSr ThU ADDITIONAL ThU -
Ri 1546 Yi 1496
L Desolder First
Begins with reaching to wicking braid. Includes cutting, stripping, andforming curve in wicking braid, positioning wire to terminal , getting andcleaning soldering iron, positioning iron to terminal, wicking off excesssolder. Ends with asiding iron and wicking braid.
Desolder Additional
Begins with cutting, stripping, and forming curve in wicking braid. Includespositioning wire to terminal , getting and cleaning soldering iron, positioningiron to terminal, wicking off excess solder. Ends with asiding iron.
L
I.
92
0 .::
* DESOLDER, PUND ETP-DS-R2
REMOVE
FIRST TNU ADDITIONAL THU
R2 633 Y2 440
* Desolder First
Begins with reachinq to desoldering pump. Includes loading Diunger, getting,cleaning, and positioning iron, positioning pwip, heat pin, or terminal , -
actuating pump plunger. Ends with asiding iron and pump.
* Desolder Additional
Begins with loading plunger. Includes cleaning and positioning iron,positioning pulnp, heat pin, or terminal. Ends with actuating pumnp plunger.
I 93
q ETP-OS-R3 DESOLDER, BULB
REMOVE
FIRST TMU ADDITIONAL TMU
R3 522 Y3 422
- Desolder First
,. Begins with reaching to squeeze-bulb. Includes getting iron, squeezing bulb,positioning iron and bulb, heating terminal, regrasping bulb. Ends withasiding bulb and iron.
- Desolder Additional
Begins with squeezing bulb. Includes positioning iron and bulb, heatingterminal. Ends with regrasping bulb.
"ly "I,*.,,,;' "!.,
94
,ik
DESOLDER, VACUUM ETP-DS-R4
REMOVE
FIRST TMU ADDITIONAL ThU L
R4 230 Y4 140
Desalder First
Begins with posit-oning printed circuit board. Includes getting desolderirigtool , moving foot to foot pedal , desoldering tool to terminal , heating solder,actuating foot pedal . Ends with asiding iron and removing foot from footpedal.
Desolder Additional
Begins with moving desoldering tool to terminal . Includes heating solder and
actuating foot pedal . Ends with removing desoldering tool from terminal.
A,.
95
ETP-SE-X1 TIN WIRE
TIN
FIRST ThU ADDITIONAL TMU
U1 595 XI 482
Tin First
Begins with reaching to soldering iron. Includes cleaning tip, positioningiron in holder, getting wire or solder, tinning wire or teminal. Ends withasid i n wire or solder and soldering iron.
Tin Additional
Begins with cleaning tip. Includes getting wire or solder. Ends with tinningwire or terminal.
96
SOLDER OR UNSOLDER WIRE ETP-SE-X2
UNSOLDER SOLDER
FIRST THU ADDITIONAL THU FIRST TMU ADDITIONAL TMU
R2 220 Y2 142 12 513 ....
Unsolder First Piece
Begins with reaching to iron. Includes applying iron to terminal, unsolderingwire, disengaging wire, asiding wire. Ends with asiding iron.
Unsolder Additional Piece
Begins with positioning iron to terminal. Includes unsoldering wire,disengaging wire. Ends with asiding wire.
Solder First Piece
Begins with reaching to wire. Includes positioning wire to terminal, applying - --flux, getting solder and iron, cleaning iron, soldering wire to terminal, asiding iron .nd solder. Ends with checking connection.
97,
I
97
ETP-SE-X3 SOLDER DIP
SOLDER
FIRST TMU ADDITIONAL ThU
13 306 X3 166
Solder First Lead
Begins with applying flux. Includes getting solder and iron, cleaning iron,positioning solder and iron to lead, soldering lead, asiding iron and solder.Ends with checking connection.
Solder Additional Leads
Begins with applying flux. Includes cleaning iron, positioning iron andsolder to lead, soldering lead. Ends with checking connection.
98
98
SOLDER SLEEVE OF SHIELDED WIRE ETP-SE-X4
FIRST TMU
14 3252
First
Begins with getting wire. Includes stripping wire, tinning wire, gettingsolder sleeve, positioning solder ring of sleeve over shielding, positioningjumper wire, getting Zap gun, plugging in Zap gun, adjusting Zap gun,positioning sleeve and wires in gun, actuating Zap gun, removing wire fromgun, inspecting terminal, unplugging Zap gun. Ends with asiding wire and gun.
99
",. . ." i " " " i , . 't * ' .. . . ' '.'.'.'.. . . .
ETP-SE-X5 SURFACE MOUNTED DEVICE, SOLDERED LEADLESS CHIP CARRIER
REMOVE INSTALL
FIRST TMU FIRST TMU
R5 4762 15 2202
Remove
Begins with preheating PCB (EJP-SE-01). Includes positioning board in holder,coating chip to be removed with temperature-indicating fluid, applying flux,positioninq heat shield, turning on hot air terminal, extending hot air tubes,adjusting air flow, waiting for solder to melt, observing temperature-indicating material, disengaging chip.
Install
(Follows removal before PCB has cooled)Begins with getting new chip. Includes checking part number, positioning chipon board, applying flux, allowing time for solder to melt, observing solderthat melts. Ends with turning off hot air terminal and removing PCB fromholder.
Remarks
Analysis based on use of Hart--100 hot air terminal, manufactured oy Nu-ConceptConputer Systems, Inc.
100
I00
-. - -. - . .. .. . . . . . , . - .- . .-. . . .- . . . .. . . . . . . . .- .. . . . . .
4CHANGE BIT OR SLEEVE, WIRE WRAP TOOL ETP-WW-O1
REMOVE AND INSTALL
FIRST TMU
01 177
Rem~ove and Install
Begins with loosening chuck. Includes removing bit or sleeve, asiding bit orsleeve, getting bit or sleeve, installing bit or sleeve. Ends with tighteningchuc k
Rem~arks
Also applicable to other tocis that do not use a chuck key.
10'
EWH-BL-XX BUNDLE, LACE
REMOVE INSTALL
0 FIRST TMU ADDITIONAL TMU FIRST TMU ADDITIONAL TMU
RA 150 YA 90 IA 970 XA 140RB 240 YB 130 IB 1930 XB 330RC 300 YC 160 Ic 2830 XC 450RD 460 YD 210 ID 5090 AD 800RE 650 YE 280 IE 8690 XE 1580
Remove First Piece
Begins with reaching to diagonals or scissors. Includes cutting and removingcord. Ends with laying aside diagonals or scissors and cord.
Remove Additional Piece
Begins with moving to additional lace point. Includes cutting cord. Ends withrenoving cord.
Install First Piece
Begins with reaching to diagonals or scissors. Includes obtaining and cuttinglength of nylon ribbon or cord, tying wire bundle with cove hitch, additionalloop and three lock stitches using tweezers or needlenose as necessary, andtrimming cord end. Ends with laying aside diagonals or scissors.
Install Additional Piece
Begins witn moving to additional lace point. Ends with completing one lockstitch.
(Identical to NACL code OWH-BL-XX).
102
BUNDLE, TIE EWHBT-XX
REMOVE INSTALL
FIRST TMU ADDITIONAL TMU FIRST TMU ADDITIONAL TMURA 150 YA 90 IA 520 ....RB 240 YB 130 iB 890 .... -RC 300 YC 160 IC 1390 .... "RD 460 YD 210 ID 2340 .... "RE 460 YE 280 IE 3800 ....
Remove First Piece
" Begins with reaching to diagonals or scissors. Includes cutting and removingcord. Ends with laying aside diagonals or scissors and cord.
Remove Additional Piece
Begins with moving to additional tie. Includes cutting cord. Ends withremoving cord.
Install First Piece
Begins with reaching to diagonals or scissors. Includes obtaining and cuttinglength of nylon ribbon or cord, tying wire bundle with clove hitch, additionalloop using tweezers or needlenose as necessary, and trimming cord end. Endswith laying aside diagonals and scissors.
Install Additional Piece
Not applicable.
(Identical to NALC code OWH-BT-XX).
1
103
0 EWHt-CT-XX CABLE TIE
I NSTALL
FIRST TMU
Easy 1B 854
Moderate IC 1324
Difficult I0 2314
Remove
Use OTL--PD-XX.
Install
Begins with reaching to strap. Includes positioning strap around cable,getting cable-tying gun, positioning gun to strap, actuating gun. Ends withasiding gun.
Remarks7
* Case variable factors: distance 0%, weight 0%1, control 100%.
10
INSULATION, HEAT-STRIPPING EWH-IH-XX
FIRST TU ADDITIONAL TMU
DI 607 Zi 487
First Wire
Begins with reaching to wire. Includes getting thermal stripper, positioningwire in stripper, actuating stripper, h'.ating wire, disengaging wire fromstripper, releasing stripper. Ends with asiding stripper and wire.
Additional Wire
Begins with reaching to wire. Includes positioning wire in thermal stripper,actuating stripper, heating wire, disengaging wire from stripper, releasingstripper. Ends with asiding wire.
For nonthermal stripping use EWH-IS-XX.
105
- - - . -- . .
EWH-IS-XX INSULATION, STRIP
FIRST THU ADDITIONAL TMU
01 260 ZI --02 410 Z2 21003 1110 Z3 102004 1600 Z3 --05 4800 Z4 --
First Piece
Begins with reaching to wire(s) or cable. Includes obtaining tools, strippingshielding and/or insulation, and trimming loose threads. Ends with layingaside wire(s) or cable and tools.
Additional Piece
Begins with reaching to additional wire. Includes striping insulation andtrimming loose threads. Ends with asiding wire.
Remarks
01 -- Nonshielded, single conductor, single wire. Sizes No. 22 to No. 8.02 -- Nonshielded, single conductor, single wire of a group of loose wires.
Sizes No. 22 to No. 8.03 -- Shielded cables, center conductor. Sizes No. 22 to No. 8.04 -- Coaxial cable. Sizes to 5/16-in. outside diameter.05 -- Triaxial cable. Sizes to 3/8-in. outside diameter.
Applies to: Miller Adjustable Diagonal Stripper, Ideal Stripmaster, PyramidE-Z Stripper. Knife cases 03, 04, and 05 apply only where accessibility iseasy.
(Identical to NALC code OWH-IS-XX).
PIN, INSTALL ON WIRE EWH-PN-I1
INSTALL TMU
11 785
Install
Begins with getting wire. Includes cutting wire, stripping insulation fromend of wire, asiding strippers, twisting strands of wire together, gettingpin, positioning wire in pin, verifying wire insertion into pin, gettingcrimper, crimping pin to wire, releasing crimper, removing wire/pin. Endswith asiding crimper and wire.
Io
107
EWH-PN-12 PIN, INSTALL OR REMOVE IN PLUG
REMOVE INSTALL
FIRS1 TMU FIRST TMU
R2 952 12 1290
Remove Pin
Begins with reaching to tool. Includes checking wiring schematic, locating pinnumber in plug, positioning tool to pin, applying pressure to tool, disengagingpin from tool . Ends with disengaging tool from plug.
Install Pin
Begins with reaching to tool. Includes positioning pin to tool, checkingwiring schematic, locating pin number in plug, positioning and inserting pin inplug, disengaging tool. Ends with checking pin.
1
108
WIRE CRIMP, MANUAL TOOLS EWH-WC-XX
REMOVE INSTALL
.. .. 11 780
.. .. 12 3080R3 990 13 4260R4 1430 14 7770R5 4520 15 14190
Remove First Piece
Begins with reaching to tool. Includes cutting wire and/or unsoldering anddisassembling teminator as necessary. Ends with laying aside tools, wire orcable, and terminator.
*- Install First Piece
Begins with reaching to wire or cable. Includes obtaining stripping tools,stripping insulation, obtaining and installing terminator by crimping,soldering, and assembling as necessary. Ends with laying aside tools and wireor cable.
Remarks
11 -- Lug or splices, No. 10 to No. 22 wire.12 -- Shielded cable connectors.13 and R3 -- Coaxial cable connectors, wedge-lock (small, single shielding).14 and R4 -- Coaxial cable connectors, wedge-lock (large, double shielding).
* 15 and R5 -- Triaxial cable connectors, AMP 165-38-1001 or similar.
Does not include the use of special tools to strip coaxial or triaxial cables.
(Identical to NALC code OWH-TM-XX).
109
....................... .,*... ... ...
EWH-WW-R1 WIRE WRAP, HAND TWISTED
REMOVE INSTALL
FIRST THU ADDITIONAL THU FIRST THU ADDITIONAL TMU
Ri 474 YI 436 11 543 Xi 492
Remove First Piece
Begins with reaching to tool. Includes positioning tool to post, unwrappingwire, disengaging tool from post, disengaging wire from post. Ends withasiding wire and tool.
Remove Additional Piece
Begins with positioning tool to post. Includes unwrapping wire, disengagingtool from post, disengaging wire from post. Ends with asiding wire.
Install First Piece
Begins with reaching to tool. Includes getting wire, positioning wire in bit,positioning wire and tool to post, wrapping wire around post, disengaging tool.Ends with asiding of tool.
Install Additional Piece
Begins with reaching to wire. Includes positioning wire in bit, positioningwire and tool to post, wrapping wire around post, disengaging tool.
-1: Hand Twisted
110
, .i "
... .. .f - -' . . . .. . " ' **" * i ' "'*" ", "**, ' 'i. .. . ..
WIRE WRAP, HAND-SQUEEZE GUN EWH-WW-R2
REMOVE INSTALL
FIRST T14U ADDITIONAL T4U FIRST TMU ADDITIONAL TMU
R2 117 Y2 79 12 186 X2 135
Remove First Piece
Begins with reaching to hand-squeeze gun. Includes positioning gun to post,unwrapping wire, disengaging gun from post, disengaging wire from post. Endswith asiding wire and gun.
Remove Additional Piece
Begins with positioning hand-squeeze gun to post. Includes unwrapping wire,disengaging gun from post, disengaging wire fron post. Ends with asiding wire.
Install First Piece
Begins with reaching to hand-squeeze gun. Includes getting wire, positioningwire in bit, positioning wire and gun to post, wrapping wire around post,disengaging gun. Ends with asiding gun.
Install Additional Piece
Begins with reaching to wire. Includes positioning wire in bit, positioningwire and hand-squeeze gun to post, wrapping wire around post, disengaging.
-2: Hand-Squeeze Gun
For changing too] bit or sleeve, see ETP-WW-D1t
- EWH-WW-R3 WIRE WRAP, POWER GUN
RENOVE INSTALL
FIRST THU ADDITIONAL THU FIRST TMU ADDITIONAL THU
R3 133 Y3 95 13 202 X3 151
I Remove First Piece
• Begins with reaching to power gun. Includes positioning gun to post,unwrapping wire, disengaging gun from post, disengaging wire from post. Endswith asiding wire and gun.
S Remove Additional Piece
Begins with positioning gun to post. Includes unwrapping wire, disengaging gunfrom post, disengaging wire from post. Ends with asiding wire.
Install First Piece
Begins with reaching to powered wire wrap gun. Includes getting wire,positoning wire in bit, positioning wire and gun to post, wrapping wire aroundpost, disengaging gun. Ends with asiding gun.
Install Additional Piece
Begins with reaching to wire. Includes positioning wire to bit, positioningwire and gun to post, wrapping wire around post. Ends with disengaging gun.
I0
For wire wrap, hand, see EWH-WW-RI and R2For changing tool bit or sleeve, see ETP-WW-Dl
112
CONTROL, MANUALLY ACTUATED OAC-CM-XX
FIRST TNU ADDITIONAL TNU
03 40 Zi 2002 80 Z2 4003 170 Z3 14004 470 Z4 450
First Actuation
Begins with reaching to valve, switch, knob, or lever. Includes actuating oradjusting to desired position. Ends with obtaining a gauge or dial reading.
Additional Actuation
Begins with hand on same valve or switch or knob or lever. Ends withactuating or adjusting to additional desired position, and/or obtaining agauge or dial reading.
Remarks
01 -- Actuate single throw control or obtain instantaneous appearing reading.02 -- Actuate control and obtain instantaneous appearing reading.03 -- Actuate control and obtain momentarily appearing reading.04 -- Actuate control and obtain delayed reading.
Momentarily appearing readings are defined as requiring coarse adjustmentsand/or stabilization with the required reading to an accuracy greater than + .2.5% of a full-scale reading.
Delayed readings are defined as those requiring fine adjustments and/orstabilization with the required reading to an accuracy of + 2.5% or less of afull-scale reading.
The terms coarse and fine are related to a complete operation, including startactuation, adjust, and obtain reading.
113
OAC-LP-XX BUTTFRFLY LATCH, UNFASTEN, FASTEN
UNFASTEN FASTEN
FIRST ThU FIRST TMU
RI 107 11 143
Unfasten
Begins with reaching to tab. Includes turning tab to disengage, loosening :latch and disengaging.
Fasten
Begins with reaching to latch. Includes positioning latch in receptacle,turning tab to enqaqe receptacle and tightening. Ends with releasing tab.
114
CLIMB OR DESCEND OBM-CO-XX
FIRST THU ADDITIONAL THU
Climb Up or Down One Step D 72 Zi 35 LClimb Up D2 318 .--
* Climb Down D3 288 ....
First Step (01)
Begins with looking to ladder or stairs. Grasp rail, place foot on rung, stepup or down. Ends with placing both feet on the same level.
* Additional Step (ZU)
Begins by sliding hand along rail. Step up or down, foot on rung. Ends witheye traveling to next grasp point.
Climb Up (D2)
Begins with getting and asiding object 0 to 40 pounds. Reach 40 inches heightfrom floor to surface, raise leading foot, boost body with hands, applypressure with foot and hands, turn body raise other foot. Ends with arising.
Climb Down (03)
Begins with squatting to sit. Reach to surface, lower body with hands, lowerleading leg, lower trailing leg apply pressure with hands, push off with hand,end with body standing on lower surface. Ends with removing object.
I
i 115
OBM-WO-O0 WALK, OBSTRUCTED OR UNOBSTRUCTED
CASE TMU
01 8502 5303 60
Case
01 -- Walk 10 ft in obstructed or unobstructed area with load of 5 to 50 lb.
02 -- Walk 10 ft in unobstructed area with load of 0 to 5 lb.
03 -- Walk 10 ft in obstructed area with load of 0 to 5 lb.
116
HAND CLEAN, SIMPLE SHAPE TO 1O-ft OBJECT OCL-HS-XX
FIRST TMU ADDITIONAL TNU
01 420 Zi 13002 1250 Z2 40003 2170 Z3 62004 3000 Z4 880
First Piece
Begins with reaching to object to be cleaned. Includes selecting cloth,
tampico brush, wire brush, scraper, or sandpaper, and removing contaminationor corrosion from an area 12 in. by 12 in. by wiping, brushing, scraping, orsanding, dry or with solvent. Also includes blowing off with air and wiping.Ends with laying aside object and tools.
Additional Piece
Begins with repositionin, is necessary to gain access to area to be cleaned.Includes removing contami, tion or corrosion from an area 12 in. by 12 in. bywiping, brushing, scraping, or sanding, dry or with solvent. Ends with blowingoff and wiping.
Remarks
01 -- Light dust or small particles of dirt.02 -- Light clinging dust and dirt or readily soluble oil or grease.03 -- Heavy clinging dust and dirt, light stains, light corrosion, oil, or
grease removable by mild scrubbing.04 -- Heavy caked dust and dirt, heavy stains, heavy corrosion, hardened
grease or preservatives, removable by extensive scraping, sanding, orbrushing.
Simple surfaces are defined as readily accessible, requiring little or norepositioning during cleaning.
I
I
1.17
If?
OCP-HT-XX HOLDING CLAMP, TEMPORARY
FIRST TMU ADDITIONAL TMU
01 390 ZI 23002 520 ...-- -
03 360 Z3 21004 560 Z4 31014 460 X4 220R4 110 Y4 10005 170 Z5 90
Install First Piece
Begins with reaching to tool and/or clamp. Includes obtaining and/or adjustingclamp as necessary, and installing on work. Ends with installing clamp orlaying aside tool.
Install Additional Piece
Begins with re- to clamp. Includes obtaining and adjusting clamp asnecessary, and wiicalling on work. Ends with installing clamp.
Remove First Piece
Begins with reaching to tool or clamp. Includes loosening clamp and removingfrom work. Ends with asiding tool and/or clamp.
Remove Additional Piece
Begins with reaching to cldmp. Includes loosening clamp and removing fromwork. Ends with asiding clamp.
Remarks "
01 -- Cleco, pliers type, install and remove.02 -- Cleco, wing nut type, install and remove.03 -- Toggle ("quickie") clamp or vise grip pliers, install and remove.04-- "C" Clamp, install and remove.05 -- Spring clamp, install and remove.14-- "C" Clamp install.X4 -- "C" Clamp install, additional.R4 "C" Clamp remove.Y4 -- "C" Clamp remove, additional.
Limited to accomplishment containing some interference but wholly visible, orno interference and partially visible.
118
ESTIMATED MANUAL TIME OEL-ET-XX
CASE T4U
01 1002 10003 100004 1000
Allowed time as determined by a qualified industrial engineering technician's
estimate.
.enarks
Applies to manual operations where existing standard data elements do notproperly describe motions performed. Does not apply to process time.
I
1191
p.'
OEL-OD-XX OTHER DATA
tb-.
CASE TMU
01 1002 10003 100004 10000
Allowed time derived from standard data of acceptable quality.
Remarks -
Applies to manual motion sequences and/or machine or process time.
120
REPEAT SEQUENCE OEL-RS-XX
CASE THU
01 1002 10003 100004 10000
Allowed time derived from repeating occurrence of a sequence of elements inthe analysis of an operation.
Remarks
Applies to the repetition of any preceeding group of elements in the same timestandard.
Should not be applied to the development of other elemental standard data.
Sources from which the allowed time is derived should be referencea at thepoint of OEL-RS-XX application.
(Adaptation of NALC code OEL-RS-XX).
121
OEL-TS-XX TIME STUDY
CASE TMU
01 1002 10003 100004 10000
Allowed time as determined by stopwatch time study.
Remarks
Applies to manual operations where standard data elements do not properlydescribe the motions performed. Does not apply to process time.
1222
I
I
I .
o
°-S
S"°£
,122
So
EXAMINE, VISUAL OIT-EV-XX ,.
FIRST TMU ADDITIONAL TMU
OA 120 ZA 50 I,-0B 210 ZB 100
First Piece
Begins with reaching to object to be examined. Includes moving object to area pof vision, selecting light or magnifying glass if required and examining onefocal area (4-in. dia at 16 in. from eye). Ends with laying aside object andlight or glass.
Additional Piece
Begins with repositioning of object as necessary to examine next focal area.Ends with examining focal area.
Remarks
OA -- Cursory examination permitting rapid decision (e.g., NC or NF threads to Pa-in. dia or 1/2 in. of threads 2-in. to 4-in. dia; simple surface for ..-
condition of paint, plating, etc).
GB -- Close examination of particular detail (e.g., special or close tolerancethreads to 2-in. dia or 1/2 in. of threads 2-in. to 4-in. dia;irregular surfaces for condition of plate or plating, surfaces that are Imachined, bearing, mating, etc). Applies to yes or no evaluation notrequiring prolonged mental consideration. Use when no other operationsare being performed or where examination is the limiting factor.
12
I.
' 123
[K
OJP-AC-XX HINGED PANEL WITH HOLD-OPEN ROD
CASE TMU
Open hinged panel, engage hold-open rod D1 490Close hinged panel, stow hold-open rod 02 490
Open
Begins at hinged panel that has been unfastened. Includes opening panel,disengaging hold-open rod, and ends with positioning hold-open rod to holdpanel open.
Close
Begins at a hinged panel that is held by a hold-open rod. Includesdisengaging and stowing hold-open rod, ends with closing panel.
Remarks
D1 and D2 derived from Boeing code 530101.
1 24
6..
CORD, ELECTRIC, COIL AND UNCOIL OJP-CC-XX
CASE T1U
01 33002 65003 121004 18005 16006 28007 38008 48009 730
Uncoil
Begins with coiled cord in hand. Includes paying out cord while walking anduntangl ing cord as necessary. Ends with plug in hand.
Coil
Begins with reaching to end of unattached cord. Includes coiling cord forstorage.
*Remarks
01 -- Coil and uncoil 10-ft cord.02-- Coil and uncoil 25-ft cord.03 -- Coil and uncoil 50-ft cord.04 -- Coil 10-ft cord.05 -- Uncoil 10-ft cord.06 -- Coil 25-ft cord.07 -- Uncoil 25-ft cord.08 -- Coil 50-ft cord.09 -- Uncoil 50-ft cord.
1
125
OJP-CF-XX PROTECTIVE CAP
REMOVE INSTALL
FIRST TMU FIRST TMU
Ri 90 11 96
Remove
Begins with getting capped part. Includes reaching to cap, applying pressureto cap, disengaging cap. Ends with asiding cap.
Install
Begins with getting protective cap. Includes getting part to be capped,positioning cap. Ends with applying pressure to canplete cap installation.
126
CLOCK IN, MANUALLY ACTUATED TIME RECORDER OJP-CL-XX
FIRST ThU
01 59002 790 -i
03 640-""
04 76005 1370
Manually Actuated Time Recording Clock
Begins at time clock. Includes selecting in-process and planned work cardsfrom rack, recording time on each card and job order number (pencil entry) onplanned work card. Ends with replacing both cards in rack.
Transactor
Begins at transactor. Includes selecting identity card and transactioncard(s), placing cards in transactor, setting one or more dials, and recordingtransaction. Ends with replacing cards in rack.
Remarks
Manually actuated time recording clock
01 -- Work content as stated above.02 -- Work content as stated above except clock is at Sched-U-Man dock and
includes selecting Sched-U-Man card from rack, recording time on cardand replacing card in rack.
Transactor Actuated Recording
03 One transaction card and one dial setting.04 -- One transaction card and one to seven dial settings.05 -- Two transaction cards and one to seven dial settings.
1o27
0S
OJP-CP-XX CORD, ELECTRIC, PLUG IN AND DISCONNECT
CASE T4U
01 11002 13003 8004 4005 8006 50
Plug In
Begins with reaching to plug. Includes connecting to outlet or receptacle.Ends with plug in place.
Disconnect
Begins with reaching to plug. Includes removing plug from outlet orreceptacle. Ends with plug in hand.
Remarks
01 -- Standard two- or three-prong plug. -J02 -- Twist lock plug.03 -- Plug in (standard).04 -- Unplug (standard).05 -- Plug in (twist).06 -- Unplug (twist).
128
128
I
DRAWER, OPEN AND CLOSE OJP-DR-XX
CASE TMU
Open and Close 01 77Open 02 44Close 03 33
Open
Begins with reaching to the drawer. Includes releasing drawer latch or lock.Ends with the drawer open and locked in position.
Close
Begins with reaching to the drawer. Ends with the drawer closed and latched.
Remarks
Drawer with or without thumb latch or similar.
(Similar to NALC code MJP-DR-XX)
129
OJP-FT-X1 ROPE OR CORD, FASTEN OR UNFASTEN
FASTEN TMU UNFASTEN TMU
11 1330 Ri 370
Fasten
Begins with reaching to rope or cord. Includes positioning first end of ropeto object, tying a knot, positioning the second end of the rope. Ends withtying a knot in the second end.
Unfasten
Begins with reach to knot. Includes untying two knots. Ends with asidingrope or cord.
130
GLASSES OR GOGGLES, SAFETY, ON AND OFF OJP-GS-XX
CASE TMU
01 49002 260
Put On
Begins with reaching to glass case or goggles. Includes removing glasses fromcase and cleaning glasses or goggles as necessary. Ends with glasses orgoggles in place.
Remove
Begins with reaching to glasses or goggles. Includes removing and inserting incase. Ends with asiding glasses case or goggles.
Remarks
01 -- Safety glasses.02 -- Safety goggles.
1
'3',
OJP-MA-01 DRILL BIT, INSTALL 5
INSTALL TMU REMOVE TMU
D1 393
Install
Begins with selecting dril, bit, rotating chuck by hand open or close,inserting bit into chuck, tightening chuck by hand, getting and insertingchuck key, and tightening chuck. Ends with disengaging and asiding key.
Remove
(Use OOH-DE-OC for removing bit.)
132
P9EPARE MICROSCOPE OR MAGNIFIER OJP-MY-OX
CASE TMU
Microscope DI 1671
Eyeglass D2 108
Loupe 03 125
Illuminated Magnifier D4 500
Clean Lens 05 91
Set Up Microscope (01)
Begins with reaching to microscope. Includes positioning scope, plugging inand turning on light, all motions necessary to adjust height or length ofplane and adjust focal setting, adjust eye width, select power. Ends withworking piece in focus and asiding after use.
Position Eyeglass Mounted Loupe Down and Up (D2)
Begins with reaching to loupe. Includes positioning loupe down, reaching toloupe. Ends with loupe up.
Position Hand-Held Loupe To or From Eye (D3)
Begins with reaching to loupe. Includes positioning loupe to eye, reaching toloupe. Ends with asiding loupe.
Illuminated Magnifier (04)
Begins with positioning magnifier to work area. Includes turning on light andrepositioning magnifier. Ends with turning off light and asiding magnifier.
Clean Loupe Lens (05)
Begins with reaching to cleaning tissue. Clean lens. Ends with asidingtissue. .
L133
133
OJP-PA-X1 ENSEMBLE, CHEMICAL DEFENSE
INSTALL ThU REMOVE TMU
11 21820 Ri 11882
Install (Donning previously fitted ensemble)
Begins with donning protective suit pants. Includes removing ensemble fromensemble storage container, unzipping, zipping, unsnapping, snapping pantsfasteners. Continues with donning protective footware, protective gloves,protective coat and mask carrier, removing mask and hood from carrier,positioning mask on face and head, checking mask for leaks. Ends withpoitioning and fastening straps and cords, and closing hood and mask carrier.
Remove (Doffing uncontaminated ensemble)
Begins with doffing mask and hood by disengaging underarm straps, looseningneck cord, positioning cape over head and removing mask and hood. Includescleaning moisture from hood and mask, positioning hood and mask in carrier.Continues with doffing mask carrier and protective coat, doffing protectivegloves, footwear, and protective suitpants. Ends with packing protectiveclothing in storage container.
Remarks
Ensemble has been fitted previcusly. Hood is attached to mask and both are -
stored in the carrier. It is installed over normal items of clothing whencontamination is imminent.
Sp -
go4
134
SAFETY HARNESS OJP-SA-X1
INSTALL ThU REMOVE THU
11 4040 Ri 1220
Install
Begins with getting safety harness. Includes untangling harness, positioningshoulder straps, hooking shoulder straps, fastening belt, positioning andhooking leg straps. Ends with adjusting all straps.
Remove
Begins with unhooking leg straps. Includes unhooking belt, shoulder straps,and folding safety harness. E-ds with asiding harness.
135
OH-LA-XX GET AND ASIDE
FIRST ThU
OA 50OB 120OC 190OD 270OE 350
First Piece
Begins with reaching to object. Includes picking up and minimally controlledmoving to an approximate location. Ends with releasing object.
Remarks
OA -- Move to 18 in. and weight to 3 lb.08 -- Move to 30 in. and weight to 10 lb.OC -- Move to 4 ft including stooping if necessary and weight to 20 lb.00 -- Move to 6 ft including stooping if necessary and weight to 30 lb.OE -- Move to 8 ft includinq stooping if necessary and weight to 50 lb.
If unusual control is required, use OOH-PO.
Case variable factors: distance 80%, weight 20%
136
OBTAIN OR RETURN FILED MATERIAL OMH-OF-XX
FIRST TMU ADDITIONAL THU
01 210 Zi 110
First Piece
Begins with reaching to drawer. Includes opening unlocked drawer, searching andselecting to locate alphabetically or numerically filed identity, or positioningand removing from or replacing in drawer. Ends with laying aside identityand/or closing drawer.
Additional Piece
Begins with reaching to filed material in bin or drawer. Includes searching andselecting to locate alphabetically or numerically filed identity, or positioningand removing from or replacing in bin or drawer. Ends with identity in hand orin file.
Remarks
Filed material must be clearly identified so that only a minor separation ofpieces is required to verify selection.
4
'37
4 -
O)-0P-XX OBTAIN OR RETURN PART OR MATERIAL
FIRST THU ADDITIONAL TMU
Bin or shelf01 60 Zi 6002 100 Z2 70
Drawer or cabinet
03 160 Z3 6004 200 Z4 70
Bin or Shelf
01 -- Single or handful or obvious part(s) lying alone or jumbled with likeparts.
02 -- Single indistinguishable part among or jumbled with dissimilar parts.
First Piece
Begins at bin or shelf. Includes reaching, selecting, and picking updesired object(s) to 20 lb. Ends with laying aside object(s).
Additional Piece
Begins with placing first part on other hand. Ends with selecting andpicking up desired object.
Drawer or Cabinet
03 -- Single or handful of obvious part(s) lying alone or jumbled with likeparts.
04 -- Single indistinguishable part among or jumbled with dissimilar parts.
First Piece
Begins at drawer or cabinet. Includes reaching to doors or drawer,opening unlocked doors or drawer, selecting and picking up desiredobject(s) to 20 lb, and closing doors or drawer. Ends with laying asideobject(s).
Additional Piece
Begins with placing first part on other hand. Ends with selecting andpicking up desired object.
138
FASTENER, TURNLOCK TO 3/8-in. DIA ONF-FT-XX
FIRST TMU ADDITIONAL THU.
Unfasten RA 110 YA 60 L.Unfasten RB 160 YB 80Fasten IA 140 XA 90Fasten IB 200 XB 130
Unfasten First Piece -
Begins with reaching to tool. Includes positioning tool to fastener stud andtwisting to unfasten stud from receptacle. Ends with laying aside tool.
Unfasten Additional Piece
Begins with movinq to fastener stud with tool. Includes positioning tool to studand twisting to unfasten. Ends with unfastening stud from receptacle.
Fasten First Piece
Begins with reaching to tool. Includes positioning tool to fastener stud and
twisting stud to secure in receptacle. Ends with laying aside too. .
Fasten Additional Piece
Begins with moving to fastener stud with tool. Includes positioning tool to studand twisting to secure. Ends with fastening stud to receptacle.
Remarks
Applies to DZUS, CAMLOC, AIRLOCK and similar fasteners.
Case variable factors: distance 10%, weight 5%, control 85%.
139
ONF-LP-XX PRESSURE LATCH, FASTEN OR UNFASTEN
FIRST THU ADDITIONAL TMU
31 50 zi 40
Unfasten or Fasten First Piece
Begins with reaching to latch trigger plate. Includes placing finger or thumb totrigger plate and applying pressure to release latching plate. Ends withreleasing pressure.
Unfasten or Fasten Additional Piece
Begins with reaching to latch trigger plate. Includes placing finger or thumb totrigger plate and applying pressure to release latching plate. Ends withreleasing pressure.
Remarks
Applies to pressure-type trigger latches.
140
RING, TRU-ARC ONF-RT-XX
REMOVE INSTALL
FIRST THU ADDITIONAL THU FIRST TNU ADDITIONAL THU
RA 180 YA 150 IA 210 XA 170 -"RB 320 YB 25C
Remove First Piece
Begins with reaching to Tru-Arc pliers. Includes inserting pliers in ring andremoving ring from internal or external groove. Ends with laying aside tool andring.
Remove Additional Piece
Begins with reaching to ring with pliers. Includes inserting pliers in ring andremoving ring from internal or external groove. Ends with palming or layingaside ring.
Install First Piece
Begins with reaching to ring. Includes selecting Tru-Arc pliers, inserting inring, and installing ring in internal or external groove. Ends with laying asidetool.
Install Additional Piece
Begins with reaching to ring. Includes inserting pliers in ring and installingring in internal or external groove. Ends with releasing ring.
Remarks
Supplement with positions (OOH-PO) and disengages (OOH-OE) for higher cases.
Case variable factors: distance 10%, weight 5%, control 85%.
141
- . . . . .. . . . . . . . .. 2
ONF-SC-XX SAFETY WIRE, CONTINUOUS, NONTWISTED
REMOVE INSTALL
FIRST T1U ADDITIONAL T4U FIRST TMU ADDITIONAL TMU
RA 30.0 YA 60 IA 650 XA 80
Remove First Piece
Begins with reaching to diagonals. Includes cutting wire between two anchorpoints and removing. Ends with laying aside wire and tools.
Remove Additional Piece
Begins with cutting wire to additional anchor point. Ends with removing wire.
Install First Piece
Begins with reaching to supply of wire. Includes selecting pliers and diagonals,cutting wire to length, inserting in first anchor point, inserting in secondanchor point to 3-in. distance, returning to first anchor point, twisting tosecure, and cutting and tucking end. Ends with laying aside tools.
Install Additional Piece
Begins with inserting wire in additional point. Ends with pulling wire tight.
Remarks
Supplement with positions (OOH-PO) and disengages (OOH-DE) for higher cases.
Case variable factors: distance 10%, weight 5%, control 85%.
142
* - --- -- - -. -
SNAP RING ONF-SR-XX
REMOVE INSTALL
FIRST T4U AUOITIONAL mu FIRST TMU ADOITIONAL TU I-
RA 71 YA 63 IA 52 XA 48
Remove First Piece
Begins with reaching to scribe or awl. Includes inserting awl in ring andremoving ring with pliers from internal or external groove. Ends with layingasid2 Locls and ring.
Remove Additional Piece
Begins with reaching to ring with awl. Includes inserting tool in ring andremoving ring from internal or external groove. Ends with palming or layingaside ring.
Install First Piece
Begins with reaching to ring. Includes selecting tool and installing ring ininternal or external groove. Ends with laying aside tool.
Install Additional Piece
Begins with reaching to ring. Includes installing ring in internal or externalgroove. Ends with releasing ring.
Remarks
Maxim ,q depth of snap ring is 1 in. Maximum diameter of snap ring is 4 in.
Supplement with positions (OOH-PO) and disengages (OOH-DE) for higher cases.
Case variable factors: distance 10%, weight 5%, control 85%.
143
143 -
"" "="-
OW-ST-XX SAFETY WIRE, TWISTED
REMOVE INSTALL
FIRST THU ADDITIONAL THU FIRST T4U ADDITIONAL THU
RA 410 YA 170 IA 870 XA 320RB 950 YB 270 IB 1420 XB 600RC 2080 YC 580 IC 2750 XC 920RD 4080 YD 1170 ID 4460 XD 1290RE 7420 YE 2080 IE 6670 XE 1750
Remove First Piece
Begins with reaching to diagonals. Includes cutting wire at two anchor points
and removing. Ends with laying aside wire and tools.
Remove Additional Piece
Begins with cutting wire at additional anchor point. Ends with removing wire.
Install First Piece
Begins with reaching to supply of wire. Includes selecting pliers anddiagonals, cutting wire to length, inserting in first anchor point, twisting tosecond anchor point to 3-in. distance, inserting in second anchor point,twisting to secure, and cutting and tucking end. Ends with laying aside tools.
Install Additional Piece
Begins with twisting wire to additional anchor point to 3-in. distance. Endswith insertion in additional anchor point.
Remarks
Case variable factors: distance 10%, weight 5%, control 85%.
For removal use one firstand two additional
For removal use one first0 0 and one additional
0
For installation use one firstand one additional
For installation use two first
144
OBJECT HANDLING OOH-OB-XX
CASE TMU
Get up to four light objects Dl 480Aside up to four light objects 02 480Get and aside up to four light objects D3 960Get one medium to heavy object D4 400Aside one medium to heavy object 05 400Get and aside one medium heavy object D6 800Final position or aside small work stand D7 510Position or aside small work stand D8 1140
Get
Begins by reaching and picking up object(s). Includes carrying object(s) up to15 ft. Ends with asiding object(s) in hand.
Aside
Begins with object(s) in hand. Includes carrying object(s) up to 15 ft. Endswith asiding object(s).
Get and Aside
Begins with reaching and picking up object(s). Includes carrying object(s) upto 30 ft. Ends with asiding object(s).
Final Positioning or Asiding Work Stand
Begins by grasping small work stand. Includes moving work stand to desired worklocation or from work position to clear area. Distance allowance of 20 ft isincluded for getting to or from work stand and moving it.
Position or Aside Small Work Stand
Begins by getting control of small work stand. Includes moving stand up to 90ft or walking up to 45 ft to stand and moving stand 45 ft. Ends with stand inposition for work or in storage area.
Remarks
D1, D2, D3 derived from Boeing code 81A003.D4, D5, 06 derived from Boeing code 81A004.D7 derived from Boeing code 81A005.D8 derived from Boeing code 81A025.
145p
QO -OE-XX DISENGAGE
DISENGAGE TMU
OA 70 i- ,OB 120OC 220OD 400OE 700
Disengage
Begins with reaching to object or tool. Includes obtaining control of objectwith hand(s), or with tool whan tool is an extension of the hand(s), andloosening and extracting or removing one object from another. Ends with layingaside tool and/or object.
Remarks
Tools included are a putty knife, screw driver, pliers, or similar to overcomethe limitations of hand or finger dexterity or access. Strength may be usedwith slight to considerable effort. Use of hammer is not included.
Case variable factors: distance 45%, weight 10%, control 45%.
146
')SITION OBJECT OOH-PO-XX
POSITION TMU
OA 120 L.-OB 250OC 420OD 830OE 1670
Position
Begins with reaching to part or other object. Includes relating one part orobject to another by aligning, orienting, and engaging. Ends with objects indesired relationship.
Remarks
Does not include fastening or securing operations. Does not include extremelyprecise or minute operations requiring high skill. Includes minimal use oftools.
Case variable factors: distance 10%, weight 5%, control 85%.
p..
147
OOH-TR-XX TAG, ROUTING, REMOVE OR FILL OUT AND ATTACH
REMOVE T4U INSTALL TNU
R1 300 I1 460.-- 12 4520
Remove
Begins with reaching to routing tag. Includes untying bow knot or untwistingwire and removing tag from point of attachment. Ends with laying aside tag.Install (II)
Begins with reaching to routing tag. Includes inserting wire or string throughpoint of attachment and tying string in bow knot or twisting wire. Ends with tagsecured to point of attachment.
Install (12)
Fill out and attach tag begins with obtaining tag and pen. Includes positioningtag for writing, filling in required information, obtaining information fromother material or part name plate, certifying work or condition. Ends withinserting card or tag in an envelope and attaching it to th- -art.
148
- -- ' '"("" . m m m-- - - - - - - - - -" ", ; "
a
CAN, SCREW CAP, OPEN AND CLOSE OPK-CS-XX
FIRST TMU
01 21002 38003 29004 460
Open Can
Begins with reaching to can. Includes unscrewing cap by hand, selecting tool toremove metal seal as required, and piercing and removing seal. Ends with layingaside seal and/or can.
Close Can
Begins with reach to cap. includes placing cap to can and tightening with handpressure. Ends with cap in place.
Remarks
01 -- Screw cap can, one thread, without seal to 1-gal capacity.02 -o Screw cap can, one thread, with metal seal to 1-gal capacity.03 -- Screw cap can, one thread, without seal, 1-gal to 5-gal capacity.04 -- Screw cap can, one thread, with metal seal, 1-gal to 5-gal capacity.
L
149'
I
OPK-EO-XX ENVELOPE, OPEN AND REMOVE CONTENTS
FIRST TMU ADDITIONAL TMU
01 260 Zi 70
First Piece
Begins with reaching to envelope. Includes reading nomenclature to verifycontent, tearing envelope with care to avoid damage to contents, and extractinga single object. Ends with laying aside object and envelope.
Additional Piece
Begins with reaching to open envelope. , les extracting additional singleobject. Ends with laying aside object.
ISO
OBJECT, UNPACK OR PACK OPK-OB-XX
UNPACK TNU PACK THU
RI 487 11 405R2 1680 12 1213R3 1542 13 2119R4 881 14 ----R5 790 15 800R6 1170 16 1050 -R7 163 I7 207
18 4022Unpack
Begins with reaching to envelope, package, box, or bag. Open by tearing,cutting, unfolding or unlatching, removing packing as necessary, removingobject. Ends with laying aside object, packing, envelope, package, box, or bag. P
RI -- Envelope or adhesive sealed package, hand tear or cut open.
R2 -- Cardboard box, flaps cemented or stapled, 0 to 8-ft perimeter of opening.
R3 -- Cardboard box flaps taped, 0 to 8-ft perimeter of opening.
R4 -- Plastic dipped or coated or "bubble" pack, up to 15 in. 2
R5 -- Reusable box, no latches, lid fits loose.
R6 -- Reusable box, 2 latches, lid fits loose.
R7 -- Remove object from static-shielding bag.
Pack
Begins with reach to envelope, package, box, or bag. Open the same by spreadingapart, unfolding flaps, removing lid, or unlatching lid, removing packing ifnecessary, positioning object, positioning package, sealing edges, foldingflaps, installing lid or latching. End with asiding envelope, package, box, orbag.
11 -- Place object in envelope or package and seal.
12 -- Place object in box, fold flaps, cement or staple closed.
13 -- Place object in box, fold flaps, seal with tape.
14 -- (Not a normal maintenance operation).
15 -- Place object in box, install lid.
16 Place object in box, position lid and latch.
17 -- Place object in static-shielding bag, close bag.
18 -- Place object in vacuum-desiccated package.
p
Is'.S: ::
OPT-ET-XX ESTIMATED PROCESS TIME
CASE THU
01 1002 10003 100004 10000
Process time, related to manual or machine operations, as determined by aqualified Industrial Engineering Technician estimate. Begins with the cessationof manual motion, includes all operator idle time, and ends with the resumptionof manual motions.
Remarks
Use only when no other operations are performed or where process time is thelim,'iig factor.
1r
152
, TECHNICAL MANUAL, PROCESS ALLOWANCES OPT-TM-XX
CASE TMU01 10
02 10003 100004 10000
Process time, related to manual or machine operations, as required by authorizedtechnical directive. Begins with the cessation of manual motions, includes alloperator idle time, and ends with the resumption of manual motions.
Remarks
Use only when no other operations may be performed or where process time is inthe limiting factor.
153
i
U
ORD-TM-XX READ TECH DATA
FIRST THU ADDITIONAL ThU
Dl 3922 Zi 2572
02 380 Z2 50
First (0l)
Begins with getting technical data. Includes locating page number desired fromindex, turning to page, reading text, and observing sketch or photograph. Endswith asiding data.
Additional (Zl)
Begins with data page located. Includes reading text and observing sketch orphotograph.
First (02)
Begins with getting Form 781 (or equivalent). Includes locating desired writeup, reading ten words and assimilating information. Ends with asiding Form 781.
Addition (Z2)
Begins with desired page located. Includes reading and assimilating anadditional ten words.
Remarks
D and Z1 are for a typical page of maintenance instructions with an average of330 words.
154
COAT, AEROSOL SPRAY OST-CA-XX
FIRST THU ADDITIONAL THU
01 520 Zi 7002 550 Z2 11003 1260 Z3 780
First
Begins with reach to aerosol spray can. Includes removing cap or cover, shakingcan to agitate vehicle, positioning can for use, actuating button to coat a spotor area, inverting can, actuating button to blow vehicle from tube, andreplacing cap or cover. Ends with asiding can.
Addi ti onal
Begins with can i h,'-d. Includes positioning to additional spot or area asnecessary, actua. io button to coat surface, and in process vehicle agitation asnecessary. Ends wit ,an in hand.
Remarks
01 -- Spot (bolt head, rivet, nut or area to 2 in.2 )
02 Strip, linear I by 12 in.
03 -- Area, surface, 1 ft2
Applies to unobstructed surface treatment with primer, rust inhibitor, dri-lube,lacquer, or similar. Does not include time for agitation of new issue orequivalent condition aerosol cans.
155
OTF-BF-XX BOLT, SCREW, OR NUT FINGER TIGHT
REMOVE TMU INSTALL T4U
RA 170 IA 220RB 420 lB 470RC 590 Ic 640RD 1000 ID 1050RE 1840 IE 1890
Remove First Piece
Begins with reaching to bolt, screw, or nut. Includes initial loosening, runningoff a maximum of 10 turns, and removing from stud or threaded hole. Ends withlaying aside washer and bolt, screw, or nut.
Install First Piece
Begins with reaching to bolt, screw, or nut. Includes selecting washer,installing to stud or threaded hole, and running down a maximum of 10 threads.Ends with tightening motion.
Remarks
Applies to NF (National Fine) or NC (National Coarse) screw threads, #2 to1/2-in. diameter.
BOLT, SCREW, OR NUT, NC OR NF, MANUAL TOOLS OTF-BM-XX
RENOVE INSTALL
FIRST TNU ADDITIONAL T4U FIRST TMU ADDITIONAL TMU
No. 2 to 1/2 in.
RA 710 YA 460 IA 840 XA 580RB 1100 YB 850 IB 1220 XB 970RC 1630 YC 1370 IC 1730 XC 1450RD 2240 YD 1970 ID 2360 XD 2050RE 2940 YE 2630 IE 3060 XE 2730
9/16 to 1 in.
RF 1270 YF 950 IF 1500 XF 1210RG 1710 YG 1310 IG 1920 XG 1550RH 2310 YH 1910 IH 2570 XH 2170RI 3020 YI 2600 II 3240 XI 2770RJ 4080 YJ 3710 IJ 4240 XJ 3720
Remove First Piece
Begins with reaching to tools. Includes loosening and removing nut and washer(s)from screw or bolt and removing screw or bolt. Ends with laying aside parts andtools.
Remove Additional Piece
Begins with moving to nut with tools. Includes loosening and removing nut andwasher(s) from screw or bolt and removing screw or bolt. Ends with laying asideparts.
Install First Piece
Begins with reaching to screw or bolt. Includes inserting screw or bolt in hole,installing of washer(s) and nut on screw or bolt, selecting tools, ard•tightening, but not torquing, nut. Ends with laying aside tools.
Install Additional Piece
Begins with reaching to screw or bolt. Includes inserting screw or bolt in holeand installing washer(s) and nut on screw or bolt. Ends with tightening, but nottorquing.
Remarks
Note 1: Includes alignment of castellated nut to cotter pin hole.Note 2: To allow for extra thread length, add an add'l piece, next-easiest case.Note 3: First piece includes attaching socket and attaching extension (50% OCC.)Note 4: Add an extra aside if bolts or screws are to be moved.
Case variable factors: distance 10%, weight 5%, control 85%.
1 57
OTF-BP-XX BOLT, POWER TOOL
REMOVE INSTALL
FIRST THU ADDITIONAL TMU FIRST THU ADDITIONAL TMU
RI 600 Y1 280 11 72 Xl 42R2 1130 Y2 520
Remove First Piece
Begins with reaching to tools. Includes loosening and removing nut and washersfrom bolt and removing bolt from hole. Ends with laying aside parts and tools.
Remove Additional Piece
Begins with moving to bolt with tools. Includes loosening and removing nut andwashers from bolt and removing bolt from hole. Ends with laying aside parts.
Install First Piece
Begins with reaching to bolt. Includes inserting bolt in hole, installingwashers and nut on bolt, selecting tools, and tightening but not separatelytorquing. Ends with laying aside tools.
Install Additional Piece
Begins with reaching to bolt. Includes inserting bolt in hole and installingwashers and nut on bolt. Ends with tightening but not separately torquing.
Remarks
Includes impact wrench to 1/2-in. drive on bolts to 1/2-in. dia and Keller airwrench on bolts to 5/16-in. dia.
Includes torquing where tool contains fixed or adjustable slip clutch.
Note: R2 and Y2 apply to bolts that require the use of hand tools to breaktorque prior to removal with power tools.
158
CAP OR PLUG, THREADED, FINGER TIGHT, TO 2-1/2-in. DIA OTF-CF-XX
REMOVE TMU INSTALL TMU
RA 120 IA 140RB 240 IB 260RC 370 IC 390RD 540 ID 560RE 950 IE 970
Remove First Piece
Begins with reaching to cap or plug and part. Includes initial loosening,running off a maximum of five turns, and removing cap or plug. Ends with layingaside CAD or plug.
Install First Piece
Begins with reaching to cap or plug. Includes selecting hose, tube, or part,installing cap or plug, and running down a maximum of five turns. Ends withtightening motion.
Remarks
Applies to all aluminum or plastic caps and plugs conforming to specificationMIL-C-5501B, Type I, II, and III.
-
I.
S. 2
S
159.
-S
OTF-CH-XX CAMLOCK HIGH-STRESS PANEL FASTENERS
UNFASTEN FASTEN
FIRST TMU ADDITIONAL THU FIRST TMU ADDITIONAL TMU --
RA 400 YA 320 IA 440 XA 370
Unfasten First Piece
Begins with reaching to tool. Includes placing tool to fastener stud and turningto unfasten stud from receptacle. Ends with laying aside tool.
Unfasten Additional Piece
Begins with placing tool to fastener stud. Includes turning to unfasten. Endswith unfastening stud from receptacle.
Fasten First Piec(
Begins with rearhing to tool. Includes placing tool to fastener stud and turningstud to secure in receptacle. Ends with laying aside tool.
Fasten Additional Piece
Begins with placing tool to fastener stud. Includes turning to secure. Endswith stud fastened to receptacle.
Remarks
Applies to CAMLOC Series 4S stud and receptacle assemblies.
160
. . .. .. . . . .. .. . . . . . .. .. . - ---
SCREW, MACHINE, MANUAL IOOLS OTF-SM-XX .
UNFASTEN FASTEN
FIRST T4U ADDITIONAL TMU FIRST TMU ADDITIONAL TMU
No. 2 to 1/2 inch dia.
RA 610 YA 430 IA 680 XA 500RB 1000 YB 820 IB 1060 XB 860
RC 1430 YC 1210 IC 1570 XC 1350RD 1920 YD 1600 ID 2180 XD 1970RE 2380 YE 2010 IE 2810 XE 2580
9/16 to 1 inch dia.
RF 1090 YF 890 IF 1220 XF 1050RG 1260 YG 1070 IG 1390 XG 1200RH 1930 YH 1680 IH 2240 XH 2030R1 2490 YI 2110 II 2890 XI 2660RJ 3210 YJ 2830 IJ 3810 XH 3510
Remove First Piece
Begins with reaching to tool(s). Includes loosening and removing screw or nutfrom hole or stud and removing washer from screw or stud. Ends with laying asideparts and tool(s).
Remove Additional Piece
Begins with moving to screw or nut with tool(s). Includes loosening and removing. screw or nut from hole or stud and removing washer from screw or stud. Ends with.* laying aside parts.
Install First Pi..ce
Begins with reaching to screw or nut. Includes installing washer on screw orstud, installing s:rew or nut to hole or stud, selecting tool(s), andtightening, but not torquing. Ends with laying aside tool(s).
Install Additional Piece
Begins with reaching to screw or nut. Includes installing washer on screw orstud and installing screw or nut to hole or stud. Ends with tightening, but nottorquing.
RemarksDoes not include the use of power wrench.
Applies to NF and NC machine screws and nuts.
To allow for extra long thread length use additional piece next lower case.
Case variable factors: distance 10%, weight 5%, control 85%.
161
- V A V... l
OTF-SP-XX SCREW, MACHINE, POWER TOOLS
REMOVE INSTALL
FIRST TMU ADDITIONAL TMU FIRST TMU ADDITIONAL TMU
RI 430 Y1 210 11 460 Zi 270R2 710 Y2 450 .....
R5 1920 Y5 1520 ........
Remove First Piece
Begins with reaching to tool(s). Includes loosening and removing screw or nutfrom hole or stud and removing washer from screw or stud. Ends with laying asideparts and tool(s).
Remove Additional Piece
Begins with moving to screw or nut with tool(s). Includes loosening and removingscrew or nut from hole or stud and removing washer from screw or stud. Ends withlaying aside parts.
Install First Piece
Begins with reaching to screw or nut. Includes installing washer on screw orstud, installing screw or nut to hole or stud, selecting tool(s) and tightening,second torquing if clutching type tool. Ends with laying aside tool(s).
Install Additional Piece
Begins with reaching to screw or nut. Includes installing washer on screw orstud, and installing screw or nut to hole or stud. Ends with tightening andtorquing if clutching type tool.
Remarks
Includes impact wrench to 1/2-in. drive on screws to 1/2-in. dia: Keller airwrench on screws to 5/16-in. dia.
Note: R2 and Y2 apply to screws or nuts to 3/8-in. dia that require the use ofhand tools to break torque prior to removal with power tools.
R5 and Y5 apply to the use of a rivet gun and ratchet (persuader) to remove.rozen Phillips or Reed Prince screws.
(X3 and X4 have been omitted to retain consistency with NALC codes.)
162
V . .. . . .' -. . - . . - . . -.. , . . - .. . .. .
4 PLIERS, DIAGONAL, SIDE OR END CUTTING OTL-PD-XX
FIRST TMU ADDITIONAL ThU
01 16 Zi 12 L--02 29 Z2 25
First Piece
Begins with reaching to cutting pliers. Includes obtaining wire, string or Pcord, placing pliers to cutting point, and cutting. Ends with laying asidepliers and wire, string, or cord.
Additional Piece
Begins with moving to additional cutting point. Ends with cutting wire, string,or cord.
Remarks
01 Approximate cutting point. -
02 -- Exact cutting point.
Applies to soft iron wire to .040, stainless safety wire to .040, copper wire to.10-in. dia or similar.
1..
1633k
OTL-VA-XX VISE, MECHANICS, POSITION OBJECT AND RENOVE
CASE THU
01 53002 19003 30004 230
In and Out
Begins with reaching to vise. Includes opening vise, obtaining object, andpositioning within and closing vise, tightening handle, reaching to vise handle,opening vise, obtaining object. Ends with laying object aside.
Remarks
01 -- Work content as above with dimension to be clamped not in excess of 2 in.and weight not in excess of 20 lb.02 -- Repositioning of above object.03 -- Object in vise.04 -- Object out of vise.
164
WRENCH, TORQUE OTL-WT-XX
FIRST THU ADDITIONAL TMU
01 770 Zi 14002 480 Z2 200
First Piece
Begins with reaching to torque wrench. Includes obtaining and attaching socketand extension or adapter, adjusting torque setting if necessary, placing wrenchon bolt or nut and tightening to specified torque. Ends with laying asidetools.
Additional Piece
Begins with placing wrench on bolt or nut. Ends with tightening to specifiedtorque.
Remarks
01 -- Ratchet or nonratchet snap over torque wrench to 1600 in.-lb.02 -- Spring or dial type torque wrench to 1600 in.-lb.ZI -- Used for supplement to OTF-BM/SM (etc.) for second (or more) times(s)around. Also, use 02 to tighten/loosen.
Note: Use OOH-PO-XX for accessibility (one case lower than the SM/BM) sincespecial extensions are often used to overcome an access problem.
165
. . *. * . - * * ...
-. . . . . . . . . .,.* &*4*...*.
OWR-NT-XX NUMERIC DATA, TRANSFER
cit
CASE TMU
01 8002 18003 30004 470
Begins with eye traveling to source data. Includes reading numeric data andwriting duplicate entry on form or other document. Ends with completing entry.
Remarks
Includes writing data retained in memory such as shop number, date, or processcode. Source data must be readily available without search and select such aspage location or similar. Includes selection of data within a group or desiredline in a listing provided format of source data is familiar to the user.
01 -- 1 to 3 digits.02 -- 4 to 8 digits.03 -- 9 to 13 digits.04 -- 14 to 20 digits.
166
PROSE DATA, TRANSFER OWR-PT-XX
PER WORD TMU
01 120
Begins with eye traveling to source data. Includes reading prose data andwriting duplicate entry on form or other document. Ends with completing entry.
Remarks
Includes writing data retained in memory such as part name or shop title. Sourcedata must be readily available without search and select such as page locationor similar. Includes selection of data within a group or desired line in alisting provided format of source data is familiar to the user.
(Identical to NALC code OWR-WT-XX).
167
• . . .. . . . . .* '-° -. .. ° . • * , .- . .... o
7.3 Standard Enviroments
Some maintenance actions involve walking considerable distances to and from
the areas in which work is performed. Several standard work environments
have therefore been included to provide the analyst with uniform
assumptions on the nature of the real world. The assunptions enablemaintenance time predictions to be made for design studies involving
life-cycle costing and selection of equipment. In addition, such studies
can be readily changed into work measurement standards by comparison of the
standard work area with the actual work area. Figures 7.3-1, 7.3-2, and
7.3-3 show standard layouts for avionic and shipboard organizational level
maintenance. Figure 7.3-4 shows the layout of a repair shop appropriate
for both intermediate and depot level analysis.
168
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171
8.0 REFERENCES
1-i MIL-STD -1567AWork MeasurementAFSC/PMD, Directorate of Manufacturing, Andrews AFB, DC 20334
3-1 Pliska, T.F., Jew, F.L. and Angus, J.E.,Maintainability Prediction and Analysis Study,RADC-TR-78-169, July 1978
3-2 DuBlanica, W., Kubeck, J. and Edwards, E.,Validation of Maintainability Prediction,RADC-TR-82-185, September 1982
3-3 Williams, R.L., Allegri, T.H., Bayha, F.T., et. al.,ANSI Standard for Work Measurement and MethodsANSI Z94.12 Pmerican Society of Mechanical Engineers, July 1972
3-4 Maynard, H.B.,Industrial Engineering Handbook,McGraw-Hill Book Company Inc., 1963
3-5 Karger, D.W. and Bayha, F.H.,Engineered Work Measurements,Industrial Press Inc., 1966
3-6 DOD 5010.15.1-MStandardization of Work MeasurementVolume VII Bench Work OccupationsDOD/OIRSO, February 1977
3-7 DOD 5010.15.1-MStandarization of Work M-.asurement-Volume IDOD/DIRSO, February 1977
5-1 Appendix II DOD 5010.15.1-M, Basic Volume,DOD/DIRSO, February 1977
5-2 Introduction to Work Study, Revised EditionInternational Labor Office, Geneva 1969
5-3 Transfer Functions and Learning Curves,D.R. Towill, Ergonomics 1976, Vol. 19, No. 5 623-638
5-4 Managerial Control Systems Based On Learning Curve Models,D.R. Towill and F.W. Bevis, Int. J. Prod. Res.,1972, Vol. I, No. 3
5-5 SAC Supplement to AFR 355-1, June 10, 1983
6-1 Human Performance and Productivity,Vol. 3, p 237-247, E.A. Alliuisi and E.A. Fleishman,Lawrence Erlbaum Associates, 1982
172
... .
APPENDIX A
Index of Examples
Description Level Task Code
Conduct Flight Line Test to Organizational 152314XM01Isolate Troubles in UHF RadioSystem
Remove and Install UHF Receiver- Orgzanizational 112314XMOiTransmitter
Bench Test UHF AN/ARC-109 System Intermediate 552314XM01" Using Radio Test Set AN/ARM-113 at
an Intermediate Level
Fault Isolate a UHF Transceiver Depot 552314XM02Confirmed to be Inoperative in8oth Receive and Trasmit Modes
Remove and Install Module, Power Depot 112314XM02Supply IA8
Troubleshoot UHF Transceiver Power Depot 552314XM03Supply (A8) That Has a Faulty26.5 VDC Output
Remove and Install Capacitor C8 Depot 112314XM03
Minimum Performance Test of UHF Depot 502314XM01Power Supply Module 1A8
Perform Minimum Performance Test Depot 502314XM02on UHF Radio Receiver Transmitter
Job Preparation-Check for Presence Intermediate 81ALCMSTO1of Electrical Energy and CorrectContinuity or Opens Prior to
, Connection to Missle Ordnance andArming and Disarming Circuits
Appendix A provides examples of the use of the elemental standard data of
Section 7.0. to analyze the repair of electronic equipment. The examples
are for the F-15 airplane UHF radio arid an AG.M 86 missile. The examples
IA.
ilA.b.I;.b.
I: . i.~* . . .-.. *-.. -.
were selected because of the ready availability of technical manuals and
test instructions. To demonstrate the use of the standard data at all
levels of electronic maintenance, studies of the F-15 UHF radio system were
* made based on the following sequence of events:
1. An F-15 returns from a mission with a UHF radio inoperative. An
AN/ARM-113 test set is used to troubleshoot the system at an
organizational level. (Task Code: 152314XM01)
- 2. Organizational-level maintenance personnel remove and replace the UHF
transceiver (T/R). (Task Code: 112314XM01)
3. The intermediate-level maintenance shop personnel bench test the T/R --
unit. Tests confirm that the UHF will neither transmit nor receive and
the unit is shipped back to the depot. (Task Code: 552314XM01)
0
4. Troubleshooting at the depot reveals the main transmitter-receiver has
a defective power supply module (A8). (Task Code: 552314XM02)
5. The power supply module (A8) is removed for troubleshooting and repair
by the depot. (Task Code: 112314XM02, Step A)
"- 6. The power supply module (AB) is bench tested per maintenance manual*troubleshooting procedure at the depot. A defective capacitor (C8) is
found. (Task Code: 552314XM03)
7. The defective capacitor (CB) is removed and replaced by a depot level
technician. (Task Code: 112314XM03)
8. A minimum performance test is conducted by the depot on the power
supply module (A8). (Task Code: 502314XM01)
9. The power supply module is replaced in the T/R unit by the depot.
(Task Code: 112314XM02, Step B)
A2S.
10. A minimum performance test is conducted on the T/R unit. (Task Code:
502314XM02)
Up to the time at which troubleshooting of modules takes place (event 4
above) the maintenance actions are independent of failure mode. In the
example scenario, event 4 reveals a problem with the power supply module,
1A8. For event 4 through 9, the analyses cover work on power supply module
only.* 0
Other failure modes of the UHF radio could be analyzed in a similar manner.
An analysis of all failure modes would provide sufficient information to
determine the Mean Time to Repair (MTTR) for the UHF radio system using the
method of calculation provided in Reference 3-1. The failure rates for
each failure mode of all modules and parts are, of course, required to
canplete the calculation of MTTR..-.
In addition to the studies made of the UHF on the F-15, a study was made of
the Safe Test of the AGM86 missile, in which a check is made for presence
of electrical energy and correct continuity or opens prior to connection of
missile ordnance, arming, and disarming circuits.
A:3
_ II
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