repair station quality control manual inspection system

REPAIR STATIONQUALITY CONTROL MANUAL

INSPECTION SYSTEM

INSPECTIONS

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

Service

Receiving Inspection

Ensures product received from vendor satisfies Purchase Order requirements

A. Part NumberB. QuantityC. Shipping Damage

Incoming Inspection

Ensures product received satisfies airworthiness requirementsA. Documentation:

Certification- 8130-3 or Certificate of Conformance

B. Conformity to specification and acceptable qualityC. Shelf LifeD. Shipping DamageE. Preservation

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

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

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”

ACCEPTABLE DOCUMENTS

Part Ticket with Certificate of Conformity

UNACCEPTABLE DOCUMENTS

Invoice Certification

Form ATA 106 Form

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.

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

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

Accredited Distributor

Must be accredited by industry

Must have quality system

Must retain records Must make records

available

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.

Preliminary Inspection

Determines status of product received for maintenanceA. Documentation, identification, traceabilityB. Shipping damageC. PreservationD. Life LimitsE. AD’s Service BulletinsF. Functional tests/teardown inspectionsG. Determination of repairs/scope of work

Hidden Damage Inspection

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

In-Progress Inspections

Inspections/tests performed at various stages of teardown, maintenance and assembly.

May include tests, measurements, calibrations while work is in progress.

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.

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

CALIBRATED TOOLS

ONLY for tooling used to make Airworthiness determination

Markings:Must Have Calibration StickerCalibration Not Required

User’s Responsibility to Verify Before Use

CORRECTIVE ACTIONS

Used to remedy an undesirable situation.

Found before article released to service

Found after article released to service

Not Quality Assurance System.

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 PARTA part that does not meet the requirements of

an “APPROVED PART”.

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

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.

DETECTION

Use of approved vendors Screening potential vendors

Prices to good to be trueUnrealistic delivery schedulesNo/Inadequate documentationMarkingsAppearance

SHELF LIFE CONTROL

Adhesives, Sealants, Paints, Seals, etc. Manufacturer’s Markings Storage Procedures Check before use.

Date of Manufacture/Date of Opening Temperature Controlled

ELECTRO STATIC DISCHAGE

Used for equipment marked as ESDS sensitive.

Properly Identified and Bagged. Handling/Storage

Wrist straps for installation/removal

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

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;

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

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.

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.

NOMAD FORMS

Work order

Over & Above

Tally Sheet

Part Traveler

Parts Request Ticket

Tags

8130-3

Parts Tags

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

Work Order #

Aircraft Registration #

Manufacturer

Model

Serial #

Scope of Work

Corrective Action

Date

Description of Work

Corrective Action

Parts- Use back if more than one

LEGIBLE Signature –or Legible Printed Name and signature

Aircraft Registration #

O & A Number, Work Order # and Yes or No if Traveler required

Attach ALL parts tags and FAA Form 8130-3’s to WO.

Request Inspection when all blocks are completed and technician has signed !

Work Order #

Aircraft Registration #

Work Description

Traveler Number

Tally Sheet. Inventory of Documents in Work Order

Part Traveler Used to track part

removed for maintenance and control fabricated part. Complete applicable blocks

Aircraft & WO #

DWG/SRM Ref

Parts/Materials Used

Work Step(s)

Final Inspection Sign Off

Part #

Aircraft Registration #

Mechanic’s Name

Work Order #

Part Serial Number

Reason for Removal

White Identification TagRed Tag used for Condemned or Un-Repairable part

Green Tag used for Repairable part

ALL Removed Parts MUST be tagged

FAA Form 8130-3

MUST be retained and made a part of aircraft records

Evidence of Airworthiness of part

Part Tag MUST be Retained for aircraft records

Parts Request Tag:Used to Request Part from Stockroom.White copy stays in Stockroom for inventory controlYellow copy goes to technician with part. May be used to return excess items to Stock.