Appendix A A-7 training when they have been unqualified for an extended period of time. The requalification training process should capture the reasons why requalification training was required. An effort should be made to identify and rectify unusual requalification requirements.
Engine Run and Taxi Training ABC Air designed the engine run and taxi program to ensure maintenance personnel required to run-up or taxi the company aircraft are properly trained, qualified, and authorized. The maintenance training department authorizes the examiners and administers this program.
Engine run and taxi procedures will be taught hands-on and may be given by the following personnel:
1. Maintenance training technical instructors.
2. Maintenance personnel who hold current ABC Air engine run and taxi authorization for the type aircraft involved.
3. ABC Air flightcrew members type rated in the aircraft.
4. Trained personnel from the factory or other approved training facilities.
5. Contracted instructors authorized by the maintenance training technical instructor based on previous aircraft training and experience or successful completion of ABC Air’s engine run and taxi authorization training.
Engine run and taxi training will be conducted only on aircraft that have no open maintenance discrepancies that may affect the safe ground operation of the aircraft. The manager of training will keep a current list of authorized instructors on file electronically.
Maintenance personnel are required to meet the following criteria to possess an engine run and taxi authorization:
1. Possession of a valid Airframe and Powerplant (A&P) certificate.
2. Employment with the company for at least 6 months.
3. Completion of the engine run and taxi familiarization class (first-time applicants only) before initial engine run and taxi authorization and a score of 85 percent or better on the engine run and taxi written examination. Training will include aircraft cockpit and checklist procedures, marshalling, towing and taxi procedures, airport operations familiarization, radio communication procedures, and runway incursion prevention.
4. Completion of a minimum of four hours of hands-on instruction in engine run and taxi training on an actual aircraft and/or simulator, including but not limited to limitations, normal and emergency procedures, and engine and aircraft operation.
5. Successfully passing an initial checkride or reauthorization by passing the 12-month recurrent checkride at the appropriate time for that specific aircraft.
ABC Air may give maintenance personnel authorization to perform engine run and taxi of the aircraft if they have held such authorizations at a previous company on the same specific
Appendix A A-8 aircraft and have supplied ABC Air with the basic class training documentation from the previous experience. The manager of training will review and approve these authorizations.
The instructor providing the training sessions will record all training on the appropriate form.
When the instructor feels confident that the student has mastered the engine run and taxi procedures, they will inform the supervisor, and set up an engine run and taxi checkride for the student. If the instructor understands that the student requires additional training, the instructor will annotate the additional training on the appropriate form.
After the student successfully completes the checkride, the training department will issue an engine run and taxi authorization, which will be good for one year. Individuals holding engine run and taxi authorizations will receive an annual proficiency check covering equipment operation, limitations, emergency procedures, and engine run and taxi radio communication procedures for each aircraft type. Proficiency checks must include operation of the aircraft type for recertification. Aircraft simulator time is recognized as aircraft operation. Maintenance personnel must renew their engine run and taxi authorizations within 2 months after the expiration date for each aircraft rating to be considered for recurrent renewal. Failure to meet this renewal requirement will require the authorization holder to meet initial minimum eligibility requirements as outlined in this section.
After a practical examiner gives an engine run and taxi checkride, they will complete the appropriate form and forward it to the maintenance training department, where it will be included in the employee’s file. A copy of the engine run and taxi checkride form may be given to the student as proof of the qualification until they receive their authorization card.
Human Factors Training Program Maintenance human factors training is part of a total system in managing human error designed to discourage procedural violations in maintenance. It is an essential part of this system aimed at individuals engaged in hands-on maintenance. Human factors training covers basic safety principles and practices already incorporated in ABC Air’s safety management and quality system to ensure the work is carried out in a professional manner such that aircraft are released to service in a safe and airworthy condition.
The objective of ABC Air’s human factors training is to provide human factors principles and techniques that will help the employee do a better job by—
1. Improving safety.
2. Decreasing organizational exposure to risk.
3. Capturing and reducing errors.
Instructors should understand the aspects of human factors by embedding it into all the training curricula. To accomplish this, instructors must—
1. Have credibility in their understanding of fundamental human factors principles and the maintenance work environment.
Appendix A A-9
2. Have excellent communication and motivational skills and be able to effect attitude changes as well as impart knowledge.
3. Be aware that the instructor’s attitude and behavior carry over to the students.
4. Always follow the procedures and have them in hand.
5. Discuss personal feelings and/or needs with the students. For example, let the students know if you are feeling tired, distracted, overwhelmed, etc., and ask them to watch out for your well-being. This will demonstrate how the instructor and student can help each other avoid errors.
6. Remind students of the dollars they are responsible for. For example, taxiing a $130 million aircraft or replacing a $200,000 part.
7. Point out personal injury potentials associated with your subject matter.
8. Point out the environmental hazards you will encounter during this training. For example, wet/slick taxiways/parking spots, poor visibility, cold/hot, power on/off, etc.
Ask your students to identify “safety nets” for these conditions.
9. Use industry “lessons learned” relative to the subject matter; include associated costs and personnel injuries.
10. Debrief students after practical examinations and openly discuss mistakes and potential ramifications and how to avoid these traps on the job.
11. Advocate the training department’s knowledge, experience, and lessons learned to other departments.
As part of the human factors training, instructors should consider a reference to the Dirty Dozen relative to situations.
The Dirty Dozen are as follows:
1. Lack of C ommunication. The exchange of information that conveys meaning between two or more people. Lack of communication often leads to misunderstandings and the results could be catastrophic.
2. Complacency. Self -satisfaction accomplished by a loss of awareness of the dangers.
This often happens when doing familiar, repetitive work.
3. Lack of K nowledge. Insufficient experience or training in the task at hand. It is easy to see how lack of knowledge could lead to an error or an accident. Often lack of assertiveness plays a part because people do not like to admit they do not know something.
4. Distraction. One’s attention is drawn away; mental or emotional confusion or disturbance occurs. When working among many people, when the work is constantly interrupted, or when coping with stress, it is easy to become distracted.
5. Lack of Teamwork. Failing to work together to achieve a common goal. Lack of teamwork creates an unhealthy environment in terms of personal dissatisfaction and group disconnect.
Appendix A A-10
6. Fatigue. Weariness from labor or exertion, nervous exhaustion, temporary loss of power to respond. Shift work can have an enormous physical impact, but there are ways to combat fatigue. Examples include sleep and exercise regularly, avoid complex tasks at the bottom of the circadian rhythm, and ask others to check the work.
7. Lack of R esources. Failing to use or acquire the appropriate tools, equipment, information, or procedures for the task at hand. Lack of resources or misusing resources has been linked to many accidents or incidents.
8. Pressure. Pushing for something in spite of opposing odds or creating a sense of urgency or haste. This factor is most prevalent when deadlines approach or when trying to meet a schedule.
9. Lack of A ssertiveness. Failing to behave in a self-confident manner. Lack of assertiveness has been identified as a link in the chain of events for many accidents.
10. Stress. Mental, emotional, or physical tension, strain, or distress. Stress is not good or bad; it is how it is handled that determines its impact on the individual.
11. Lack of Awareness. Failing to be alert or vigilant in observing. Lack of awareness of the situation or your surroundings often results in error or injury to yourself or others.
12. Norms. Unwritten and, often, unspoken rules about how work is done. Always work according to the instructions or, if they are good norms, have the instructions changed to become a part of the approved procedures.
One important aspect of the human factors training program is disclosure. It is ABC Air’s policy to have maintenance personnel actively participate in the error investigation process and to reduce any anxieties maintenance personnel might have when participating in an error investigation. The purpose of the investigation is not to determine who made the error, but rather find out why the error occurred. Maintenance personnel should feel free to disclose any unintentional errors. Any good human factors program should include a company-wide, just culture without fear of punishment or retaliation.
Aircraft Fueling and Vendor Training This training course provides information to fueling vendors to obtain authorization for fueling ABC Air aircraft to meet the requirements of ABC Air’s fueling manual.
Unscheduled On-Call Maintenance Training This training provides information to on-call maintenance technicians who may be called upon to perform maintenance functions on ABC Air aircraft.
Borescope Qualification Process Borescope training is provided to individuals requesting level one or level two borescope qualifications. Training includes familiarization of various borescope equipment types, techniques, and return-to-service criteria.
Appendix A A-11 IX. Instructional Methods ABC Air uses various instructional methods as part of its training program. It is the responsibility of the training department to periodically revise and update, as necessary, the approved instructional methods. Currently, ABC Air has the following approved instructional methods:
1. Classroom T raining. This method is usually conducted away from the production worksite in an academic classroom environment. It is appropriate for presenting new material, showing relationships between theory and practice, and teaching a skill. Only qualified maintenance instructors, contracted instructors, or designated maintenance instructors may teach classroom courses.
2. Practical Training. This method helps students gain confidence. It is prescheduled hands-on training conducted by a qualified instructor where students learn by doing, using training aids, mockups, or serviceable equipment. It is part of a planned course and does not result in actual servicing or repair.
3. On-the-Job Training (OJT). This method helps employees gain competence and may or may not use structured learning. It is task-specific training conducted at the worksite by an OJT instructor that involves actual work performance. Technical documents used at the worksite must be used as a performance standard reference. See OJT program.
4. Computer-Based Training (CBT). This method is used to provide technical information to all maintenance department personnel. The content is of an advisory nature only and cannot be used as a reference for documenting maintenance action.
Examples of CBT use include the following:
a. Notices regarding aircraft fleet differences.
b. Amplifying and clarifying existing instructions found in maintenance manuals.
c. Tips and hints on accomplishing specific maintenance tasks.
d. Clarification of methods, techniques, and practices unique to the company.
X. Training Devices To further enhance training, the training department must provide the appropriate training devices as part of the curriculum and courses it develops. These devices may include unserviceable parts. The training department will maintain an inventory of all aircraft parts used for training purposes. The manager of training is responsible for the acquisition and accountability of all training devices.
XI. On-the-Job Training (OJT) Program The training department will manage the OJT program to augment classroom training and provide documentation for experience or tasks that are best taught through actual work performance. OJT must be conducted by a qualified OJT instructor. Once the training is accomplished, that training will be documented with the appropriate OJT form. The completed form will be sent to the training department for insertion into the individual’s training file. Line
Appendix A A-12 stations with only one employee will use OJT task sheets to document work experiences on nonflight critical tasks. These noncritical tasks are annotated on the individual OJT task sheet.
OJT may include, but is not limited to, tasks such as aircraft servicing, component replacements, troubleshooting skills, maintenance techniques and procedures, use of test equipment, component repair, or engine ground-runs and taxi. OJT is conducted in the work environment. OJT will be recognized for those individuals who have satisfactorily accomplished specific tasks, procedures, or techniques. The instructor conducting the training will fill out the appropriate OJT form that will contain a handwritten or computer-generated record describing the training and the source data used, as applicable. The training curriculum for each OJT segment is subject to approval by the manager of training.
OJT may be conducted by any of the following people:
1. OJT instructor.
2. Designated OJT instructor.
3. Managers, supervisors, leads, or aircraft mechanics who have previously demonstrated satisfactory completion of those specific tasks being instructed.
The training department will coordinate managers and supervisors to maintain and conduct required training as operational needs arise. The training department also will coordinate with managers and supervisors to establish training schedules for OJT. The schedule is established with a goal for maximizing training of the technical workforce while minimizing the impact on production. The manager of training may approve vendors, factory representatives, and other recognized vendor training program personnel as designated OJT instructors. The manager of training and the OJT instructors will coordinate meetings to recommend suggestions for improvement and report on the OJT program status.
XII. Training Records The purpose of the training records system is to keep accurate records of training history and certification data for maintenance personnel. Individual training records can be generated from the training database for any ABC Air employee or nonemployee who has completed ABC Air’s maintenance training lessons or holds an ABC Air maintenance qualification.
Training records for outside labor personnel are recorded in the training database using the individual’s name, company name, and station location.
Every employee’s training records will be duplicated as a hardcopy file in the event a certificate is lost/stolen or the computer system fails. Training files for personnel who have transferred out of the maintenance department or who have terminated their employment or contract with ABC Air will be placed in a terminated/resigned file for a period of five years and archived in the computer system, and will no longer be maintained as an active record. These files will be retained in accordance with Federal law and regulations.
Each training database file must contain the following information:
Appendix A A-13
1. Name, employee number, and certification number.
2. Job title, station location, and date of hire.
3. Records of training completed, including course title, description, instructor, grade, and completion date.
4. Qualification and certification records with issue and renewal dates.
5. Hours of training received.
6. Certification of all events by supervisor, instructor, or company, as appropriate.
7. Duration of initial and recurring training events.
Records of training from other approved training providers and/or vendors are acceptable documents and will be used in the approval process for entering training records into the training database. Training from other approved providers that are credited to the individual’s training must be included in the records for that individual. Photocopies, facsimiles, electronically generated, emailed, hard copies, and faxed copies of training documents and forms are acceptable for use in the approval process for entering records into the training database.
All personnel authorized for aircraft maintenance records access and data entry must be given OJT for the recordkeeping system. This OJT must consist of familiarization with the system and the requirements of the maintenance personnel training program. These individuals will have a training file established to ensure all OJT training is on file.
Access to individual training records is restricted to the manager of training, vice president of maintenance, director of maintenance, director of quality control, designated data entry clerks, and FAA personnel with the proper identification. All requests for training records and all approvals or authorizations required for certification and ratings must be received in writing (email or paper copy) by the authorized department manager or their designee before making any updates to the training database. Training records will be entered into the training database only with verification that all applicable training and prerequisites have been met, and the authorized individual has provided direct approval in writing (paper or email).
For verification purposes, each mechanic employed by ABC Air will have a copy of their A&P certificate on file with the training records department. Outside labor mechanics must have their certificates verified for authenticity and records kept by their respective employer. ABC Air employees must immediately notify the training records department of certificate status changes by submitting a copy of the new certificate. For example, when the mechanic receives a new A&P number, when the temporary certificate becomes permanent, or when the certificate has been suspended or revoked.
XIII. Measuring Training Effectiveness ABC Air has three measures to validate that maintenance employees are capable of performing the assigned tasks and that the training program has been effective:
Appendix A A-14
1. Written Tests. ABC Air will administer written tests immediately after completion of a training course. All written test scores will be recorded as a percentage of 100. A minimum of 80 percent is required to pass, and all tests will be administered and proctored by the manager of training or their designee. The completed test will remain on file in the training department for 12 months after the testing event.
2. Practical Tests. ABC Air will require a demonstration of capability by employees during the performance of the task. Practical tests will be recorded as a pass or fail grade mark.
3. Course Evaluations. ABC Air will periodically evaluate its training courses to determine if the employee has met the training objectives and to see if the instructors appropriately transferred to the students the essential knowledge, skills, and abilities.
All instructors will report failing scores to the manager of training. Appropriate competency-based training, including testing, will be scheduled by the manager of training for individuals who do not receive a passing grade. If upon retraining, an individual does not perform to standards, the matter is referred to the appropriate department director for action.
XIV. Training Program Reevaluation The manager of training or their designee will reevaluate ABC Air’s training program and records at least annually for the need of revision based on performance of the program, CASS findings, training needs assessments, and aircraft or equipment changes.
The training program reevaluation process consists of conducting three levels of evaluation, reviewing student feedback, and taking action as required. These activities include—
1. Conducting student feedback evaluations.
2. Conducting post-test evaluations.
3. Conducting behavioral evaluations.
The manager of training will develop and oversee the evaluation process, including reviewing student feedback and any resulting corrective action. For each course, before the completion of training, students will complete a student feedback evaluation, and instructors will administer post-test and/or practical exercises covering material covered in the course.
Behavioral evaluations are conducted 60 to 90 days after training has been completed using a job performance survey/questionnaire. The survey/questionnaire will be customized to meet the needs of the training department. This activity will be conducted on an as-needed basis.
Instructors, supervisors, and the manager of training will review feedback from evaluations to determine if corrective action is required. This could include modification to curriculum, establishing course prerequisites, and/or evaluating instructor competence.
NOTE: The CAMP portion of the manual should set forth its method of documenting the annual review and for ensuring any changes to the training program are accomplished.
Advisory Circular Feedback Form If you find an error in this AC, have recommendations for improving it, or have suggestions for new items/subjects to be added, you may let us know by contacting the Flight Standards Directives Management Officer at 9-AWA-AFB-120-Directives@faa.gov.
Subject: AC 120-124, Continuous Airworthiness Maintenance Program (CAMP) Training Program Date: _____________________ Please check all appropriate line items:
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