0015727 U.S. Department Advisory of Transportation Circular Federal Aviation Administration Subject: GUIDE FOR DEVELOPING AND Date: 5/22/97 AC No: 140-8 EVALUATING AN SFAR 36 Change:
ENGINEERING PROCEDURES MANUAL Initiated by: AIR-110
1. PURPOSE. This advisory circular (AC) sets forth an acceptable means, but not the only means, for developing and evaluating a 14 Code of Federal Regulations (14 CFR) Special Federal Aviation Regulation (SFAR) 36 engineering procedures manual. As such, the terms "shall" and "must" used in this advisory circular pertain to an applicant who chooses to follow the method presented.
2. RELATED CODE OF FEDERAL REGULATIONS (14 CER). 14 CFR parts 1, 21, 43„ 121, 125, 127, 135, 145, SFAR 36, and FAA Order 8000.42, Authorization To Develop & Use Major Repair Data Not Specifically Approved By The Administrator.
3. BACKGROUND. The development of an SFAR 36 engineering procedures manual that adequately covers all pertinent regulations and engineering procedures has proven to be a timeconsuming task for the applicant and the Federal Aviation Administration.
4. DISCUSSION. This AC may be used as a guide for development and evaluation of an engineering procedures manual for major repairs required by SFAR 36, paragraph 4. A sample engineering manual in shown in appendix 1. These "Examples" are intended to illustrate the requirements specified by the SFAR. The SFAR 36 engineering procedures manual should be developed within the limitations of the certificate holder's rating(s) and engineering staff capabilities to develop the technical data for major repairs. The engineering procedures manual must accurately describe the engineering operations use to develop major repairs under SFAR
36. The sample manual includes additional information necessary to administer the regulation such as, the requirement for a list of effective pages, company SFAR 36 organizational chart, and recommending the frequency of reporting requirements.
John K. McGrath, Manager, Aircraft Engineering Division, Aircraft Certification Services
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEFRING PROCEDURES MANUAL FIGURE 1. MANUAL COVER PAGE (COMPANY NAME) (COMPANY ADDRESS)
CERTIFICATE NUMBER
ENGINEERING PROCEDURES MANUAL FOR
MAJOR REPAIRS DEVELOPED
IN ACCORDANCE WITH SPECIAL FEDERAL AVIATION REGULATION (SFAR) NO. 36 APPROVED BY:_ (COMPANY'S) FAA-APPROVED SFAR 36 SIGNATURE AUTHORITY DATE:
APPROVED BY:
MANAGER, (COGNIZANT) AIRCRAFT CERTIFICATION OFFICE
FEDERAL AVIATION ADMINISTRATION (REGION) DATE:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 2. CONTENTS (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE_
CONTENTS
PAGE NUMBER
i. TITLE PAGE ii. LOG OF REVISIONS.
iii. LIST OF EFFECTIVE PAGES iv. TABLE OF CONTENTS
v. MANUAL CONTROL
1.0 INTRODUCTION..
2.0 PERSONNEL DUTIES & RESPONSIBILITIES
3.0 DURATION OF AUTHORIZATION
4.0 MAINTENANCE OF ELIGIBILITY
5.0 TRANSFERABILITY.
6.0 INSPECTIONS.
COMPANY APPROVAL:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 2. CONTENTS (CONTINUED) (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE CONTENTS (Continued)
PAGE NUMBER
7.0 LIMITATIONS
7.1 Product Limitations..
7.2 Repair Data Limitations.
8.0 PROCEDURES .
8.1 Approving & Controlling Technical Data..
8.2 Traceability of Repairs..
8.3 Differentiating Between Major & Minor Repairs..
8.4 Differentiating Between Major & Minor Alterations.
8.5 Determining Compatibility of Repair(s)..
8.6 Quarterly Report of Accomplished Repairs.
8.7 Maintenance of Current Records..
8.8 Retention of Current Records.
9.0 SERVICE DIFFICULTIES ..
APPENDICES A. Letter of Authorization ..
B. Repair Station Certificate & Operations Specifications or Commercial Operator Operating Certificate C. SFAR 36 Organization Chart.
D. Sample Forms..
E. Staff Qualifications.
COMPANY APPROVAL:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 3. LOG OF REVISIONS PAGE (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE
LOG OF REVISIONS [SFAR 36, paragraph 6.(b)(3)]
REVISION PAGE FAA APPROVAL
NUMBER NUMBER DESCRIPTION OF REVISION /DATE COMPANY APPROVAL:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 4. LIST OF EFFECTIVE PAGES (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE
LIST OF EFFECTIVE PAGES Please insert the revised pages into this manual and delete obsolete pages in accordance with the following list of effective pages. Revised pages are indicated by the letter "R," added pages by the letter "A," and deleted pages by the letter "D." Superseded and deleted pages shall be removed from the manual and retained separately.
The list of effective pages records not only each page of subject revision but also each previously issued page which is still current. Blank pages and pages which are no longer current do not appear on this list. If there is any question about the currency of the recipient's copy, it is recommended that each page in the manual be checked against this list of effective pages. Any page which does not appear on the list of effective pages should be removed.
Section Page Number Revision Date COMPANY APPROVAL:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SEAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 5. MANUAL CONTROL PAGE (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER_ DATE
MANUAL CONTROL FAA CONTROL:
The latest revision(s) to a page will be indicated by a vertical bar along the right hand margin and the revision number and date in the upper right hand corner.
All revisions to this manual will be submitted by the company's FAA-approved signature authority and approved by the FAA Administrator (address below) prior to incorporation into the manual. [SFAR 36, paragraph 6.(c)] (INSERT AIRCRAFT CERTIFICATION OFFICE ADDRESS) (COMPANY NAME) CONTROL:
(INSERT THE NAME OF THE INDIVIDUAL) will be responsible for all manual updates and distribution.
(INSERT A LIST OF WHO IS TO RECEIVE THE MANUAL AND MANUAL UPDATES) (INSERT COMPANY'S PROCEDURE FOR MANUAL CONTROL) COMPANY APPROVAL:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 6(A). BASIC MANUAL (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER _ SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE
1.0 INTRODUCTION.
(COMPANY NAME) may approve an aircraft, airframe, aircraft engine, propeller or appliance (INSERT WHAT IS APPLICABLE)] for return to service after accomplishing a major repair if the data used for the repair was developed by (COMPANY NAME) in accordance with SFAR 36 authorization. (SFAR 36, paragraph 3.)
This manual sets forth the procedures used by (COMPANY NAME) to develop and use major repair data that are not specifically approved by the FAA Administrator. The FAA Administrator is defined as the cognizant aircraft certification office. (SFAR 36, paragraph 3. and FAA Order 8000.42A, paragraph 1.)
SFAR 36 is applicable to major repair ONLY.
The specific paragraphs) of SFAR 36 and/or other regulatory material and/or FAA Order 8000.42A, being addressed is/are shown in brackets at the end of the explanatory statements). Those statements, including FAA Order 8000.42A, are for reference and guidance purposes for that particular topic.
All communications with the FAA will be conducted with (INSERT THE NAME AND TELEPHONE NUMBER OF THE INDIVIDUAL DESIGNATED AS POINT OF CONTACT BY THE COMPANY).
(FAA Order 8000.42A, paragraph 11.b.(2)(h)) COMPANY APPROVAL:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 6(B). BASIC MANUAL (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE
2.0 PERSONNEL DUTIES & RESPONSIBILITIES.
The following personnel meet the requirements of SFAR 36, paragraph 5.(a)(3), 5.(b)(1,2,3,4) and FAA Order 8000.42A, paragraph 11.a. and are approved under this authority. Resumes for each individual below are located in Appendix E or on file at the [Name of local ACO]. For approval of compliance with Damage Tolerance Requirements or other special requirements imposed by the Administrator, individuals should contact their local FAA office before proceeding.
Name/Title Signature Field of Engineering Scope of Authority *Denotes alternate signature authority.
COMPANY APPROVAL:
5122/97 AC 140-8 Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SEAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 6(C). BASIC MANUAL (CONTINUED) (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE
3.0 DURATION OF AUTHORIZATION.
(COMPANY NAME) authorization issued under this Special Federal Aviation Regulation is effective until January 23, 1999, unless it is surrendered or the Administrator suspends, revokes, or otherwise terminates it at an earlier date. (SFAR 36, paragraph 7.)
4.0 MAINTENANCE OF ELIGIBILITY.
(COMPANY NAME) is required to continually meet the requirements of this authorization or to notify the FAA Administrator within 48 hours of any change (including changes in personnel) that could affect the company's ability to maintain eligibility under the requirements of SFAR 36. (SFAR 36, paragraph 5.(c)) Note: No new major repair data in the area directly effected by a personnel change can be approved by the authorization holder during this period. Reauthorizations in this area will depend on a thorough review of the new individuals qualifications.
(COMPANY NAME) must hold a current domestic repair station certificate under 14 CFR part 145, an air carrier certificate under 14 CFR part 121 or 127, or a commercial operator certificate under 14 CFR part 121, or be an air taxi operator subject to the requirements of 14 CFR part 135.2. (SFAR 36, paragraph
5.(a)(1))
5.0 TRANSFERABILITY.
This authorization issued under this Special Federal Aviation Regulation is not transferable. (SFAR 36, paragraph 8.)
6.0 INSPECTIONS.
Upon request, (COMPANY NAME) shall allow the FAA Administrator to inspect the facilities, products, and records related to the major repair programs performed under this authorization. (SFAR 36, paragraph 9. and FAA Order 8000.42A, paragraph 5.)
COMPANY APPROVAL:_ 9
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SFAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 6(D). BASIC MANUAL (CONTINUED) (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER DATE
7.0 LIMITATIONS.
7.1 Product Limitations. (INSERT A STATEMENT OF PRODUCT LIMITATIONS PLACED ON THE COMPANY). (SFAR 36, paragraphs 10. and 11., and FAA Order 8000.42A, paragraph 11.b.(1))
7.2 Repair Data Limitations. (INSERT A STATEMENT OF REPAIR DATA LIMITATIONS). (FAA Order 8000.42A, paragraph 11.b.(1)) FAA engineering approval is required:
a. before the use of all equivalent safety provisions are applied under 14 CFR part 21.21. (FAA Order 8000.42A, paragraph 11.b.(1)(a)) before the use of data procured from specialized services not part of (COMPANY NAME) facility. (FAA Order 8000.42A, paragraph 11.b.(1)(b))
c. before the use of data concerning a repair that may result in an acoustical change in the product.
(FAA Order 42A, paragraph 11.b. (1)(c))
d. before accomplishing a repair that affects any Airworthiness Directive (AD) requirements. (14 CFR part 39)
e. before the use of data concerning repairs to life-limited items.
8.0 PROCEDURES.
(COMPANY NAME) is responsible for showing compliance with the applicable airworthiness requirements (14 CFR part 21.101). (FAA Order 8000.42A, paragraph 11.b.(3)) The data developed and used for each major repair shall show that the condition of the repaired product will be at least equal to its original structural integrity. This includes subsequent products using previously approved SFAR 36 major repair data as referenced in SFAR 36.3(b). In accomplishing this, the data shall show compliance with the applicable airworthiness standards. (FAA Order 8000.42A, paragraph
11.b.(3)(a)) COMPANY APPROVAL:
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING A SPECIAL FEDERAL AVIATION REGULATION (SEAR) NUMBER 36 ENGINEERING PROCEDURES MANUAL FIGURE 6(E). BASIC MANUAL (CONTINUED) (COMPANY NAME, CERTIFICATE NUMBER) PAGE NUMBER SFAR 36 ENGINEERING PROCEDURES MANUAL REV. NUMBER_ DATE The data shall show how the product that has been repaired meets all the requirements of the applicable FAR's and, when operated within the approved flight envelope of the certificated aircraft and when maintained in accordance with FAA-approved manuals or an FAA-approved continuous airworthiness maintenance program, will function reliably throughout its established inspection interval. (FAA Order 8000.42A, paragraph 11.b.(3)(b))
8.1 Approving & Controlling Technical Data.
(FAA Order 8000.42A, paragraph 11.b. (2)(a)) (INSERT COMPANY PROCEDURE AND FLOW CHART) Sample forms being utilized for this procedure appear in Appendix D of an applicant's proposed engineering procedure's manual.
8.2 Traceability of Repairs. (i.e., identification and product repair records) All repairs accomplished under SFAR 36 authority shall be identified by--- (SFAR 36, paragraph 13. and FAA Order 8000.42A, paragraph 11.b.(2)(f)) (INSERT COMPANY'S MEANS OF IDENTIFYING/TRACING SFAR 36 REPAIRS) Differentiating between Major and Minor Repairs. (FAA Order 8000.42A, paragraph 11.b. (2)(c), 14 CFR part 1.1. and Part 43., Appendix A) (DEFINE COMPANY PROCEDURE FOR DIFFERENTIATING BETWEEN MAJOR AND
MINOR REPAIRS)
8.4 Differentiating between Major Repairs and Major Alterations. (FAA Order 8000.42A, paragraph
11.b. (2)(d), 14 CFR part 43, Appendix A, 14 CPR part 1.1.)
(DEFINE COMPANY PROCEDURE FOR DIFFERENTIATING BETWEEN MAJOR REPAIRS AND MAJOR ALTERATIONS) Note: Major alterations are outside the scope of SFAR 36.
COMPANY APPROVAL: