REPAIR STATION QUALITY CONTROL MANUAL

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REPAIR STATIONQUALITY CONTROL MANUAL

• INSPECTION SYSTEM

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INSPECTIONS

• Receiving Inspection
• Incoming Inspection
• Preliminary Inspection
• Hidden Damage Inspection
• In-Progress Inspection
• Final Inspection/Approval for Return To Service

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Receiving Inspection

• Ensures product received from vendor satisfies
  Purchase Order requirements
• A. Part Number
• B. Quantity
• C. Shipping Damage

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Incoming Inspection

• Ensures product received satisfies airworthiness
  requirements
• A. Documentation
• Certification- 8130-3 or Certificate of
  Conformance
• B. Conformity to specification and acceptable
  quality
• C. Shelf Life
• D. Shipping Damage
• E. Preservation

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Advisory Circular 20-62D

• Eligibility, Quality and Identification of
  Aeronautical Parts
• Eligible Parts
• Approved Parts
• PMA
• TSO
• Type Certificated Product
• Acceptable Parts
• Standard Parts
• Owner/Operator Produced
• Conformed by Certificated Person

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QUALITY Condition for Safe Operation

• Factors
• Shelf Life
• Storage Time
• Fabric
• Dope, Paint, Sealants and Adhesives
• Internal Seals
• Rotating Components

• Factors
• Manufacturing Rejects
• Damaged Aircraft
• Rebuilt Engines
• Heat Fire
• Corrosives

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IDENTIFICATION/MARKINGS

• Airworthiness Approval Tag
• FAA Form 8130-3, EASA Form 1
• FAA PMA Symbol
• FAA TSO Marking
• Shipping Ticket from PAH (Production Approval
  Holder)
• Direct Ship Authority
• Maintenance Release Document
• FAA Form 337, 8130-3, Work Order, Yellow Tag

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ACCEPTABLE DOCUMENTS
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Part Ticket with Certificate of Conformity
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UNACCEPTABLE DOCUMENTS

• Invoice
• Certification Form
• ATA 106 Form

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ATA 106 Form Unacceptable Statements

• Remarks Block 13
• The above parts have not been subjected to
  extreme stress (as in a major engine failure,
  accident or fire) and it was not obtained from
  any US government or military source.

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ATA 106 Form Unacceptable Statements

• Block 15 New Parts Certification
• The following signature attests that the part (s)
  identified above was (were) manufactured and
  inspected in accordance with the code of the
  Federal Regulations 14 or the AIRWORTHINESS
  Authority of the Country of origin and/or
  established industry or U.S specifications

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ATA 106 Form Unacceptable Statements

• Block 16 Used, Repaired or Surplus Parts
• The following signature attests that the
  documentation specified above or attached is
  accurate with regard to the item (s) described.
  Repaired parts conform and were inspected in
  accordance with the Code of Federal Regulations
  14 or the Airworthiness Authority of the Country
  of origin and are approved for return to service

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• Accredited Distributor
• Must be accredited by industry
• Must have quality system
• Must retain records
• Must make records available

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NON CERTIFICATED PERSON

• Someone without a FAA certificate (individual or
  organization)
• When a Non Certificated person states that they
  are shipping the correct part ordered, the ONLY
  thing they are stating is that the part number
  agrees with the purchase order, NOT the status of
  FAA acceptability of the part.

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Preliminary Inspection

• Determines status of product received for
  maintenance
• A. Documentation, identification, traceability
• B. Shipping damage
• C. Preservation
• D. Life Limits
• E. ADs Service Bulletins
• F. Functional tests/teardown inspections
• G. Determination of repairs/scope of work

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Hidden Damage Inspection

• Inspection of article involved in accident for
  Hidden Damage before maintenance is performed.
• A. Includes inspections of adjacent areas
• B. May not be required in all cases.

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In-Progress Inspections

• Inspections/tests performed at various stages of
  teardown, maintenance and assembly.
• May include tests, measurements, calibrations
  while work is in progress.

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Final Inspection and Approval for Return To
Service

• Ensures inspection, testing, and/or calibration,
  including documentation is completed at the
  completion of maintenance.
• Includes Final Sign Off, Log Book Entry.

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CALIBRATION SYSTEM

• System to control and perform calibration of
  tools and test equipment used to make an
  airworthiness determination.
• Traceable to a standard acceptable to the FAA,
  NIST or other national authority.
• Maintenance of Records

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CALIBRATED TOOLS

• ONLY for tooling used to make Airworthiness
  determination
• Markings
• Must Have Calibration Sticker
• Calibration Not Required
• Users Responsibility to Verify Before Use

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CORRECTIVE ACTIONS

• Used to remedy an undesirable situation.
• Found before article released to service
• Found after article released to service
• Not Quality Assurance System.

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SUSPECTED UNAPPROVED PARTS

• SUSPECTED UNAPPROVED PART-
• Definition A part, component or material that is
  SUSPECTED of not meeting the requirements of an
  APPROVED PART.
• UNAPPROVED PART
• A part that does not meet the requirements of an
  APPROVED PART.

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APPROVED PART

• Those which are produced in accordance with a FAA
  Approved Manufacturing and Inspection System. TC,
  PC, STC, PMA, TSO
• Meet applicable design standards
• Maintained IAW FAR Part 43 and/or 145
• Manufactured by a repair station during
  alteration IAW STC

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ACCEPTABLE PART

• Standard Parts that conform to established
  industry or U.S. specification
• Owner/Operator Produced
• Fabricated by a person qualified to RTS Aircraft,
  Powerplant or propeller
• Parts for which inspections and tests have been
  accomplished by appropriately certificated
  persons authorized to determine conformity to
  FAA-approved design data.

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DETECTION

• Use of approved vendors
• Screening potential vendors
• Prices to good to be true
• Unrealistic delivery schedules
• No/Inadequate documentation
• Markings
• Appearance

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SHELF LIFE CONTROL

• Adhesives, Sealants, Paints, Seals, etc.
• Manufacturers Markings
• Storage Procedures
• Check before use.
• Date of Manufacture/Date of Opening
• Temperature Controlled

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ELECTRO STATIC DISCHAGE

• Used for equipment marked as ESDS sensitive.
• Properly Identified and Bagged.
• Handling/Storage
• Wrist straps for installation/removal

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FAR Part 43.3

• 43.3   Persons authorized to perform maintenance,
  preventive maintenance, rebuilding, and
  alterations.
• (b) The holder of a mechanic certificate
• (c) The holder of a repairman certificate
• (d) A person working under the supervision of a
  holder of a mechanic or repairman certificate
• (e) The holder of a repair station certificate

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FAR Part 43.5

• 43.5   Approval for return to service after
  maintenance, preventive maintenance, rebuilding,
  or alteration.
• No person may approve for return to service any
  aircraft, airframe, aircraft engine, propeller,
  or appliance, that has undergone maintenance,
  preventive maintenance, rebuilding, or alteration
  unless --
• (a) The maintenance record entry required by
  43.9 or 43.11, as appropriate, has been made

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FAR Part 43.7

• 43.7   Persons authorized to approve aircraft,
  airframes, aircraft engines, propellers,
  appliances, or component parts for return to
  service after maintenance, preventive
  maintenance, rebuilding, or alteration.
• (b) The holder of a mechanic certificate or an
  inspection authorization
• (c) The holder of a repair station certificate

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FAR Part 43.9

• 43.9   Content, form, and disposition of
  maintenance, preventive maintenance, rebuilding,
  and alteration records
• (1) A description (or reference to data
  acceptable to the Administrator) of work
  performed.
• (2) The date of completion of the work performed.
  
• (3) The name of the person performing the work if
  other than the person specified in paragraph
  (a)(4) of this section.
• (4) If the work performed on the aircraft,
  airframe, aircraft engine, propeller, appliance,
  or component part has been performed
  satisfactorily, the signature, certificate
  number, and kind of certificate held by the
  person approving the work.

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43.12   Maintenance Records

• Falsification, reproduction, or alteration.
• (a) No person may make or cause to be made
• (1) Any fraudulent or intentionally false entry
  in any record or report that is required to be
  made, kept, or used to show compliance with any
  requirement under this part
• (2) Any reproduction, for fraudulent purpose, of
  any record or report under this part or
• (3) Any alteration, for fraudulent purpose, of
  any record or report under this part.
• (b) The commission by any person of an act
  prohibited under paragraph (a) of this section is
  a basis for suspending or revoking the applicable
  airman, operator, or production certificate,
  Technical Standard Order Authorization, FAA-Parts
  Manufacturer Approval, or Product and Process
  Specification issued by the Administrator and
  held by that person.

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NOMAD FORMS

• Work order
• Over Above
• Tally Sheet
• Part Traveler

• Parts Request Ticket
• Tags
• 8130-3
• Parts Tags

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SIGNATURE REQUIREMENTS

• Technicians
• Legible Signature
• Legible Printed First Last Name, Signature
• Inspector
• Legible Signature
• Legible Printed First Last Name, Signature
• Stamp
• Approval for Return To Service
• Legible Signature and Certificate Number ONLY

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Work Order
Aircraft Registration Manufacturer Model Serial

Scope of Work
Corrective Action
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Date
O A Number, Work Order and Yes or No if
Traveler required
Description of Work
Aircraft Registration
Corrective Action
Attach ALL parts tags and FAA Form 8130-3s to
WO.
Parts- Use back if more than one
Request Inspection when all blocks are completed
and technician has signed !
LEGIBLE Signature or Legible Printed Name and
signature
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Aircraft Registration
Work Description
Traveler Number
Tally Sheet. Inventory of Documents in Work Order
Work Order
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Part Traveler

• Used to track part removed for maintenance and
  control fabricated part. Complete applicable
  blocks

DWG/SRM Ref
Aircraft WO
Parts/Materials Used
Work Step(s)
Final Inspection Sign Off
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Part Serial Number
Aircraft Registration

Mechanics Name
Reason for Removal
Part
Red Tag used for Condemned or Un-Repairable
part Green Tag used for Repairable part ALL
Removed Parts MUST be tagged
Work Order
White Identification Tag
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FAA Form 8130-3
MUST be retained and made a part of aircraft
records
Evidence of Airworthiness of part
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Part Tag MUST be Retained for aircraft records
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Parts Request Tag Used to Request Part from
Stockroom. White copy stays in Stockroom for
inventory control Yellow copy goes to technician
with part. May be used to return excess items to
Stock.
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