In order to fulfill your maintenance and repair responsibilities along with your administrative and supervisory responsibilities you must plan your work ahead of time.

You must determine all the work that must be done and prepare a schedule to ensure that it is done. You must also keep your schedule flexible enough to allow unexpected maintenance and repair work to be done whenever the need for such work arises.

Review the Maintenance and Material Management (3-M) Manual, OPNAVINST 4790.4, it will make your planning and scheduling considerably easier.

Materials and Repair Parts

The responsibility for maintaining adequate stocks of engineroom repair parts and repair materials belongs at least as much to you as it does to the supply department. The duties of the supply officer are to procure, receive, stow, issue, and account for the support of the ship. However, the supply officer is not the prime user of repair parts and repair materials; the initiative for maintain-ing adequate stocks of repair materials, parts, and equipment must come from the personnel who are going to use such items. Namely You!

Basic information on supply matters is given in Military Requirements for PO 3 & 2, NAVED-TRA 10056 (current edition), Military Re-quirements for PO 1 & C, NAVEDTRA 10057 (current edition), and OPNAVINST 4790.4, volume II.

Identification of Repair Parts and Materials

Identification of repair parts and materials is not usually a great problem when you are dealing with familiar equipment on your own ship; but it may present problems when you are doing repair work for other ships, as you would if assigned to the machine shop on a repair ship or tender.

The materials and repair parts to be used are specified for many repair jobs but not for all. When materials or parts are not identified in the instructions accompanying a job, you will either have to use your own judgment or do research to find out just what material or part should be used. When you must make the decision yourself, select materials on the basis of the service conditions they must withstand. Operating pressure and operating temperature are primary considerations in selecting materials and parts for most engineroom repair work.

The fact that materials and repair parts are not specified in the instructions accompanying a job does not mean that you are free to use your own judgment in selecting parts and materials to accomplish a job. Instead, it usually means that you must know where to look for information on the type of material or repair parts needed, then locate and requisition them in order to complete the assigned job.

There are several shipboard sources of information that will be useful to you in identifying the equipment and/or the repair parts needed. They include the Coordinated Shipboard Allowance List (COSAL); nameplates on the equipment; manufacturers technical manuals; and ships plans, blueprints, and other drawings.

COORDINATED SHIPBOARD ALLOWANCE LIST (COSAL).The COSAL is both a technical and a supply document prepared for an individual ship. It lists the equipment or components required for the ships operation; the repair parts and special tools required, the overhaul and repair equipment, and the miscellaneous portable items necessary for the care and upkeep of the ship.

For your purpose, the COSAL is the basic source of information on repair parts and materials needed for a job. A COSAL gives you information on such items as the noun name of a system (engine, pump, ejector, etc.), the manufacturers name and the I.D. number (General Motors Corporation #3255), the technical manual number for the system, the manufacturers drawing numbers, and the Allowance Parts List (APL) numbers for related systems (governors, starters, transmissions, etc.). In addition, COSAL provides specific informa-tion about National Stock numbers (NSNs), units of issue, costs, and the number of items needed. It may also include lists of part numbers and Federal Stock Numbers (FSNs) for crossover checks.

To request materials and repair parts from the supply department aboard ship, you must fill out and submit a NAVSUP Form 1250, a single item consumption/management document. If the item is not stocked aboard ship, the supply department will requisition the material from a supply activity, using the identifying information that you have given on the NAVSUP Form 1250. However, if all the information you have available is a manufacturers part number, then you must also fill out and submit, along with the NAVSUP Form 1250, a DD-1348-6 Form, NON-NSN REQ-UISITION.

For information on how to fill out these supply forms, review Military Requirements for PO 3 & 2, volume II of OPNAVINST 4790.4, or ask your ships supply personnel for assistance. Whenever you find it necessary to request materials or repair parts, remember two things:

1. If at all possible, find the correct NSN for each item requested. All materials now in the supply system have been assigned an NSN, and you should be able to locate them by using the COSAL and the other sources of information available to you such as the following:

a. NAMEPLATES on equipment supply information regarding the characteristics of the equipment. Nameplate data seldom, if ever, include the exact materials required for repairs; however, the information given on the characteristics of the equipment and on pressure and temperature limitations may provide useful clues for the selection of materials.

b. MANUFACTURERS TECHNICAL MANUALS are furnished with all machinery and equipment aboard ship. Materials and repair parts are sometimes described in the text of these technical manuals; more commonly, however, details of materials and parts are given on the drawings. Manufacturers catalogs of repair parts are also furnished with some shipboard equip-ment; when available, these catalogs are a valuable source of information on repair parts and materials.

c. SHIPS PLANS, BLUEPRINTS, and OTHER DRAWINGS available on board ship are excellent sources of information on materials and parts to be used in making various kinds of repairs. Many of these plans and blueprints are furnished in the regular large sizes; but lately, microfilm is being used increasingly for these drawings. Information obtained from plans, blueprints, and other drawings should always be checked against the information given on the ships COSAL to be sure that any changes made since the original installation have been noted on the drawings.

2. Work informally with the supply department personnel who are actually responsible for identifying and requesting material. You have the technical knowledge, and you know what you need. If you cannot find the correct stock number, however, your job is to give enough standard identification information, such as manufacturer part numbers, and Allowance Parts List/Component Identification Description (APL/CID) numbers, so that supply personnel on board ship or ashore can identify the item you want. Experienced supply personnel are familiar with identification publications and can help you to locate the cor-rect stock numbers and other important identi-fying information.

SHIP EQUIPMENT CONFIGURATION ACCOUNTING SYSTEM (SECAS).When the structure or composition of either the ship or a particular system or equipment on board a ship is modified, this modification must be documented. This action will ensure proper ac-counting of configuration changes, and will help improve supply and maintenance support technical manuals, PMS coverage, updated COSAL, etc., to your ship. SECAS is the designated system responsible for maintaining the configuration status reported by your ship. Although the responsibility for identifying and reporting these changes rests at all levels of the command, the work center supervisor is responsible for ensuring that the proper documentation is completed and processed as described in volume II of OPNAVINST 4790.4.

OPNAV Form 4790/CK, Ships Configura-tion Change Form, is used to report configura-tion changes at the individual equipment level. SHIP-TO-SHOP WORK.Many repair jobs are designated by the ship or approved by the repair activity as ship-to-shop jobs. In this type of job, the ships force does a large part of the repair work. For example, the repair or renewal of a damaged pump shaft might well be written up as a ship-to-shop job. The ships force will disassemble the pump and remove the shaft. Then the shaft and any necessary blueprints or technical manuals are delivered to the designated shop of the repair activity. After the shaft has been repaired, or a new one has been made, it is picked up and brought back to the ship by the ships force. The pump is reassembled, inspected, and tested by the ships force to make sure that it is operating satisfactorily.

An important thing to remember is that while the repair facility is responsible for ensuring that its personnel repair or manufacture this shaft to the manufacturers specifications, perform all tests required by Quality Assurance (QA), and fill out properly all the required forms, it is your responsibility to witness any test required by QA, to monitor the status of the job at all times, and to reassemble and test operate the equipment properly, so that the end results will produce a reliable operating piece of equipment.

EQUIPMENT TESTS.As an EN1 or ENC, you have the responsibility for scheduling and per-forming various tests on your equipment. The purpose of those tests is to determine how your equipment is performing and if there are any equipment malfunctions. These tests are per-formed at various times, such as (1) before going to the shipyard for overhaul, (2) after post deployment, (3) during a tender availability, or (4) as required by PMS. The tests are performed by the ships force, IMA personnel, shipyard personnel, or by an inspection team (such as the Board of Inspection and Survey (INSURV Board)). Detailed types of inspections are described in COMNAVSURFLANT Inst. 9000.1 or COM-NAVSURFPAC Inst. 4700.1A.