Appendix 1 FIGURE 33. RECORD OF PRECISION TEST EQUIPMENT CALIBRATION.
Reference: FAK Sections 140.4/(b) and 145.57 (b). Identity the person (by title) responsible for the calibration and the test records. The should include the manufacturer, model ard serial or company assigned number, date of check, the method used to calibrate and the equente to ta quiere de prese or made, den the rext ifortion is due, the results (NAME OF OOMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 17 Title: Inspection System Issue Date: 7/1/78
CONTROL OF PRECISION TOOLS AND TEST EQUIPMENT Precision tools, gauges, scales, pressure gauges, ammeters, ohmmeters, voltometers, radio, electronic, X-ray, eddy current and ultrasonic test equipment used in the repair station operations are subject to periodic checks and calibration in accordance with appropriate repair station (List equipment here and outline procedures as appropriate.)
All repair station personel, before using test equipment, are responsible to check that the testing unit has a current calibration label attached. Any piece of test equipment found in the repair station without a current calibration label attached shall be given to the inspection department for recalibration.
TEST EQUIPMENT CALIBRATION REQUIREMENTS Test equipment shall be calibrated at periodic intervals established on the basis of stability, purpose and degree of usage. One year shall be the maximum calibration interval. (List calibration periods on equipment list.)
Each piece of test equipment will be labeled. The label will identity the unit by manufacturer, model and serial number. The attached label must indicate the last calibration date and next calibration due date.
During the first week of each month the chief inspector will review the test equipment calibration history card file and give cards for test equipment requiring calibration to the maintenance manager and each shop foreman as appropriate. It will be the resporsibility of those persons to issue work orders to repair station shops or outside contractors as recessary for the calibration of the units and attachment of updated calibration labels. After calibration, unit will be checked for proper labeling and the equipment calibratior.
history card will be updated and returned to the inspection department APPROVED: О.т. Вого General Manager 46
I8/{I/Z AC 145-3 Appendix 1 FIGURE 33. RECORD OF PRECISION TEST EQUIPMENT CALIBRATION (CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No:
Title: Inspection System Issue Date: 7/1/78
TEST EQUIPMENT CALIBRATION REQUIREMENTS (CONTINUED) At no time will any person be permitted to perform work or aircraft or components using test equipment which is out of calibration. The cest equipment labels will be checked by supervisors at random to assure that equipment in use is in calibration. If at any time a piece of test equipment inadvertently exceeds its calibration due date, it will immediately be removed from service until a calibration check has beer performed.
Standards used to calibrate test equipment must be traceable to U.S.
Bureau of Standards or an approved 'foreign country's standards by certificate from the testirg facility. Frequercy for calibration standards may vary for different units but must never exceed a 12-month APPROVED: 9. 2. 1020 General Manager 47
AC 145- 3 2/13/81 Appendix 1 FIGURE 34. FINAL INSPECTION AND RELEASE TO SERVICE Reference: FAR Sections 43.9 and 145.59(a). This should explain compliance with the rules, who performs the inspection (by title), how it is recorded, and require a check of maintenance work package for completion.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 19 Title: Inspection System Issue Date: 7/1/78
FINAL INSPECTION AND RELEASE TO SERVICE Prior to approval for return to service, irrespective of the method to be used to indicate such approval, the Chief Inspector will audit the records "package" as identified by the work order, to determine that all work has been inspected as required for compliance with this inspection system and FAR Section 145.59(a). He will indicate affirmative findings approving the form per Section VI of this manual.
hen approval has been given to the above audit, either the Chief inspector or the individual authorized in the official roster ax individual summary of employnent, will approve the article for return to service.
This approval will be accomplished as sppropriate to the work done, the article involved, the records available with the article, and the instructions of the custamer. Care will be exercised to comply with FAR Part 43 in every case.
completed treet ede othere. able does not waive any FAR Part 145 records requirements. Neither will FAR Part 43 or FAR Part 91 be considered waived by FAR Part 145 records requirements.
irticles such as appliances, accessories, and individual parts o components will not have an individual record to which an entry may be added. However, the installation of these items on an aircraft constitutes an aircraft maintenance or alteration, and records must be made accordingly.
Routinely, major repair approvals will be handled in accordance with Saintenance release grappleted a pert of Apollorder the work order for at the time of approval for return to service. A separate maintenance release card will be completed and shipped on an article that is shipped to a customer. At the request of the customer (to be indicated on the work order when originated), FAA Form 337 will be completed instead of the maintenance release approval for retum to service in accordance with the procedure in paragraph (a) of FAR Part 43, Appendix B.
In all cases where major alteration is involved, FAA Form 337 will be completed per FAR Part 43.9 and FAR Part 43, Appendix B.
APPROVED: al. Mo fres General Manager 48
I8/£I/Z AC 145-3 Appendix 1 FIGURE 34. FINAL INSPECTION AND RELEASE TO SERVICE (CONTINUED (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 20 Title: Inspection System Issue Date: 7/1/78
FINAL INSPECTION AND RELEASE TO SERVICE (CONTINUED) The authorized supervisor in whose area the repair or alteration is accomplished will be responsible for establishing that the repair or alteration was made in accordance with the requirements of FAR Part 43 and will sign the conformity statement (Item 6) on FAA Form 337.
Authorized personnel responsible for the approval for return to service of aircraft will indicate such approval by signing the approval for return to service (Item 7) on FAA Form 337. Appropriate entries will be made in the aircraft record pertinent to the repairs and alterations accomplished by the repair station. Specific reference will be made by calendar date to the applicable FAA Form 337. The original FAA Form 337 will be inserted in the aircraft record with a copy forwarded to the local FAA-district office and one copy retained with the copy of the aircraft work order.
It is the responsibility of the person authorizing retur to service to assure that the aircraft flight manual is properly revised following any alteration or modification to the aircraft and that the weight and balance record has been amended as necessary.
Aircraft components, appliances, and other items, other than completed aircraft repaired or overhauled as authorized by the repair station specifications, will be retumed to service through the use of a maintenance release preprinted on the serviceable parts tag described in this section of this manual. The authorized supervisor under whose jurisdiction the work is accomplished will be responsible for the release of units in the category.
No aircraft or unit may be released for return to service until the work order and other records have been reviewed for completeness and final acceptance cleared by inspection. Particular attention shall be accorded the status of applicable airworthiness directives.
APPROVED: O.M. Bus.
General Manager
Appendix 1 FIGURE 35. SAMPLE OF MAINTENANCE RELEASE (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 21 Title: Inspection System Issue Date: 7/1/78
MAINTENANCE RELEASE STATEMENT A maintenance release statement stamp and/or preprinted tag, prepared in accordance with FAR Part 43, Appendix B, will be used to release to service major repairs which have been accomplished by this station in accordance with FAR Part 43. Other records required by FAR Part 43.9 will be executed, as required, regardless of whether an FAA Forn 337 or maintenance release has been used to return the article to service. In any event, the station will indicate on their copy of the work order whether or not a maintenance release was used, including the signature of the authorized representative.
"Example" MAINIENANCE RELEASE (title) The (use only applicable rating or ratings) aircraft, airframe, aircraft engine, propeller or appliance identified above was repaired and inspected in accordance with current maintenance rules of the Federal Aviation Regulations and is approved for return to service. * "pertinent details of the repair are on file at this „repair station under Work Order No. Date Signed (Signature of authorized representative) for_ (Repair station name & certificate number) (Address) NOTE 1: Inspection stamp/symbol will not be used on the maintenance release.
APPROVED: IM. BOsO General Manager 50
Appendix 1 FIGURE 35A. SAMPLE OF MAINTENANCE RELEASE FOR AIR CARRIER WORK Reference: FAR Section 43.13(c) (d), FAR Section 145.2, Subpart L of FAR Part 121, Subpart G of FAR Part 125, Subpart I of FAR Part 127, Subpart J of FAR Part 135.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 21A Title: Inspection System Issue Date: 7/1/78
MAINTONANCE RELEASE STATEMENT A maintenance release statement stamp and/or preprinted tag, prepared in accordance with FAR Part 43, Appendix B, will be used to release to service major repairs which have been accomplished by this station in accordance with FAR Part 43. Other records required by FAR Part 43.9 will be executed, as required, regardless of whether an FAA Form 337 or maintenance release has been used to return the article to service. In any event, the station will indicate on their copy of the work order whether or not a maintenance release was used, including the signature of the authorized representative.
"Example" MAINTENANCE RELEASE (title) The (use only applicable rating or ratings) aircraft, airframe, aircraft engine, propeller or appliance identified above was repaired and inspected in accordance with current instructions contained in (name operator and manual or program), the maintenance rules of the Federal Aviation * Regulations under which the operator is certificated and is * approved for return to service as per those requirements.
"pertinent details of the repair are on file at this repair station under Work Order No. _Date Signed (Signature of authorized representative) for_ (Repair station name & certificate number) (Address) NOTE 1: Inspection stamp/symbol will not be used on the maintenance release.
APPROVED: 9. Ж. Воло General Manager 50-1(50-2)
Appendix 1 FIGURE 36. MALFUNCTION OR DEFECT AND MECHANICAL RELIABILITY REPORT Reference: FAR Section 145.63(a) and (b). This section should explain in detail how compliance with rules and reporting requirements ace to be met, and prescribe the responsibility (by titie) of persor(s) who prepare and submit reports.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 22 Title: Inspection System Issue Date: 7/1/78
MALFUNCTION OR DEFECT REPORT This repair station will report to the FAA within 72 hours after it discovers any serious defect in, or other recurring unairworthy condition of, an aircraft, powerplant, or propeller, or any component of any of them. The report will be made on an FAA Form 8010-4, Malfunction or Defect Report, describing the defect or malfunction completely without withholding any pertinent information. (See Forms Section VI for copy of for.)
In any case, where the filing of a report under the preceding paragraph might prejudice the repair station, it will be referred to the Administrator for a determination as to wether it must be reported.
If the defect or malfunction could result in an imminent hazard to flight, the repair station will use the most expeditious method it can to inform the Administrator.
MECHANICAL RELIABILITY REPORTS When work is being accomplished for an air carrier and a defect as described under the Malfunction or Defect Report is found, the air carrier will be notified in order that a Mechanical Reliability Report may be issued by the air carrier.
RESPONSIBILITY FOR SUBMITTING REPORTS The General Manager and Chief Inspector are responsible for preparing and submitting a Malfunction or Defect Report to the FAA General Aviation District Office. (Show location of office.)
›PROVED: General Manag 51
Appendix 1 FIGURE 37. SUBCONTRACTED MAINTENANCE PROCEDURES (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCFDURES MANUAL Section: V Page No: 23 Title: Inspection System Issue Date: 7/1/78
SUBCONTRACTED MAINTENANCE Any work performed by another agency for this repair station will be inspected by the Chief Inspector or an inspector delegated for such inspection. This inspection will be to verify that the work was performed in an airworthy manner, that parts and materials used were of such a quality to be airworthy, and that the paperwork received with the material verifies the authenticity of the part and work performed. At no time shall the stockroom manager release any parts made by, or parts having had work performed on them by a subcontractor until the Chief Inspector or an inspector delegated has approved the materials as being airworthy.
All subcontracted work shall be kept separate from regular stock until this inspection has been performed and the material accepted for use.
If for any reason subcontracted material is rejected as being unairworthy, it will immediately be identified as unairworthy and the proper disposition made, such as scrap or return to vendor.
LIST OF SUBCONTRACTED MAINTENANCE
1. Metal plating or anodizing.
Complex machine operations involving the use of planers, shapers, milling machines, etc.
Abrasive air blastina and chemical cleaning operations.
Heat treament.
Magnetic inspection.
Fabricate wood spars.
7. Overhaul and repair hydraulic-pneumatic shock absorber units.
Overhaul and repair hydraulic system components.
10. Recovering and refinishing of components and entire aircraft. Fluorescent inspecton of alloy parts.
APPROVED: I. M. 1B0RO General Manager 52
Appendix 1 FIGURE 38. PERFORMANCE OF MAINTENANCE, PREVENTIVE MAINTENANCE,
ALTERATIONS AND REQUIRED INSPECTION UNDER THE CONTINUOUS AIRWORTHINESS REQUIREMENTS OF FAR PARTS 121, 125, 127, AND 135 This section should show how the rule is to be complied with, that the work is to be accomplished in accordance with the operator's manual and a current copy of the manual is available.
(NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 24 Title: Inspectior System Issue Date: 7/1/78
PERFORMANCE OF MAINTENANCE, PREVENTIVE MAINTENANCE, ALTERATIONS AND
REQUIRED INSPECTION UNDER THE CONTINUOUS AIRWORTHINESS REQUIREMENTS OF FAR PARTS 121, 125, 127, AND 135.
This repair station will perform this work in accordarce with the operator's manual. The repaix station will have a current copy of the applicable section of each operator's manaul which contracts with the repair station for the performance of that operator's maintenance.
chief inspector will be responsible for keeping each operator's manual revised and determining that the operator's manual is current before a work order is issued.
REQUIRED INSPECTION ITEMS (RII) Any maintenance operations which, it improperly pertormed, could be critical to the safe flight of an aircraft will be given a require‹ A qualified inspector, familiar with all inspection methods, techniques, ard equipment will be assigned to determine the quality of airworthiness of the article involved. Wher work is performed for an operator un er the continuous airworthiness requirements of FAR Parts 121, 125, 127, and 135, the RII items specifiedby the operator will be maintained as RII items.
APPROVED: J.M. Bro General Manager 53
Appendix l FIGURE 39. PERFORMANCE OF WORK AT A LOCATION OTHER THAN THE REPAIR STATION.
Reference: FAR Section 145.51(d). In accordance with FAR Section 145.51(d), a repair station may maintain or alter any article for which it is rated at a place other than the repair station providing certain preparations are made and certain conditions are met as required by FAR Section 145.51(d)(1) and (2).
Performance standards are required to remain acceptable at such places of work.
FAR Section 145.51(d) (3) requires the inspection procedures manual to contain the approved procedures governing the work to be performed at a place other than the repair station. This is a frequently overlooked manual requirement.
In order for a procedure to be valid for approval it should:
Be described in terms understandable to those persons who are governed by it in the performance of the work.
2. Be monitored regularly so as to ensure it covers the nature of the work that may be needed outside the repair station. This is necessary as it is difficult to predict the nature of work to be done outside the station.
3. Be tailored for the particular station, the nature of work and the frequency expected. The following are items reconmended for consideration:
a. who will authorize the work, organize the project, direct it, and who will perform the work?
b. what type of work tasks will be required (supply, repairs, inspections, communications)?
c. Where some of the work is to be done. It may be advantageous to perform support work on components or parts at the base repair station as a standard procedure.
d. How will the work projects be monitored and reviewed to assure procedures are adequate and that records identify the projects for accountability?
e. Occasional explanations within the system description of why certain requirements, controls or reports are necessary will help employees to understand and accept the system.
4. The privilege to perfor work at a location other than the repair station is to be done on a temporary basis. If a permanent station is established at the location, it will be necessary for the repair station to make application for a satellite to the main repair station, or make an original application for a repair station at the location.
Appendix 1 FIGURE 39. PERFORMANCE OF WORK AT A LOCATION OTHER THAN THE REPAIR
STATION CONTINUED) (NAME OF COMPANY)
REPAIR STATION - INSPECTION PROCEDURES MANUAL Section: V Page No: 25 Title: Inspection System Issue Date: 7/1/78
PERFORMANCE OF MAINIENANCE AT A LOCATION OTHER THAN THE REPAIR STATION (Name of Company) will provide maintenance service for its customers on an emergency on-call basis at a place away from the repair station.
(Name of Company) can only provide this service for work for which the repair station is rated. Only the general manager or the chief inspector are authorized to initiate a work order for such work.
The maintenance manager will be responsible for assigning personnel necessary to perform the work and appoint a person to be in charge of the work force. The chief inspector will assign the inspector (s) responsible to inspect the work and assure that all required forms and work are completed as necessary.
inspector will assign one inspector with the responsibility for returning the article to service.
The maintenance manager will ensure that the article to undergo maintenance and the work force will be in an area safe for the work to be performed and that they will be protected from the elements. The maintenance manager will be responsible for providing all the necessary manpower, work forms, technical data, tools, and equipment necessary for the accomplishment of the maintenance. The maintenance manager will establish a system of communications between the field force and the The stockroom manager will be responsible for assigning a stockperson who will provide parts and supply support between the repair station and the field force. All articles removed by the field force from a product undergoing maintenance at a location away from the repair station will be routed through the stockroom parts receiving department. The article(s) will be inspected in accordance with the repair station inspection procedures and either routed to the repair station shops or to contract repair agencies as appropriate.
All personnel assigned to accomplish work away from the repair station shall accomplish the specific function of work in the same manner as when performed at the repair station and in accordance with FAR Sections 145.57 through 145.61.
APROVED: I. M. BOsO General Manager 55
Appendix 1 FIGURE 40.. SECTION VI - FORMS SAMPLE COVER PAGE:
Reference: _FAR Section 145.45(f). This section is required to contain samples of each of the forms used by the repair station in the performance of maintenance and the method of executing them. The instruction for executing a form may be contained on the form if it is found practical.
However, if it is necessary to change any of the procedures for handling * the form it would require a reprint of the form. Unless a form is judged * stable, it may be more economical to provide separate instructions on a manual page. It would then be a simple task to revise the manual page to show the. change.
1. When planning a form system, important functions to be considered are the control of operational procedures and recordation of all work performed on each article processed.
2. The number and content of the forms would be influenced by the size of the repair station, the complexity and variety of the articles for which the repair station is rated, and the needs of its customers.
3. Some factors to consider during the development of instructions for completing a form are:
How the form is to be introduced, (at what point in the maintenance process) and when it is to be completed.
b. The person or section responsible to start the form, who will contribute to its completion, and who will finish it.
c. How the form will be executed (what kind of information, in what form, etc.).
d. The purpose of the form, and how it fits into the system.
How the form will travel and what its final destination in the records system will be.
f. A system to locate and check the progress of products enroute thru the repair station.
4. Detailed inspection forms and checklists which may be used in the performance of annual or other approved inspection programs, or engine overhaul inspection sheets, need not be included in this manual. These forms should be referenced in the forms section by form number, revision date and title. The manual should contain instructions for use and a copy of the detailed forms should be available for inspection upon request of the FAA and other authorized persons.