AC 145-3 DATE 2/13/81 Consolidated Reprint -- Includes Change 1
ADVISORY CIRCULAR
GUIDE FOR DEVELOPING AND EVALUATING REPAIR STATION
INSPECTION PROCEDURES MANUALS
DEPARTMENT OF TRANSPORTATION Federal Aviation Administration Washington, D.C.
AC 145-3 DATE 2/13/81
ADVISORY CIRCULAR
DEPARTMENT OF TRANSPORTATION Federal Aviation Administration Washington, D.C.
Subject: GUIDE FOR DEVELOPING AND EVALUATING REPAIR STATION
INSPECTION PROCEDURES MANUALS
1. PURPOSE. This advisory circular (AC) provides information for developing and evaluating a repair station inspection procedures manual. This information sets forth an acceptable means, but not the only means, of complying with referenced regulations.
RELATED FEDERAL AVIATION REGULATIONS (FAR). FAR Parts 43, 91, 121, 125, 127, 135 and 145.
3. BACKGROUND. The development of a repair station inspection procedures manual that adequately covers all pertinent FAR and the repair station's inspection system has proven to be a time-consuming task for the operator and the Federal Aviation Administration. This guide was developed to reduce that time and to provide a standardized format that may be used to develop a manual that contains a repair station's inspection procedures.
4. DISCUSSION. This document is intended for use as a guide for the development and evaluation of the repair station's inspection procedures manual required by FAR Section 145.11(a)(2) and Section 145.45(f).
This guide is not intended to provide a complete sample inspection procedures manual for all repair stations. "Examples" in Appendix 1 are intended to illustrate a requirement related to the FAR. Each inspection procedures manual should be developed within the ratings authorized and the size and complexity of the station. It is important to note that the inspection procedures in the manual are necessary for a satisfactory quality control system, and those procedures should be designed for use by the repair station to satisfactorily perform under its rating(s). In that regard, a repair station with a Limited Specialized Service Rating for Nondestructive Testing would have a different inspection system criteria than a repair station with a Class 3 Airframe Rating. Material is included in portions of this document which may not directly relate to or be required by a referenced Initiated by: AWS-340
FAR. However, that material is considered to be valuable as a part of a system for repair station management and illustrates integration of the required inspection procedures and other FAR Part 145 requirements into such a system.
b. A complete inspection procedures manual should at least:
(1) Satisfy the minimum requirements of the FAR.
(2) Accurately describe the repair station operations as related to its ratings.
The repair station manual content requirements are outlined in FAR Section 145.45(f) and Section 145.51(d)(3). The following is a brief outline of those manual requirements:
(1) Detailed explanation of the repair station's inspection system.
(2) Details for the continuity of inspection responsibility.
(3) Detailed system of inspecting incoming material.
(4) Detailed system of preliminary inspection.
(5) Detailed system for hidden damage inspection.
(6) Reference to manufacturer's inspection standards for a particular article when applicable or necessary.
(7) Sample of inspection forms and the method of their execution or reference to a document in the forms manual.
(8) Methods and procedures for training inspection personnel.
(9) Approved procedures governing work performed outside the repair station.
(10) Procedures for acceptance of work performed by other facilities.
(PAR Section If splicable, procedures for work performed for air carriers
d. An air carrier with an FAA approved repair station rating(s) may make its repair station's inspection procedures manual a part of its air carrier manual provided all of the manual requirements of FAR Part 145 are satisfied.
se Pontecoro seph Pontecorvo Aeting Director of Airworthiness 2 Par 4
Appendix 1 APPENDIX 1. GUIDE FOR DEVELOPING AND EVALUATING REPAIR STATION INSPECTION
PROCEDURES MANUALS FIGURE 1. MANUAL COVER PAGE Reference: FAR Section 145.1l(a) (2). This page should identity the manual as an "Inspection Procedures Manual."
INSPECTION PROCEDURES MANUAL FOR FAA APPROVED REPAIR STATION NO. _ (Insert repair station #) d/b/a (NAME OF COMPANY) (ADDRESS) (STREET, CITY, STATE AND ZIP CODE) MANUAL: CONTROL NO. - ASSIGNMENT:
AC 145-3 I8/51/Z Appendix 1 (NAME OF COMPANY
REPAIR STATION - INSPECTION PROCEDURES MANUA TABLE OF CONTENIS-PAGE 1 OF 3 Page No.
MANUAL CONTROL ii RECORD OF REVISION iii LIST OF EFFECTIVE PACES iv
SECTION I HOUSING & FACILITIES Housing and Facilities Facility Floor Plan 2
SECTION II COMPANY ORGANIZATION Organization Chart Authority and Roster of Authorized Inspection Personnel 2-3
SECTION III PERSONNEL & TRAINING Training 1 Employment Summary 2
SECTION IV DUTIES & RESPONSIBILITIES General Manager Chief Inspector 2-3-4 Maintenance Manager 5-6 Avionics Manager 7-8 Stockroom Manager 9
SECTION V INSPECTION SYSTEM General Inspection Personnel APPROVED: I.Ж. Boas General Manager 2
Appendix 1 FIGURE 2. TABLE OF CONTENTS (CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURE MANUAL TABLE OF CONTENTS - PAGE 2 OF 3
SECTION V INSPECTION SYSTEM (CONTINUED) Page No.
Inspectors, Mechanics and Supervisors Continuity of Inspection Responsibility Parts Receiving Policy General Test Requirementa Work Order Record of Work Preliminary Inspection Inspection for Hidden Damage Progressive Inspection Major Repair And Alteration, Aircraft And Components Repair, Alteration and Overhaul Accessories and Appliances Inspection Procedures Maintenance Inspection Continuity of Maintenance Responsibility Handling of Parte Tagging and Identification of Parts Part Finishing Preservation of Parts Shelf Life Incoming Material Hardware and Equipment Storage Record of Specialized Inspection Test and/or Calibration Record of Inspections Record of Test and Calibration of Precision Equipment Work by Outside Contractors Control of Precision Tools and Test Equipmeni lest Equipment Calibration Requirement: Final Inspection and Release to Servic 17-18 19-20 APPROVED:. M. SA teneral Manager
Appendix 1 FIGURE 2. TABLE OF CONTENTS (CONTINUED (NAME OF COMPANY
REPAIR STATION - INSPECTION PROCEDURE MANUAL TABLE OF CONTENTS PAGE 3 OF 3
SECTION V INSPECTION SYSTEM (CONTINUED) Page No.
Maintenance Release Statement 21 Maintenance Release Statement For Air Carrier Work Malfunction or Defect Report Mechanical Reliability Reports Responsibility for Submitting Reports Subcontracted Maintenance Performance of Maintenaned Inspection Under the List of Subcontracted Maintenance Preventive Maintenance, Alterations and Required Continuous Airworthiness Requirements of CAR Parts 121, 125, 127, 24 Required Inspection Items (RII) 24 Performance of Work at a Location Other Than The Repair Station 25
SECTION VI FORMS List as Required for Repair Station Operation APPROVED: I.M. Boo General Manager 4
Appendix 1 FIGURE 3. INTRODUCTION PAGE Reference: FAR Section 145.11(a) (2) and Section 145.45(f). This page should reflect the company's philosophy and an explanation of the manual.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Title: Introduction Page No:
Issue Date: 7/1/78 This inspection procedures manual has been prepared in accordance with the current Federal Aviation Regulations (FAR) and the policies of (insert name of company).
This manual explains the internal inspection system in detail, including the continuity of inspection responsibility.
samples of inspection forms used and their method of execution.
manual gives a detailed explanation of the following portions of the inspection system: incoming materials, preliminary inspection, hidden damage, inspection continuity and final inspection of the article being maintained or altered at this facility.
The general repair, overhaul or alteration of products will be performed in accordance with the current Federal Aviation Regulations, manufacturer's data, drawings, specifications and bulletins, or other technical data approved by the Administrator for the particular (insert appropriate rating(s) or limited rating(s) airframe, engine, propeller or appliance). Limited rating specialized service for (insert appropriate rating) will be performed in accordance with the procedures outlined in the (insert name of company) Process Specification (insert number) approved by the Federal Aviation Administration (FAA) dated (insert date approved by FAA).
This repair station will not maintain or alter any item for which it is not rated, and will not maintain or alter any article for which it is rated if it requires technical data, equipment, materials facilities or trained personnel that are not available. (FAR 145.53).
The technical library and this inspection procedures manual, required for operation of this repair station, will be maintained in a current status at all times.
Each supervisor and inspector working for this repair station will have a current copy of this manual and should thoroughly understand its contents. It will also be available to other repair station personnel.
(If applicable) include the following: The performance of any maintenance, preventive maintenance, alteration or required inspections for an air carrier or commercial operator having a continuous airworthiness program under Section 145.2 5
Appendix 1 FIGURE 4. MANUAL CONTROL PAGE Reference: FAR Section 145.45(f). This page should explain how the manual is to be maintained and kept current.
(NAME OF COMPANY
REPAIR STATION - INSPECTION PROCEDURES MANUAL Title: Manual Control Page No: 11 Issue Date 7/1/78 Each manual will have a control number and an assigment entry on the manual cover page. A master list containing the menual number, location and revision status will be kept in the general manager's office.
The general manager will obtain from the chief inspector and each shop supervisor opce each month a manual status report. This report will either confirm that the manual is still current and valid for that department's use, or will identify needed changes.
A follow-up file will be maintained in the general menager's office showing, on a continuous basis, the disposition of each needed change which is identified.
The general manager will have those revisions he finds necessary produced in a final form for coordination with the FAA General Aviation District Office at (insert location). Each page of the manual and revision thereto will be approved by the general manager.
Upon acceptance by. FAA, sufficient copies will be made and distributed to provide revision pages for each manual holder.
Upon receipt of a revision, each menual holder will be responsible for inserting the revised pages in its menual, record the revision on the manual's record of revision page and return the acknowledgment form (provided with the revision) to the general manager showing the holder has revised its menual.
A list of effective pages will be issued with each revision ao each manual can be checked and kept current.
APPROVED: I.M. Boso General Manager 6
Appendix 1 FIGURE 5. Reference: FAR Section 145.45(f). RECORD OF REVISION PAGE This page should contain a record of all revisions.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Title: Record Of Revision Page No: iii Issue Date: 7/1/78 Manual No. Manual Holder Retain this record in the manual. Upon receipt of revisions, insert revised pages in the manual and enter the revision number, revision date, insertion date and initials of person incorporating the revision, in the appropriate block on the record of revisions. Return acknowledgment form requirements, when the need is apparent, to the general manager. to general manager. All personnel are expected to suggest revision Rev. NO. Rev. Date Insertion Date By No. Rev • Rev. Date Date Insertion By Original 7/1/78 7/1/78 HDQ Issue
Appendix 1 Reference: FAR Section 145.45(f). This page should list each page in the manual and show the current effective date of that page. A new list of effective pages would be required with each revision in order to provide a means for the manual holder to check that its manual is current.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Title: list of Effective Pages Page No:
Issue Date: 7/1/78 Revision No:
Section Table of Page NO. 1 Thru Date Section No. Page Date Section No. Page Date Contents 3 7/1/78 Introduction 7/1/78 Manual 7/1/78 Control Record of Revisions ili 7/1/78 List of Effective Pages iv 7/1/78 1 Thary 7/1/78 II 3 thru 7/1/78 III 2 There 7/1/78 IV 9 Thru 7/1/78 1 Thru 7/1/78 25 VI List as necessary for repair station operation APPROVED: Basi neral Manage 8
Appendix l FIGURE 7• SECTION I - HOUSING AND FACILITIES COVER PAGE This information is not required by FAR to be included in the manual. If inclusion is desirable examples are provided.
(NAME OF COMPANY)