federal aviation administration aircraft maintenance documentation

Federal AviationAdministrationAircraft Maintenance

Documentation

Federal AviationAdministration

2Aircraft Maintenance Documentation

Introduction

This course provides a review of aircraft

maintenance documentation requirements.

It emphasizes the importance of proper

documentation.

It identifies common documentation problems

that can lead to maintenance errors.



Accident Data



Regulation Cited



Common Findings

• No documentation.• Inadequate description of work performed.• Using the wrong reference.



Maintenance Related Accident

3/24/2005 Prescott, AZ Robinson R22The helicopter's main rotor drive belts broke on the

base leg and the helicopter rolled over during the

subsequent autorotation and landing.

Upon exiting the helicopter, the instructor observed

that the V-belts were shredded.




A company mechanic had performed a 100-hour inspection about 4.3 hours prior to the accident flight.

During the inspection, he had loosened the self locking nut and stop screw on the belt actuator housing assembly.




The mechanic forgot to reposition the stop screw and

tighten the nut. This action resulted in the main rotor

drive V-belts becoming excessively loose. The belts

exited their seated position on the lower pulley

sheave and were severed.



NTSB Finding

Probable Cause

The company mechanic's improper

maintenance actions, which resulted in the

total failure of the main rotor drive belt system



Sept. 11, 1999 near Eagle Lake Texas.

Continental Express Flight 2574 an EMB 120

In flight the left horizontal stabilizer leading edge bent down and then separated from the aircraft

14 passengers and crew killed near Eagle Lake Texas.



NTSB Finding

Departures from approved procedures included failures to solicit and give proper shift / turnover reports, failures to use maintenance work cards as approved, failures to complete required maintenance/inspection shift / turnover forms, and a breach in integrity of the quality control system.



The Regulations (Title 14 CFR)

• Part 43 MAINTENANCE, PREVENTIVE MAINTENANCE, REBUILDING, AND ALTERATION

• Part 91 GENERAL OPERATING AND FLIGHT RULES Subpart E--Maintenance, Preventive Maintenance, and Alterations



• Part 135 OPERATING REQUIREMENTS: COMMUTER AND ON-DEMAND OPERATIONS Subpart J--Maintenance, Preventive Maintenance, and Alterations

• Part 121 OPERATING REQUIREMENTS: DOMESTIC, FLAG, AND SUPPLEMENTAL OPERATIONS Subpart L--Maintenance, Preventive Maintenance, and Alterations

The Regulations



• Part 145 Repair Stations

The Regulations



The RegulationsSec. 43.9 (a) Maintenance record entries. Except as provided in paragraphs (b) and (c) of

this section, each person who maintains, performs preventive maintenance, rebuilds, or alters an aircraft, airframe, aircraft engine, propeller, appliance, or component part shall make an entry in the maintenance record of that equipment containing the following information:

(1) A description (or reference to data acceptable to the Administrator) of the 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. The signature constitutes the approval for return to service only for the work performed.



The Regulations

Sec. 91.417 (a) (1) Maintenance Records

The records must include--

(i) A description (or reference to data acceptable to the Administrator) of the work performed; and

(ii) The date of completion of the work performed; and

(iii) The signature, and certificate number of the person approving the aircraft for return to service.



The RegulationsSec 91.417 (a) (2) Records containing the following information:

(i) The total time in service of the airframe, each engine, each propeller, and each rotor.

(ii) The current status of life-limited parts of each airframe, engine, propeller, rotor, and appliance.

(iii) The time since last overhaul of all items installed on the aircraft which are required to be overhauled on a specified time basis.



The Regulations

(iv) The current inspection status of the aircraft, including the time since the last inspection required by the inspection program under which the aircraft and its appliances are maintained.

(v) The current status of applicable airworthiness directives (AD) and safety directives including, the method of compliance, the AD or safety directive number and revision date. If the AD or safety directive involves recurring action, the time and date when the next action is required.

vi) Copies of the forms prescribed by Sec. 43.9(a) for each major alteration to the airframe ,engines, rotors, propellers, and appliances.



Record retention

• The owner or operator shall retain the following records for the periods prescribed:

• The records specified in paragraph (a)(1) of this section shall be retained until the work is repeated or superseded by other work or for 1 year after the work is performed.

• The records specified in paragraph (a)(2) of this section shall be retained and transferred with the aircraft at the time the aircraft is sold.



The Regulation

• Sec. 135.427 Manual requirements • c) Each certificate holder shall put in its manual a

suitable system (which may include a coded system) that provides for the retention of the following information--



(1) A description (or reference to data acceptable to the Administrator) of the work performed;

(2) The name of the person performing the work if the work is performed by a person outside the organization of the certificate holder; and

(3) The name or other positive identification of the individual approving the work.

•135.427 Manual requirements



The Regulations

Sec.145.219 Recordkeeping.

(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. The signature constitutes the approval for return to service only for the work performed.



INCORPORATION BY REFERENCE

• You don’t have to write a book.• The regulations permit reference to technical data in

lieu of making a long step by step detailed entry• Common references include maintenance manuals,

service letters, bulletins, work orders, advisory circulars (AC43.13-1B), and others

• Major alterations may reference STC’s• Reference documents must be retained



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.

The signature constitutes the approval for return to service only for the work performed.



Airworthiness Directive

FAR Part 39



AIRWORTHINESS DIRECTIVES

An unsafe condition exist in a product.

The condition is likely to exist or develop in other products

of the same design.



RESPONSIBILITY

The Owner/Operator is primarily responsible for maintaining the aircraft in an airworthy condition, including compliance with ADs

The Owner/Operator is responsible for ensuring that properly certificated persons perform the work.



RESPONSIBILITY

Maintenance personnel have the responsibility of compliance at the time they are performing inspections to determine all airworthiness requirements are met.



RECORDS

The owner must keep a record showing the current status of applicable ADs.

This record must include the following:

The current status of ADs applicable to the aircraft, including the AD number and revision date, the method of compliance, and the time‑in‑service, or the cycles, and/or the date when the next action is required for a recurring AD.



Sample Logbook Entry

N12345 Tach/Hobbs: ____________ ACTT: ____________ Enter the type of inspection(s) performed:Enter accomplishment of all A.D.’s including the number, revision date, method of compliance,

and if recurring, the next time/date it is due.Enter replacement or inspection of any component part with Airworthiness Limitations

(include part, serial number, and total time in service for that component).Enter removal and installation of any serialized component replacement parts

(include part, serial number, and total time in service for that component).Enter description of any other general maintenance performed.

I certify that this aircraft was inspected in accordance with a (insert type) inspection and was determined to be in an airworthy condition. All work was accomplished in accordance with current Federal Aviation Regulations and manufacturer’s maintenance instructions. Details of work performed can be found on XYZ Company work order _______.

______________________ __________________________ ____________

Signature Certificate # Date



DESCRIPTION OF WORK PERFORMED

The description should be in sufficient detail to permit

a person unfamiliar with the work, to understand what

was done, and the methods and procedures used.



Shift /Turnover

The transfer of critical information between work groups or shifts

It needs to be as detailed as necessary, depending on the tasks involved

Sharing of information by the people doing the task



Why is Shift/Task Turnover Important

Data show that poor shift/task turnover is a common contributing factor to events.

Challenges related to shift turnover include:

1. A high demand for teamwork and communication skills

2. Lack of structured and standardized policies and procedures

3. Using a location that is not conducive for discussion and planning



Why is Shift/Task Turnover Important

4. Finishing workers are tired and want to depart facility.

5. Lack of adequate shift overlap to provide time to give one-on-one briefings between the teams

6. Absence of a process to ensure departing personnel have documented all tasks accomplished or started.

7. Minimal training on procedures for shift/task turnover

High-quality shift/task turnover procedures enable improvement in practice and improve safety and accountability to all involved in the work.



How do you implement a Shift/Task Turnover process?

• Formalize policy and procedures that make the turnover as important as the work.

• Communicate policy and procedures to all personnel.

• Consider technology enhancements that improve the transfer of visual information (e.g., photos, graphics, movies).



How do you implement the Shift/Task Turnover process?

• Provide a time and place for formal shift/task turnover.

• Ensure the quality of shift/task turnover Information.

• Deliver initial and recurrent training on how to conduct a good shift/task turnover.

• Define acceptable communication practices.



Summary

The basic requirements for aircraft maintenance documentations are the same.

The method of meeting those requirements may be different depending on the type of operation.



Summary It may be a simple airframe, engine, propeller log book,

or an air carrier’s maintenance record system.

A description of the work performed, date the work was performed and the signature with certificate number and type are always required.



Common problems

• No documentation.• Inadequate description of work performed.• Using the wrong reference.• Poor shift turnovers



Easy solutions

• Follow the regulations.• Follow company procedures (GMM).• Use the Maintenance Personal Minimums Checklist !



BEFORE



AFTER



Thank you.

federal aviation administration aircraft maintenance documentation

Documents

preventive maintenance

maintenance errors

maintenance work cards

common documentation

accident flight

main rotor drive vbelts

operating requirements

continental express