THE HASHEMITE KINGDOM OF
CIVIL AVIATION AUTHORITY
No. : AC 50-1A
Date : July , 2006
SUBJECT: Outline for Developing a Repair Station Inspection Procedures Manual.
- PURPOSE: The purpose of this Advisory Circular is to provide information for developing a Repair Station Inspection Procedures Manual. This outline sets forth an acceptable means, but not the only means, of complying with the referenced regulations.
- REFERENCES: Civil Aviation Regulations Parts 65,91, 43, 145 and 121. Federal Aviation Administration Advisory Circular AC 145-3 as amended.
- DISCUSSION: This outline was developed to assist the applicant in preparing the inspection procedures required by CAR 145.45 (f) and other requirements of the CAR's for approval as a certificated repair station.
The Circular is not intended to provide complete instructions for developing procedures for all repair stations as each inspection procedures manual should be developed within the ratings it desires and the size and complexity of the station. Guidance material is provided in this outline which may not directly relate to or be required by a referenced CAR. However, that material is considered to be valuable as a part of a system for repair station management and illustrates integration of the required inspection procedures and other CAR Part 145 requirements into such a system.
Capt. Nayef Shukri
Director Flight Safety
Outline for Developing a Repair Station Procedures Manual
- A cover page should be provided which identifies the document as an. inspection procedures Manual and lists the name and address of the company.
- A table of contents should be provided. The table of contents should be structured by section and page.
- An introductory page should be provided which reflects the company policy and an explanation of the manual.
This Repair Station will not maintain or alter any item for which it is not rated and will not maintain or alter any article for which it is rated if it requires technical data, equipment, materials, facilities or trained personnel that are not available.
The Technical Library and this Inspection Procedures Manual, required for operation of this Repair Station, will be maintained in a current status at all times.
Each supervisor and inspector working for this Repair Station will have a current copy of this manual and should thoroughly understand its contents. It will also be made available to other Repair Station personnel. The maintenance, repair and alteration of products will be performed in accordance with the current Civil Aviation Regulations, Manufacturer’s Data, Drawings, Specifications and Bulletins, or other Technical Data approved by the CAA for the particular rating.Explanation
This Manual explains the internal inspection system in detail, including the continuity of inspection responsibility, it gives examples of inspection forms used and their method of execution. The manual gives a detailed explanation of the following portions of the inspection system; incoming materials, preliminary inspection, hidden damage inspection, continuity and final inspection of the article being maintained or altered. This inspection procedures manual has been prepared in accordance with ,the current Civil Aviation Regulations and the Policies of this Company.
- A page should explain how the Manual is to be maintained and controlled.
Each page should be numbered and an issue date typed on each page. Each manual will have a control number and an assignment entry on the manual cover page. A master list containing the manual number, location and revision status will be kept in the Engineering Office files.
Revisions to the manual will be the responsibility of the Engineering Department and will be submitted to the Flight Safety Office for acceptance. Upon acceptance, copies will be made and distributed to each Manual Holder.
Upon receipt of a Revision, each Manual Holder will be responsible for inserting the revised pages in his manual. A list of effective pages will be issued with each Revision.
- A page should contain a record of all Revisions to the Manual. Instructions should provide that the revision number, be entered, revision date, insertion date and initials of the person incorporating the Revision.
- List of Effective Pages. This page should list each page in the Manual and show the current effective date of that page.
- Housing and Facilities. This page should contain a description of the type of building, facilities and type of construction. Include type floors, heating, lighting, electrical and compressed air outlets, other special requirements applicable to the proposed rating should be shown.
- Facility Floor Plan . This page should contain a floor plan of the shops, hangar, stock area, offices, etc. Dimensions should be given.
- Company Organization.This page should contain the Company Organization Flow Chart indicating authority by title only. It should reflect separation between supervision of the maintenance and inspection departments.
- Authority and Roster of Authorized Personnel.
This page should include a roster of supervisory personnel including names of officials of the Repair Station, Technical Supervisors, Foremen and the names of inspection personnel including the names of the Chief Inspector and those inspectors who make final airorthiness determinations before releasing an article to service.
- Training. This page should identify the methods used to assure that its personnel can perform, supervise and inspect the work for which it is rated.
Training of Repair Station Inspectors and other personnel will be accomplished by classroom instruction plus factory and On the Job Training as necessary.
Factory Training will be scheduled as necessary for personnel to become familiar with new aircraft and aviation products or product improvement.
Current records will be maintained for each employee in “Record of Employee Training”. The Record will indicate the type of training (detailed) method, duration, date of completion, location and include the name of the instructor that conducted the classroom and On the Job training. Copies of certificates issued for Factory Training will be kept in the employees file.
- Employment Summary. A separate summary is required for each person referred to in Para 9 and 10 of this Advisory Circular. The format should follow the requirement of CAR 145.39 and space provided for signature of the individual. The employment Summary is required to be maintained in accordance with CAR 145.39. Repairman Certificates are to be applied for in accordance with AC 20-1 as amended.
Name_____________________________ Title: Chief Inspector
Scope of Present Employment: Has complete Repair Station Inspection Responsibility Mechanic Certificate No. A&P 5252, Repairman 6951 Instrument & NDT.
Years of Aviation Experience:
From To Employer/Address Position
- Duties & Responsibilities. This section should contain the duties and responsibilities of Key Positions by Title, one page for each position shown on the Organization Chart, No names should appear, only titles.
NOTE - ONE PAGE FOR EACH POSITION
The chief inspector is responsible to the general manager for the overall operation of the inspection department and, as such, will have the final authority in the releasing to service of airframes, engines, propellers, appliances and the component parts thereof. In addition, the inspector is responsible for directing, planning and laying out the details of inspection standards, methods and procedures used by the repair station in complying with all applicable Civil Aviation Regulations, manufacturer's specifications and recommendations.
It is the chief inspector's duty to:
- Assist, supervise and direct all personnel assigned to the inspection department.
- Ascertain that all inspections are properly performed and all completed.
- Maintain and keep current a file of pertinent Civil Aviation Regulation, specifications, type certification data sheets, and airworthiness directives.
- Determine that all technical data on all articles overhauled or repaired by the repair station are secured and kept current with latest revisions by the respective department inspectors. This data will include repair station's process specification for limited rating specialized services, manufacturer's overhaul manuals, service bulletins, part specifications related Civil Aviation Authority approved data and other technical data used by the repair station.
- Assure that periodic checks are made on all inspection tools and the calibration of precision test equipment used by the repair station and mechanics who have their own precision equipment. Further, assure that a current record ,of those inspections and test is maintained.
- Determine that no defective, unserviceable, or unairworthy parts are installed in any component or articles released by the repair station.
- Submit reports of defects of unairworthy condition in accordance with CAR 145.63.
- Assure the proper execution of CAA Form 109 when required, and/or a maintenance release.
- Accomplish the final acceptance of all incoming material, including new parts, supplies and the airworthiness of articles on which work has been performed outside the repair station by contract.
- Conduct the preliminary, hidden damage, in-progress, and final inspection of all articles processed by the repair station and record results outlined in this manual.
- Oversee the proper tagging and identification of all parts and components as outlined in this manual.
- Provide for continuity of inspection responsibility, assuring completion of required inspection when personnel shift or assignment changes occur.
- See that rejected and unserviceable parts are handled in such a way as to prevent their reuse as serviceable parts.
- Ascertain that all inspections are properly performed on all completed work before it is approved for return to service, and that the proper inspection and maintenance records, reports, and forms required for each release are properly executed.
- Maintain files of completed work orders and inspection forms in such a manner that the file pertaining to a specific item repaired can be readily located for review.
- Inspect all radio work that requires the qualification of an A&P mechanic, such as airframe structures, airframe electrical wiring, and weight and balance.
Note:The inspector may delegate all duties assigned to any qualified assistant as necessary, however, such delegation does not relieve the chief inspector of the overall responsibilities.
- Inspection System - General (CAR 145.45) Inspection responsibility should be shown concerning compliance with airworthiness and record keeping requirements, and conformity to the system by the chief inspector, inspection personnel, mechanics and supervisors.
The chief inspector is responsible to the General Manager for full compliance with all procedures outlined in this system as appropriate to any item being inspected, repaired, overhauled or altered by the repair station. The airworthiness of those items and compliance with record requirements of the operators of those items and of the repair station, depends on conformity to the procedures of this system.
Inspection personnel are required to be familiar with all inspection methods, techniques and equipment used in their area of responsibility. They must maintain proficiency, etc.
All inspectors, mechanics, supervisors are required to be thoroughly familiar with the requirements of this manual, CAA Regulations, Airworthiness Directive, etc.
(a) Continuity of Inspection Responsibility (CAR 145.45 (f)) This paragraph should explain the procedure for an inspector and mechanic to follow if he leaves a job before he finishes or turns over the job to another inspector or mechanic. It should also include procedures for shift change.
(b) Parts Receiving Inspection (CAR 145.45) This paragraph should identify the person responsible for receiving all parts arriving at the repair station meet specific requirements and a record of such inspection is made. Procedure should be developed to assure parts that do not meet repair station requirements are separated until they are disposed of, also, those parts requiring a functional check will be checked in accordance with the manufacturers instructions. Procedures should be established to assure that all adhesives, sealers, seals and other products, including pumps, valves motors, having a shelf life are identified by material control labels or tags.
(c) Work Order. This paragraph should explain the use and describe how to fill out and complete the work order. The work order should have a serial number, show the name of the repair station, address the CAA assigned repair station number. It should show the customer’s name and address, complete identification of the item worked on, detailed instructions for work to be accomplished and space for performance instructions for work to be accomplished. For work accomplished sign- off space for mechanics and inspectors should be reserved.
(d) Record of Work. This paragraph should describe how records of work accomplished will be maintained and the length of time the records will be kept.
(e) Preliminary Inspection. This paragraph should describe responsibility for a preliminary inspection of all products coming into the repair station for maintenance, repair or overhaul. A record of each preliminary inspection should be recorded on a Company Form.
The chief inspector is responsible for the performance of appropriate inspections including functional and nondestructive tests to assure that all units delivered to the repair station for maintenance, alteration or repair under the privileges of the repair station certificate are subjected to a preliminary inspection to determine the state of preservation and any defects on the items involved. This inspection will be recorded on the Preliminary Inspection Form with any discrepancies noted and the form must be attached to the work order identified with the unit involved. It will remain with the applicable inspection records until the unit is released for service. Appropriate supplemental forms will be used to record the results of functional and non destructive tests. Those forms will show the work order number and will be routed attached to the work order.
(f) Inspection for Hidden Damage This paragraph should refer to the preliminary inspection procedure ( Para l4(e)-Example) and explain that the preliminary inspection is not limited to the obvious damage or deterioration but includes a searching inspection for hidden damage. This paragraph should also describe who is to perform the inspection (by title), the inspection of areas adjacent to obviously damaged members or components, the recording of the inspection and correction of the defects.
(g) Progressive Inspections This paragraph should provide for inspectors to make progressive inspections at various stages of teardown, overhaul and repair of all units and to make these inspections at a frequency determined by the repair station.
(h) Major Repair and Alteration-Aircraft and Components. This paragraph should provide that following the preliminary inspection, procedures should include the authority for repair and alteration and approved engineering or other approved technical data authorizing the repair or alteration, where special approvals are made to cover specific or special repairs or alterations, a copy should be included in the aircraft file. Identify procedure for units removed from the aircraft and reason for removal.
(i) Repair, Alteration and Overhaul-Accessories and Appliances. This paragraph should explain the procedure for identification of accessories and appliances received for repair or overhaul, how they are tagged and proposed.
(j) Inspection Procedures. This paragraph should describe responsibility for inspections and the inspection procedures.
The Chief Inspector is responsible for the complete and efficient performance of inspectors assigned to the repair station to assure inspection acceptance in accordance with Manual Specifications or other approved technical data.
Shop Supervisors are responsible for the accomplishment of all work in accordance with Manual Specifications or other approved technical data.
Alterations and repair will be subject to progressive inspections by the inspection department. Discrepancies found during the progress of accomplishing the work will be recorded in the specified form. Discrepancies recorded will be corrected before the unit is submitted for final inspection.
Upon completion of a special operation, the mechanic will sign-off the work indicating the item is complete and ready for inspection, the action accompanied to correct a specific discrepancy will be noted under each item to assure conformance to specifications and established methods, techniques and practices. Functional checks of any system affected by the work involved will be accomplished before final acceptance inspection. Acceptance will be indicated by the inspector’s stamp.
(k) Maintenance Inspection. This paragraph should describe the procedure for the performance of maintenance inspections and the completion of required records and paperwork.
One hundred hour, progressive inspections and other periodic inspections of aircraft will be accomplished in accordance with the inspection cards or inspection schedule provided for the specific aircraft. The inspection paper work will be supplemented where necessary to cover items to be replaced for time, special inspection items, discrepancies and Airworthiness Directives. All 100 hour and annual inspection paperwork will comply with CAR Parts 43 and 91.
No aircraft will be returned to service following an inspection as outlined above until all discrepancies affecting airworthiness have been corrected.
Maintenance Supervisors are responsible for screening completed work orders covering work performed in their assigned area to assure that all items on the work order have been cleared, that there are no open discrepancies, and that all major work accomplished is covered by approved data. Inspection will assure compliance.
After work orders have been screened for completeness and accuracy, they are routed to the office. Inspection and work records will be retained in an active file for two years and then will be transferred to an inactive file.
(l) Continuity of Maintenance Responsibility
This paragraph should describe the procedure informing the next shift of the status of each job that has not been completed. The purpose is to assure a continuing maintenance responsibility for work progress.
(m) Handling of Parts. This paragraph should explain processing of parts identification tag, segregation, protection from damage and contamination, parts finishing, preservation, stock control and shelf life.
All items or components undergoing maintenance, repair and/or alteration shall have the parts segregated or in containers in order to assure that all parts of the same units are kept together. Suitable racks, trays, stands and protective coverings (as required) will be used to ensure protection of all parts. Rejected parts will be identified by a red reject tag and final disposition will be the responsibility of the Supervisor Quality Control.
Painting and spraying will be accomplished in an area segregated from the assembly area.
Components are preserved in accordance with manufacturer’s recommendations or other acceptable industry standard. To afford protection against humidity, extreme temperature, dust, rough handling or other damage; the component will be preserved by wrapping in suitable containers, plastic bags, and/or rigid boxes containing suitable shock absorbing material.
For those items having a specific shelf life, the repair station assigned form should be completed by the receiving inspector each month to determine if any components have exceeded their shelf life. Components or parts that have exceeded their shelf life will be red tagged and forwarded to the Supervisor Quality Control for final disposition.
(n) Tagging and Identification of Parts. While there are many methods employed for the identification and control of parts, an example of one way to tag and identify parts is shown below:
White Tag - used for identification of component or unit, to be completed by shop supervisor or designated employee.
Green Tag - will be attached to units or parts requiring repairs or test and will include work to be performed. To be executed and signed by inspector only.
Yellow Tag - To be attached to units which have received final inspection and are approved for return to service, the maintenance release is printed or stamped on the reverse side of the tag, this release will only be signed by an employee designated to do so.
Red Tag - will be attached to rejected parts, pending final disposition.
All tags shall contain the following information: Manufacturer, Model, Part Number, Serial Number, Name of Part’s Owner.
The yellow tag will remain attached to the parts returned to the customer.
The red, white, and green tags will be made part of the work order file. If the rejected part is returned to the customer, the red tag will remain attached and a record will be made on the work order showing the part was returned to the customer.
- Record of Special Inspection or Calibration.
This paragraph should describe the procedure for recording special inspections or calibration of equipment. Copies of the completed form should be attached to the work order. These records include compass calibration, navigation equipment calibration, pilot static system tests, etc.
- Control of Precision Tools and Equipment
Identify the position (by title) responsible for the calibration and the test records of all precision tools and equipment used by the company. The record should include the manufacturer, model and serial number date of check, the method used to calibrate and the frequency, and the results and/or corrections made, when the next inspection is due, and requirement to tag equipment as appropriate. Describe the procedure for shop personnel to follow in the use and control of precision test equipment.
- Final Inspection and Release to Service
This paragraph should explain compliance with the regulations, who performs the inspection (by title), how it is recorded and to require a check of the maintenance work package for completion.
Final inspection and release to service prior to approval for return to service. The Chief Inspector will audit the records "package" as identified by the work order to determine that all work has been inspected as required for compliance with this inspection system.
When approval has been given to the above audit, either the Chief Inspector or the individual authorized in the official roster and individual summary of employment, will approve the article for return to service.
Articles such as appliances, accessories, and individual parts or components will not have an individual record to which an entry may be added. However, the installation of these items on an aircraft constitutes an aircraft maintenance or alteration, and records must be made accordingly.
Routinely, major repair approvals will be handled in accordance with CAR 43 Appendix B.
A maintenance release is completed as part of the work order form at the time of approval for return to service. A separate maintenance release card will be completed and shipped on an article that is shipped to a customer. At the request of the customer (to be indicated on the work order when originated), CAA Form 109 will be completed instead of the maintenance release approval for return to service in accordance with the procedure of CAR Part 43, Appendix B.
In all cases where major alteration is involved, CAA Form 109 will be completed per CAR Part 43, Appendix B.
The authorized supervisor in whose area the repair or alteration is accomplished will be responsible for establishing that the repair or alteration was made in accordance with the requirements of CAR Part 43 and will sign the conformity statement.
Authorized personnel responsible for the approval for return to service of aircraft will indicate such approval by signing the approval for return to service. Appropriate entries will be made in the aircraft record pertinent to the repairs and alterations accomplished by the repair station. The original CAA Form 109 will be inserted in the aircraft record with a copy forwarded to the Flight Safety Office and one copy retained with the copy of the aircraft work order.
It is the responsibility of the person authorizing return to service to assure that the aircraft flight manual is properly revised following any alteration or modification to the aircraft and that the weight and balance record has been amended as necessary.
Aircraft components, appliances, and items, other than completed aircraft repaired or overhauled as authorized by the repair station specifications, will be returned to service through the use of a maintenance release pre-printed on the serviceable parts tag described in this section of this manual. The authorized supervisor under whose jurisdiction the work is accomplished will be responsible for the release of units in the category.
No aircraft or unit may be released for return to service until the work order and other records have been reviewed for completeness and final acceptance cleared by inspection. Particular attention shall be paid to the status of applicable airworthiness directives.
Maintenance Release Statement
A maintenance release statement stamp and/or pre-printed tag prepared in accordance with CAR Part 43 and other records required by Part 43 will be executed as required. In any event, the station will indicate on their copy of the work order whether or not a maintenance release was used, including the signature of the authorized representative.
The (use only applicable rating or ratings) airframe, aircraft engine, propeller or appliance identified above was repaired and inspected in accordance with current instructions contained in (name operator and manual or program), the maintenance rules of the Aviation Regulation under which the operator is certificated and is approved for return to service as per those requirements.
"Pertinent details of the repair are on file of this repair station under Work Order No. _________ Date ______________
(Signature of authorized representative
(Repair station name & certificate number)
NOTE 1: Inspection stamp/symbol will not be used on the maintenance release.
Malfunction or Defect Report.
This paragraph should explain how compliance with the CAR 145.63 is to be met, and prescribe the responsibility (by title) of the position(s) who prepare and submit the report.
This paragraph should explain that this repair station is responsible for all work subcontracted to an outside agency. The Chief Inspector should verify that the contracted work meets the Jordan Civil Aviation Regulations. A list of sub contractors should be included.
Performance of Work at a Location Other than at the Repair Station.
In accordance with CAR 145.51 (d), a Repair Station may maintain or alter any article for which it is rated at a place other than at the repair station provided certain preparations are made and certain conditions are met as required by CAR 145.51 (d) (1) and (2). The inspection procedures manual should contain the procedures governing the work to be performed as required by CAR 145.51 (d) (3). The following should be considered when preparing the detailed procedures.
Performance of Maintenance at a Location other than the Repair Station
(Name of Company) will provide maintenance service for its customers on an emergency on-call basis at a place away from the repair station. (Name of Company) can only provide this service for work for which the repair station is rated. Only the general manager or the chief inspector are authorized to initiate a work order for such work.
The maintenance manager will be responsible for assigning the personnel necessary to perform the work and appoint a person to be in charge of the work force. The chief inspector will assign the inspector(s) responsible to inspect the work and assure that all required forms and work orders are completed as necessary. The chief inspector will assign one inspector with the responsibility for returning the article to service.
The maintenance manager will ensure that the article to undergo maintenance and the work force will be in an area safe for the work to be performed and that they will be protected from the elements. The maintenance manager will be responsible for providing all the necessary manpower, work forms, technical data, tools, and equipment necessary for the accomplishment of the maintenance. The maintenance manager will establish a system of communications between the field work force and the repair station.
The stockroom manager will be responsible for assigning a stockperson who will provide parts and supply support between the repair station and the field work force. All articles removed by the field work force from a product undergoing maintenance at a location away from the repair station will be routed through the stockroom parts receiving department. The article(s) will be inspected in accordance with the repair station inspection procedures and either routed to the repair station shops or to contract repair agencies as appropriate.
All personnel assigned to accomplish work away from the repair station shall accomplish the specific function of work in the same manner as when performed at the repair station and in accordance with CAR part 145.
Forms This section of the manual should contain samples of forms used by the repair station. Detailed inspection forms and checklists which may be used in the performance of annual/100 hour inspection, engine overhaul sheets, routine inspection forms, ,etc., need not be included in the manual.
When planning a forms system, important functions to be considered are the control of operational procedures and recordation of all work performed on each article processed.
The number and content of the forms should be determined by the size of the repair station, the complexity and variety of the articles for which the repair station is rated, and the needs of its customers.
Some factors to be considered during the development of a forms system are:
(a) At what point in the maintenance process is the form introduced and when it is to be completed?
(b) What is the purpose of the form and how it fits into the system?
(c) The person (by title) or section responsible to start the form, who will contribute to its completion, and who will finish it?
(d) How the form will be executed?
(e) How the form will travel and where its final destination in the records system?
(f) Form should have adequate space for entering the required information and appropriate instructions for its use including specific assignment of responsibility to assure that it can be properly identified with the operation for which it is used and for recordation of work performance.