material properties of the original article through destructive testing by qualified and/or accredited laboratories. Have these accredited laboratories discern at least the following:
• Composition of each material in the article. However, for metal alloys, a small sample size for composition testing will limit the applicant to a small range of variability in each constituent of the alloy, which may inhibit material acquisition for the PMA;
• Material metallurgical, mechanical and physical properties (that is, moduli, density, strength and fatigue characteristics, hardness, grain structure, coefficient of expansion etc.);
• Form of material (that is, casting, forging, bar stock, sheet, etc.); and
• Use of special processes (that is, nitriding, heat treat, shot peen, etc.) and resulting effects on material properties.
Note: Some methods of material analysis cannot establish the needed material properties on their own. Supplement any shortfalls with established industry conventions and data from the original manufacturer
f. Weight and Mass Properties. The mass properties of an article are often significant to its function and impact on the associated product. A comparison of mass properties to assess their effects on the next higher assembly and product is essential for dynamic components. This assessment accounts for weight differences and inertial properties between the proposed article and the original article to ensure the absence of detrimental effects. For example, a small weight increase in compressor blades may affect disc life.
27. Test Scope and Plan. The nature of an article and its effect on safety determines the need, type and scope of testing to support either a comparative or general analysis. Testing verifies the replacement article’s functional design and its performance relative to an article in a type design.
This testing may include performance, durability, resistance to fatigue, creep, corrosion, durability, dynamic properties, operational loads; etc., which shows compliance with the applicable airworthiness standards. Some non- critical articles that have little impact on safety may need little or no testing.
a. Functional testing has many purposes, including:
• Verifying design characteristics (for example, vibratory, fatigue, coating effectiveness, etc.);
• Verifying that variations in the manufacturing process have no detrimental effects on the functional design of the replacement article;
• Verifying article interactions with the next higher assembly and affected systems (for example, gears, bearings, seals, blades, etc.); and
• Evaluating sophisticated articles made of intricate components.
b. Test Plan. If the design warrants testing, include a proposed test plan and a draft request for conformity via the National Automated Conformity Inspection Process (NACIP) webtool in your application to the ACO. At a minimum, the test plan identifies the:
• Test purpose;
• Physical and functional description of the test article and setup;
• Number of test units;
• Unit identification;
• Test conditions and duration;
• Test methods and their suitability;
• Test method accuracy;
• Criteria for test success and failure;
• Test instrumentation and data collection;
• Test safety control; and
• Control of test procedures.
c. Test Article Conformity and Test Reports. Conduct tests using articles that conform to their proposed design. Coordinate with the responsible ACO and MIDO via NACIP for any required FAA conformity inspections. Use designees, as allowed by the ACO or MIDO, to witness conformity inspections, subsequent tests and teardown inspections. Upon completion of testing, send reports of these inspections and tests to the responsible ACO, including any analyses of the test results and associated showings of compliance to applicable airworthiness standards. Also include the results of any comparative testing of the article within a product.
d. Flight Testing. If needed to confirm the functional design, conformance and intended function, conduct flight tests as necessary. However, get an approved type inspection authorization when any flight tests require an FAA test pilot or designee. Use FAA Form 8110-1.
e. Test Standards. Use one or a combination of the following test standards to gauge the compliance of the PMA article:
• Comparative Testing uses articles from the TC or STC holder that have documented zero service time. Perform side-by-side tests of corresponding PMA and TC articles under conditions representative of the environment within their product.
• General Testing verifies that the article meets the applicable airworthiness requirements of its product, and if applicable, the technical standard orders (TSO) performance requirement.
• Other test standards deemed acceptable by the FAA.
28. Maintenance Instructions and ICA. ICA give information essential to the airworthiness of your article in its product. See the appropriate product appendix in 14 CFR for the content and format of these ICA. Design differences between your replacement article and the original may warrant revised maintenance instructions. Provide these supplemental ICA for FAA review.
Then make these ICA readily available per 14 CFR 21.50. If the ICA for the original article is valid for your replacement article, show and stipulate such in your ICA submission. See Note 2 on the sample draft supplement in appendix C.
29. Article Identity and Marking Requirements. 14 CFR 45.15(a) requires permanent and legibly markings on your articles. These markings identify the article’s manufacturer, part number and its production under FAA-PMA. Define the marking location and method on your design drawings. Ensure the marking location and process does not degrade airworthiness.
Installation eligibility markings are no longer required on the article, but are still required on the associated PMA supplement.
a. Marking Critical Parts. Parts with a fixed replacement time, inspection interval or related procedure as specified in the airworthiness limitations section of a product’s ICA require a serial number per 14 CFR 45.15(c). Ensure your design data specifies the method and location of the serial number marking on these parts. The method of marking must not compromise the life or integrity of the part.
b. Marking an Assembly. As required by 14 CFR 45.15, apply PMA article markings to the top-level assembly of the approved replacement or modification article. The FAA does not require markings on subassemblies or individual detail articles unless the associated PMA supplement lists them separately. For example, if the top- level assembly is a hydraulic pump, mark this assembly accordingly. Marking the detail articles of the pump with part numbers and trademarks is optional. However, if the PMA supplement lists these detail articles individually, mark them accordingly as distinct replacement articles for corresponding TC articles.
c. Part Numbering. Identify your article with a number that distinguishes it from the corresponding TC or STC holder article number. It is sufficient to add a prefix or suffix to the TC holder’s article number as long as the prefix or suffix does not replicate the TC or STC holder’s marking practices for design changes. You can also use a prefix or suffix to satisfy 14 CFR 45.15(a)(1) requirements for marking the article with a name, trademark or symbol.
This only applies if the prefix or suffix is consistent across your entire PMA product line. A final requirement per 14 CFR 45.15 is that each article must bear “FAA-PMA.”
d. Supplier Numbers. If you are a supplier to a PAH that uses your supplier article numbers in their approved designs, and you later apply for a PMA, you may continue to use your original article numbers with the added marking requirements of 14 CFR 45.15(a)(1) and (2).
These added requirements entail permanently marking the article with your name, trademark or symbol, as well as “FAA-PMA”.
e. Articles Impractical to Mark. If your article is too small or otherwise impractical to have all of the information marked on it, show evidence of such and request relief from the specific marking requirement per 14 CFR 45.15(d). Stipulate the proposed location of the 15
missing information. It will usually go on an attached tag or the article's container label. The responsible MIDO grants this relief as part of the production approval.
f. Eligibility Information. 14 CFR 45.15 no longer requires installation eligibility information on the article itself, but it is still required on the associated PMA supplement (see Appendix C). Make the eligibility lists readily available to installers of your articles. Since the list is likely to change, a tag or label on a container may refer to your publicly available article eligibility information. You may provide a manual or catalog via the Internet. However, access to the Internet is not universal. Therefore, you must have an alternative means of providing the manual or catalog.
g. Marking a PMA Article installed in a TSO Assembly. Mark PMA articles that go on TSO assemblies per 14 CFR 45.15 with the needed information from the respective supplements.
Do not list any TSO identification information (that is, TSO-C149, TSO-C63C, TSO-C8SA, etc.)
in the eligibility column on the associated supplement.
30. Delegation in PMA.
a. Designees can expedite the review and approval process for PMA. Individual designees can make findings of compliance to airworthiness standards within their authorized limitations in support of the PMA process. Identify the names, contact information and authorizations of your proposed designated engineering representatives (DER) in your application letter or PartSCP.
Get prior approval from the ACO before these designees make any specific findings of compliance.
b. PMA holders with PMA Organization Designation Authorization (ODA) must notify their respective FAA ODA management teams and process their showings of compliance through their ODA engineering unit members.
31. Communication and Coordination. Establish a good line of communication with the project ACO. Discuss and coordinate with them any changes to the approach used in your application.
SusanjICable FoR David W. Hempe Manager, Design, Manufacturing & Airworthiness Division Aircraft Certification Service
Appendix A Appendix A. Sample Compliance Listing Compliance Listing ARTICLE: New Aileron Control Bracket, Smith Manufacturing P/N 441284 A as a replacement for Piper P/N 441284 AIRCRAFT APPLICABILITY: PA-31-350 AIRCRAFT CERTIFICATION BASIS: 14 CFR part 23 Amendment 42 Requirement Compliance Method of Document Ref Compliance Claimed 14 CFR 23.603 Yes Analysis/Test First Article Report Workmanship 14 CFR 23.605 Yes Analysis/Test First Article Report Fabrication 14 CFR 23.613 Yes Analysis/Test Report No 1 Material Strength 14 CFR 23.619 Yes Analysis Report No 1 Para 6 Special Factors 14 CFR 23.625 Yes Analysis/Test Report No 5
Fitting Factor
14 CFR 23.621 N/A Nil castings Casting Factor 14 CFR 23.693 Yes Test Report No 4
Joints
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Appendix A Requirement Compliance Claimed Method of Compliance Document Ref 14 CFR 23.627 Fatigue Strength Yes Test and Analysis Report No 3 14 CFR 23.629 Flutter Yes Analysis Report No 6 14 CFR 23.641 Strength Yes Test Report No 2 14 CFR 23.657 Hinges Yes Test Report No 4 14 CFR 23.689 Cables Yes Cable system Unchanged Drawing No 884 General Instructions
1. Address only relevant sections of the design requirements. Also this example had no changes to the flight envelope, landing and take off performance. Thus, this table omits these detailed compliance citations. However, note such in the application package.
2. This list may support your certifying statement of compliance. This statement is due upon completion of the applicable showings.
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Appendix B Appendix B. PMA Project Checklist PMA Project Checklist Company Name: ___________________
Article name and P/N: _____________________
Application based on Test & Computation
1. __ Application letter __ Your company’s name and address __ Address of your manufacturing facility if different __ Identity of your article __ Installation eligibility information; make, model/series __ P/N of the article from a type certificate (TC, ATC, STC) __ Method of design approval
2. __ Draft PMA supplement (See Appendix C) __ Provide a copy on digital media
3. __ Data Package __ Drawings with pertinent material and process specifications __ Compliance checklist with a qualifying statement per AC 21-51 __ Test reports and computations on the compliance checklist __ Reverse engineering report(s) __ Safety Assessment
a. Description of the article and its intended function(s)
b. A qualitative assessment of failure modes and effects
c. Effect of article failure on the next higher assembly and its performance
d. Effect of article failure on the product and its performance
__ Manufacturing Inspection and test procedures **
__ Manufacturing Test Results **
__ Airworthiness Limitations **
__ Life Assessment (applicable to cyclic load environments)
__ Airworthiness Directives (ADs) or service difficulties involving article
__ Continued Operational Safety (COS) Plan.
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______________________________________________________________________________ ______________________________________________________________________________ ____________________________________________________________ 3/21/14 AC 21.303-4
Appendix B __ Maintenance Instructions and Instructions for Continued Airworthiness (ICA)
__ Article Marking [Compliance to 14 CFR 45.15]
__ Test Plans with a draft conformity request when warranted
__ Evidence of installation eligibility
__ DER 8110-3 forms (as required)
4. __ A separate statement of compliance upon completion of regulatory showings
5. __ Quality Manual (if a new PMA applicant, or changes/revisions when applicable)
6. __ List of proposed designees and ACO concurrences
7. __ Unnumbered draft PMA Supplement (MS Word format) ** If article is Critical or Life-Limited Note: Life Limited Parts require a supplement to the limitations section of the ICA per 14 CFR 21.50.
Notes:
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Appendix C Appendix C. Draft PMA Supplement Use this MS Word table format where each article name and number occupies a separate row. Do not add extra fields, rows, or columns to separate data. Each page of the supplement must contain the PMA header and page number footer to ensure correctness in the event supplement pages are separated. While formatting may vary between offices, all information shown below must be present for the supplement to be valid.
FEDERAL AVIATION ADMINISTRATION - PARTS MANUFACTURER APPROVAL Smith Engineering Corporation PMA NO._________________ (Applicant address) SUPPLEMENT NO._________ DATE____________________ Article Name Article Number Approved Replacement for Article Number Approval Basis and Approved Design Data Make/TCH Eligibility Model /Series Eligibility Spring SE24689 24689 Identicality per 14 CFR 21.303 DWG No: SE 25206, Rev: None Date: 3/31/13 or later FAA-approved revisions PW Canada PT6T-3, 3A, -3B, 3BE, -3D, -3DE, 3DF, -6 Pin SE24695 24695 Test and Computations per 14 CFR 21.303, DWG No: SE 25207, Rev: None Date: 3/31/13 or later FAA-approved revisions Aerospace Technologies N22B, N24A Boeing (McDonnell Douglas) DC-10-10, DC-10-30, DC-10-40, MD-11, MD-11F -------------------------------------------END OF DATA------------------------------------------ GENERAL NOTES:
1) Provide minor design changes in a manner as determined by the ACO. Handle major design changes to drawings and specifications in the same manner as that for an original FAA-PMA.
2) The FAA accepted the ICA approach for the above articles with their designs. These ICA may refer to those of the respective articles from the holders of type certificates. Otherwise, provide supplemental ICA for differences in the replacement articles. Make referral statements or supplemental ICA readily available per 14 CFR 21.50.
__________________________ _____________________________ Manager, (ACO name)Aircraft Manager, (MIDO name)Manufacturing Certification Office Inspection District Office Pg. 1 of X C-1
Appendix D Appendix D. Other Documents
1. Related References.
a. AC 21-9, Manufacturers Reporting Failures, Malfunctions, or Defects
b. AC 21-43, Production Under 14 CFR Part 21, Subparts F, G, K and O
c. AC 21-45 Commercial Parts
d. AC 33.8, Parts Manufacturer Approval of Turbine Engine and Auxiliary Power Unit Parts under Test and Computation
e. AC 33.70-1, Guidance Material for Aircraft Engine Life-Limited Parts Requirements
f. AC 43-18 Fabrication of Aircraft Parts by Maintenance Personnel
g. Order 8110.37, Designated Engineering Representative (DER) Handbook
h. Order 8110.42, Parts Manufacturer Approval Procedures
i. Order 8110.54, Instructions for Continued Airworthiness Responsibilities, Requirements, and Contents
j. Order 8120.22, Production Approval Procedures
k. Order 8150.1, Technical Standard Order Program
2. How to Get Referenced Documents. Get copies this AC, other referenced guidance and orders from our regulatory guidance library (RGL). Go to http://www.faa.gov/regulations_policies/advisory_circulars/ for ACs. Go to http://www.faa.gov/regulations_policies/orders_notices/ for orders. You can obtain a copy of MARPA’s guidance on COS at www.pmaparts.org/gvt/COSGuidance.pdf.
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Appendix E Appendix E. Sample FAA-PMA Letter of Application from a New Applicant The ABC Tool Company 3000 Hill St.
Randolph, MA 02368
(781) 555-1212 FAA - New England Region 12 New England Executive Park Burlington, MA 01803
(781) 238-7199 Attention: Mr. Mark Jones Manager, Engine Certification Office, ANE-140 Subject: Request for New FAA-PMA Approval Mr. Jones:
We are applying for parts manufacturer approval for our part number (P/N) ABC 13579. We request your review of the enclosed data in support of this application. ABC 13579 is a bushing assembly eligible for installation on PS PT9D-1, -7, -9 series engines. We base this requested approval on submitting test reports and computations per 14 CFR 21.303(a)(4). ABC 13579 replaces PS bushing assembly P/N 13579 installed on B767-400 series aircraft. Our bushing assembly complies with the applicable airworthiness requirements of the eligible engines as specified on the enclosed compliance listing. See our enclosed statement of compliance.
We will manufacture this bushing assembly in our facility at 3000 Hill Street, Randolph, MA 02368. We have (or will establish) an approved quality system per 14 CFR 21.307 for manufacture of this article.
Very truly yours, PMA Administrator, ABC Tool Company Enclosures:
1 copy ABC drawings, specifications and processes 1 copy ABC Tool Company Quality Manual 1 copy Draft PMA supplement 1 copy DER list 1 copy Statement of compliance 1 copy Compliance Checklist 1 copy Substantiating data and reports 1 copy Continued operational safety plan 1 copy Instructions for continued airworthiness (ICA) E-1
Appendix F Appendix F. List of FAA Aircraft Certification/Field Offices Go to http://www.faa.gov/aircraft/air_cert/locate_office/aco/ to find the appropriate ACO in your region.
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