AC 145- 3 2/13/81 Appendix 1 FIGURE 25. INCOMING MATERIALS (CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Page No:
Title: Inspection System Issue Date: 7/1/78
PARTS RECEIVING POLICY (CONTINUED) NOTE: Functional checks are performed in accordance with instructions contained in the appropriate manufacturer's publications.
However, if such specific instructions are not available, unctional check requirements will be determired by the chief compliance therewith. If suitable test facilities are not inspector, and issued on a form to provide a means of recording available in repair statior, components may be functionally checked in the aircraft. In any case, all functional checks must be monitored and recorded by the chief inspector or designee.
4. The Supervisor - Quality Control may request a functional check of any component overhauled or repaired by any agency, when of the opinion that such a check is required in order to returr, the component to service.
limited shelf-life are identified by material control labels showing the All adhesives, sealers, primers, finishing and other materials having specifications. expiration date of the shelf-life as established by applicable Inspectors and mechanics will dispose of any materials shelf-life. found in the shop or store rooms without such identification or with expired The detailed functions of material inspection are covered by the manufacturer's quality assurance directive and inspection bulletins which will be used to implement the operation of the repair statior with respect to the control and identificationof materials, parts and equipment received release for installation by the repair station. from vendors will be checked for proper approval documentation prior to for direct use in the repair station. All parts new or overhauled purchased APPROVED: O.M4. BORo Ceneral Manager 34
Appendix 1 FIGURE 26. WORK ORDER Reference: FAR Section 145.61. The work order should have an identification number, show the name of the repair station, address and the FAA assigned repair station rumber. It should show the customers name and address, complete identification of the items worked on, detailed instructions for work to be accomplished and space or reference instructions for work to be accomplished. For the work accomplished sign off space for mechanics and inspector. And instructions for sign off of work as acceptable to the company.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Page No:
Title: Inspection System Issue Date: 7/1/78
WORK ORDER Upon receipt of a work request for maintenance or alteration on an airirame, engine, accessory, propeller, instrument, radio or a product requiring a specialized service covered by the repair station certificate, the maintenance department will issue a (name of company) Repair Station Work Order Form 1234 to authorize that work to be accomplished. The form is prenumbered and that number will be the basic reference for the product's maintenance record. The work order will specify the work to be accomplished.
supplemented as necessary with detailed inspection instructions along with applicable forms, to assure proper inspection and repair of the unit involved. The number of additional forms used will be identified on The original of the printed and numbered work order form will be retained in the maintenance manager's office.
A logbook will be maintained in the maintenance manager's office for recording each work order in numerical order, identifying the customer, the product for which it was issued along with the manufacturer serial number, special instructions and the work accomplished.
It will be the responsibility of the respective shop manager and chief inspector to assure that proper supplemental instructions are furnished to assure proper progressive servicing, inspection and testing of the product involved.
Mechanics will enter work accomplished and use last names to sign off that work on the form. Inspectors will use their inspection stamp to sign off inspections. A list of inspectors and stamp numbers are contained in this manual under Section II, Page 2.
See copy of work order and supplemental forms in Section VI of this manual.
APPROVED: 9, 8M. coas General Manager 35
Appendix 1 FIGURE 27. RECORD OF WORK Reterence: FAR Section 145.61. A copy of the work order with all attachments should be on file as a permanent record of all work accomplished. The record should reflect the signature of each mechanic and inspector that performed maintenance on each unit. it should reflect exactly what work was accomplished. It should show all of the parts used. The records should be maintained for a period of not less than two years.
(NAME OF COMPANY)
REPAIR SIATION - INSPECTION PROCEDURES MANUAL See No: y Page No:
Title: Inspection System Issue Date: 7/1/78
RECORD OF WORK A detailed record shall be kept of all work performed by the repair station.
A copy of each Work Order Form 1234 with all attached supplementary form(s) will be maintained in the repair station records section. A separate file area is provided for all paper work associated with the repair statior's work activities. Each work record is checked by an inspector for work accomplished, parts used, signature of mechanic and inspectors who performed maintenance. Records are maintaired in active file for two (2) years then transferred to dead storage for 5 additional years.
APPROVED: 9.M. Boso General Manager 36
Appendix 1 FIGURE 28. PRELIMINARY INSPECTION.
Reference: FAR Sections 145.2 and 145.45(d. This information should indicate who is to perform the inspection, the method of inspection and any special testing requirements. Instructions should include the type of form to be used, how defects noted are recorded and the requirement to make them part of the work order.
(NAMF, OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 8 Title: Inspection System Issue Date: 7/1/78
PRELIMINARY INSPECTION The Chief Inspector of the repair station is responsible for the performance of appropriate inspections including functional and nondestructive tests to assure that all units delivered to the repair station for maintenance, alteration or repair under the privileges of the repair station certificate are subjected to a preliminary inspection to determine the state of preservation and any defects on the items involved. This inspection will be recorded on the Preliminary Inspection Form 567 with any discrepancies noted and the form must be attached to the work order identified with the unit involved. It will remain with the applicable inspection records until the unit is released for Appropriate supplemental forms will be used to record the results of functional and nondestructive tests. Those forms will show the work order number and will be routed attached to the work order.
Before any work is bequn, the Chief Inspector will, in the case of work to be performed for an air carrier under the continuous airworthiness requirements of FAR Parts 121, 125, 127, or 135, make sure that all necessary current information and specifications are included or referred to in the work instructions that are to accompany the article through the repair station, and that the work is done in accordance with the air APPROVED: 9. M. Bo Ceneral Manager 37
Appendix 1 FIGURE 29. HIDDEN DAMAGE INSPECTION Reference: FAR Section 145.45(e). This section should describe who any defects noted and the requirement to make the inspection a part of the work order.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section. V Page No:
Title: Inspection System Issue Date: 7/1/78
INSPECTION FOR HIDDEN DAMAGE The preliminary inspection is not limited to the area of obvious damage or deterioration but includes a thorough and searching inspection for hidden damage in areas adjacent to the damaged area and/or in the case of deterioration, a thorough review of all similar materials or equipment in a given system or structural area. The scope of this inspection will be governed by the type of unit involved with special consideration accorded previous operating history, Malfunction or Detect Reports, service bulletins and AD notes applicable to the unit involved. The inspector is responsible for listing all discrepancies noted during inspection on the work order prior to release for return to service. See Section VI of this manual for proper forms and instructions for using them.
APPROVED Я. т. Рого General Manager 38
Appendix 1 FIGURE 30. RECORD OF INSPECTION Reis section should explain how the results of required inspections are FAR Sections 145.59(a), 145.59(d) through (f) and 145.61.
recorded and made part of the applicable work order.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Sage No: 10 Page No:
Title: Inspection System Issue Date: 7/1/78
PROGRESSIVE INSPECTION Authorized inspectors will be assigned to make inspections at various stages of teardow, overhaul, and repair of all units or components received by the repair station for service. Progressive inspections are accomplished with a frequency determined by applicable marual recommendations and/or repair station originated work forms.
MAJOR REPAIR AND ALTERATION AIRCRAFT AND COMPONENTS Following the preliminary inspection, additional records may be prepared by the inspection department to provide a comprehensive historical record of the work performed. These records will contain torpection, detailed figures related to funervor teres and special nondestructive tests to be accomplished. The approved engineering or other approved technical data authorizing the repair or alteration will be clearly indicated. where special drawings are made to cover specific repair conditions, a copy of the drawing will be included in the aircraft records.
Ubits removed from the aircraft will be tagged with the appropriate inspection identification tag listing the aircraft serial number, wit serial number and reason for removal.
No item removed and tagged as above described will be reinstalled unless the unit is cleared as "serviceable" by inspection.
REPAIR, ALTERATION AND OVERHAUL ACCESSORIES AND APPLIANCES with a green repairable part tag with appropriate repair instructions entered on the face of the tag, as authorized by the work order.
such unit shall be approved for returned to service without a maintenance release tag authorizing its return to service.
PPROVED: . . 1507 eneral Manage 39
Appendix 1 FIGURE 30. RECORD OF INSPECTION (CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 11 Title: Inspection System Issue Date: 7/1/78
INSPECTION PROCEDURES the Chier Inspector is responsible for the complete and efficient performance of inspections assigned to the repair station to assure inspection acceptance in accordance with manual specifications or other approved technical data.
Shop supervisors are responsible for the accomplishment of all work in accordance with manual specifications or other approved technical data.
The work done under the repair station's Limited Rating- Specialized Service Nondestructive Inspection by X-ray, magnetic particle, eddy current or ultrasonic must be accomplished in accordance with the (name of company) FAA approved process specification NDI-1 dated 7/1/78.
Alterations and repair will be subject to progressive inspection by the inspection department. Discrepancies generated during the process of accomplishing the work involved will be recorded on the appropriate work forms. Discrepancies so recorded will be corrected before the unit is submitted for final inspection. Upor completion of this progressive inspection, the area affected is given a shakedown inspection and after all rework is accomplished and accepted, the inspection will clear the unit for final acceptance.
Upon completion of a specific operation, the mechanic will sign off the records using his signature indicating that the iten is complete and ready for inspection. The action accomplished to correct a specific discrepancy will be noted under each item on the work order.
The inspector will then inspect the item to assure conformance to specifications and established workmanship standards.
checks of any system affected by the work involved will be accomplished before final acceptance. Inspection acceptance will be indicated by the inspector's stamp.
APPROVED: О. ж. Воо General Manager 40
18/£I/Z AC 145-3 Appendix 1 FIGURE 30. RECORD OF INSPECTION (CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 12 Title: Inspection System Issue Date: 7/1/78
MAINTENANCE INSPECTION One-hundred hour and progressive inspections, inspections of amateur built aircraft and aircraft on FAR Section 91.217 programs will be accomplished in accordance with the inspection cards or inspection schedule provided for each specific model aircraft. The inspection paperwork will be supplemerted as recessary to cover items to be replaced for time, specia in ectahour and armal inspection airworthiness directives. annual inspection paperwork will comply with FAR Part 43 Appendix D.
No aircraft will be retured to service following an inspection as outlined above until all discrepancies affecting airworthiness have been corrected.
Maintenance supervisors are responsible for screening completed work approved data. Inspection will recheck to assure compliance with this After work orders have beer screened for completeness and accuracy they are routed to the maintenance manager's' office. Such inspectior and work records will be retained in active file for a period of not less than two years (as required by FAR Part 145) and then transferred to dead storage for 5 additional years.
CONTINUITY OF MAINTENANCE RESPONSIBILITY A status book will be provided in the hangar and each shop in which a status report will be entered by each of the lead mechanics informing the next shift of the status of each job not completed. Its purpose is to assure a continuing maintenance responsibility for work in APPROVED: D.M. PorRo General Manager 41
Appendix 1 FIGURE 31. HANDLING OF PARTS Reterence: FAR Sections 145.35, 145.35(a) (3), 145.35(d) 145.35(a) (4) and
145.35(e). This section should explain compliance with the rule.
Processing of parts, identification, tag, segregation, protection from damage and/or contamination, parts finishing, preservation, stock control and shelf-life.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 13 Title: Inspection System Issue Date: 7/1/78 All items or components undergoing maintenance, repairs and/or alterations in the repair station shall have the component parts segregated and in containers in order to assure that all parts of the same unit(s) are kept together. Suitable trays, racks, stands and protective coverings (as required) are to be provided in shop areas to ensure maximum protection of all parts. Rejected parts will be identified by the use of a red reject tag and final disposition will be the responsibility of the Supervisor - Quality Control.
TAGGING AND IDENTIFICATION OF PARTS The following is our four (4) tag system:
White tag - Used for identification of unit and customer only. Io be completed by shop supervisor or a designated employee.
Green tag - Will be attached to units or parts requiring repairs or test and will include work to be performed. To be executed and signed by inspector only.
Yellow tag - To be attached to completed units which have received final inspection and are approved for return to The maintenance release is printed or stamped on the reverse side of this tag. (See Maintenance Release Statement , Section V, Page 21). This release will be signed by a designated person only.
Red tag - Will be attached to rejected parts, pending final quites, they cane peda tal . container marked "rejected parts." This tag to be completed by an inspector.
PPROVED: • M. 100 eneral Manage 42
18/21/2 AC 145-3 Appendix 1 FIGURE 31. HANDLING OF PARTS (CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 14 Title: Inspection System Issue Date: 7/1/78
HANDLING OF PARTS (CONTINUED) All tags contain the following information:
Manufacturer - model - part number - serial rumber - name of part - owner.
The yellow tag will remain attached to the parts returned to the customer.
The red, white and green tags will be made a part of the work order file. will remair attached and a record will be made or the work order If the rejected part is returned to the customer, the red tag showing the part was returned to the customer.
PART FINISHING Painting and spraying is accomplished in an area segregated from the assembly areas.
PRESERVATION OF PARIS Components are preserved in accordance with manufacturer's recommendations or other acceptable industry standards. To afford protection against humidity, extreme temperatures, dust, rough handling or other damage, the component will be preserved by wrapping in suitable containers, plastic bags, and/or rigid boxes containing suitable shock absorption material.
Storage of "Repair Station" preserved components will be accomplished by storing in a separate "Repair Station" location maintained by the "Stores" department. The location should provide maximm protection from physical damage. storage requirements to suit the products worked on under the repair (Expand as necessary the preservation and station ratings.)
SHELF LIFE For those items having a specific shelf life, Repair Station Form 2468 is completed by the receiving inspector during the first ten (10) calendar days of each month.
Components or parts that have exceeded allowable shelf life limits will be red tagged (Condenned) and will be forwarded to the Supervisor, Quality Oontrol for final disposition.
Appendix 1 FIGURE 31. HANDLING OF PARTS (CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page NO: 15 Title: Inspection System Issue Date: 7/1/78
INCOMING MATERIAL All incoming material shall be inspected for quantity, quality, conformity to dimensions or specifications and state of preservation.
At this time the cure date of material having shelf life shall be noted, and the older stock shall be used first provided it is not vond manufacturer's specifications.
HARDWARE, AND EQUIPMENT STORAGE The Stockroom Manager is responsible to the General Manager for the operation of the stockroom and is responsible for controling, segregating and maintaining all stock and tools as to a serviceable or unserviceable category approved by the Chief Inspector.
In addition the Stockroom manager is required to:
Properly store, segregate and protect materials, parts and supplies.
Provide suitable storage facilities for storing standard parts, spare parts and assure that raw materials are separated from shop and working space.
Provide for the preservation of all articles or parts, while in inventory, that are subject to deterioration and shelf-life specifications.
Only acceptable parts and supplies will be issued for any job.
Acceptable industry practices shall be followed for the proper protection and storage of materials. (The standards for use by the repair station should be detailed here.)
APPROVED: 9. 2. BORO General Manager 44
Appendix 1 FIGURE 32. RECORD OF TEST AND/OR CALIBRATION. This section should include in-house tests applicable to the repair station ratings and those contracted to outside agencies. It should include a requirement for the signature of the mechanic and/or inspector as appropriate. The record should identify the article by serial number or company assigned number.
(NAME OF COMPANY
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 16 Title: Inspection System Issue Date: 7/1/78
RECORD OF SPECIALIZED INSPECTION, TEST AND/OR CALIBRATION Specific notations, attesting accomplishment, will be made on either Form 468 and/or appropriate printed work forms for recording specialized inspection, testing and/or calibration of a component or aircraft. (See
RECORD OF INSPECTIONS Where a record of the inspection by dimensions, tests or calibration is required by the manufacturer's technical data such rećord shall be made on an appropriate form properly identified with the Work Order; it must also be dated and signed by the mechanic performing the inspection, tests or calibration and/or the inspector as appropriate.
RECORD OF TESTS AND CALIBRATION OF PRECISION EQUIPMENT A system is maintained on all precision test equipment that will properly identify each piece of equipment. A file system is maintained to properly identify the equipment and record the date and person testing or calibrating each individual piece of precision equipment.
(Give details of system here, or state where it can be obtained.)
WORK BY OUISIDE CONTRACTORS When test and/or calibrations are performed by the following outside contractors they will be required to provide the records as outlined above. (List here the outside agencies and the work for which they are contracted to do for the repair station.)
tanage 45