(New Business) How to Write a Repair Station Manual

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                                                LIST OF EFFECTIVE PAGES


FAA APPROVED REPAIR STATION {Your Number Here}


{Your Company Here  }

OFFICE/HANGAR

Your address here

Phone number Here









Section 1

Page # i

Title List of Effective Pages

Revision No: Original Issue

Date: May 11, 2011




RECORD OF REVISIONS


Retain this record in the manual
Upon receipt of revisions, insert revised pages in the manual and enter on this page the revision number, revision date, section number and page number.

All personnel are expected to suggest revision requirements to the Accountable Manager when the need is apparent.

REVISION NUMBERREVISION DATESECTION NUMBERPAGE NUMBER











Section 1

Page # 2

Title: List of Effective Pages

Revision No. Original Issue

Date: May 11, 2011

LIST OF EFFECTIVE PAGES

Section

Page Number

Date

Revision

Original Issue

List of Effective Pages

Original Issue

List of Effective Pages

Original Issue

Table of Contents

Original Issue

Original Issue

Repair Station Manual
Record of Revision

i

Original Issue

Repair Station ManualSection I
Introduction pp. 1-5

Original Issue

Repair Station ManualSection II
Housing, Facilities, Equipment and Materials pp. 1-2

Original Issue

Repair Station ManualSection III
Company Organization
pp. 1-2

Original Issue

Repair Station ManualSection IV
Personnel p. 1

Original Issue

Repair Station ManualSection V
Duties and Responsibilities
pp.1-4

Original Issue

Repair Station ManualSection VI
Repair Station Operations
pp. 1-4

Original Issue

Repair Station ManualSection VII
Training
p. 1-4

Original Issue

Original Issue

Quality Control Manual
Record of Revision

i

Original Issue

Quality Control ManualSection I
Introduction
pp. 1-2

Original Issue







Approved___________________________________________(Manager)

Section 1

Page # 3

Title: List of Effective Pages

Revision No. Original

Date: May 11, 2011

List of Effective Pages continued

Section

Page Number

Date

Quality Control Manual

Section II

Inspection System

pp. 1-2

Original Issue

Quality Control ManualSection III
Continuity of Inspection and Qualification of Inspection Personnel
pp. 1-2

Original Issue

Quality Control ManualSection IV
Parts Receiving Policy
pp.1-5

Original Issue

Quality Control ManualSection V
Inspection Procedures
pp.1-8

Original Issue

Quality Control ManualSection VI
Subcontracted Maintenance
pp. 1-3

Original Issue

Quality Control Manual

Section VII

Precision Test Equipment

pp.1-3

Original Issue

Quality Control ManualSection VIII
Corrective Action
pp.1-2

Original Issue

Quality Control ManualSection IX
Forms pp.1-20

Original Issue







Approved_____________________________________(Manager)








TABLE OF CONTENTS


FAA APPROVED REPAIR STATION NO.{Your Number}


{Yours} CENTER, LLC


OFFICE/HANGAR

{Address Here}

{Phone Number Here}
















Section 1

Page # 1

Title: Table of Contents

Revision No. Original

Date: May 11, 2011

Table of Contents

List of Effective Pages

Page No.

Section 1
Revision
List of Effective Pages

2-3

TABLE OF CONTENTS
Table of Contents

1-4

REPAIR STATION MANUAL
Record of Revision

I

SECTION 1: INTRODUCTION
Purpose

1

Scope

1

Revisions

1

Identification

2

Control

2

Acceptance/Approvals

3

Distribution

3

Method of Application

3-4

Contract Maintenance

4

Capability List

4-5

Technical Specifications

5

SECTION 2: HOUSING, FACILITIES, EQUIPMENT AND MATERIALS
Location

1

Hangar

1

Shop/Office

1

Environmental

1

Special Use

1

Material

1

Equipment

1-2

Change of Location

2






Section 1

Page 2

Title: Table of Contents

Revision No. Original

Date: May 11, 2011

Drawing of Hangar and Shop

2

SECTION 3: COMPANY ORGANIZATION
Organization Chart

1

Roster of Authorized Management, Supervisory and Inspection Personnel

2

SECTION 4: PERSONNEL
Summary of Employment

1

Repairman Certificates

1

SECTION 5: DUTIES AND RESPONSIBILITIES
Owner
Chief Inspector
SECTION 6: REPAIR STATION OPERATIONS
Operational Overview

1

Maintenance Records

2

Malfunction or Defect Report Procedures

2

Mechanical Reliability Reports

3

Detecting and Reporting Suspected Unapproved Parts

3

Performance of Maintenance at a Location Other Than Repair Station

3-4

SECTION 7: TRAINING
Training

1

Records

1

AMT Training

1

QUALITY CONTROL MANUAL { Separate Manual}
Record of Revision

I

SECTION 1: INTRODUCTION
Purpose

1

Scope

1

Overview

1-2






Section 1

Page 3

Title: Table of Contents

Revision No. Original

Date: May 11, 2011

Air Carrier/Commercial Operator/RII

2

Ratings per FAA Approved Repair Station 4LMR233B

2

Organization

2

SECTION 2: INSPECTION SYSTEM GENERAL
General

1

Inspection Personnel

1

Owner/Chief Inspector

2

Technical Data

2

SECTION 3: CONTINUITY OF INSPECTION, SATUS OF WORK, AND QUALIFICATION OF INSPECTION PERSONNEL
General

1

Status of Work

1

Return to Service

1

Qualification of Inspection Personnel

2

SECTION 4: PARTS RECEIVING POLICY
General

1

Visual Test Requirements

1

Limited Shelf-Life Materials

1

Controlling Documents

1

Identification of Approved Aircraft Parts

2

Approved Parts Controlling Document

2

Reporting of Suspected Unapproved Parts

2

Functional Checks

2

Handling of Parts

3

Major Repairs and Alterations of Aircraft and Components

3

Repair, Alteration and Overhaul of Accessories and Appliances

3

Work Order

4

Work Order Logbook

5

SECTION 5: INSPECTION PROCEDURES
General

1

Tagging and Identification of Parts

1

Article Identification

1





Section 1

Page 4

Title: Table of Contents

Revision No. Original

Date: May 11, 2011

Repairable

1

Serviceable

1

Rejected or Condemned

2

Shelf Life of Limited Material

2

Incoming Inspection

2

Preliminary Inspection

3

Hidden Damage Inspection

3

In-Process Inspection

4

Completion of Maintenance

4-5

Final Inspection and Approval for Release to Service

5

Final Inspection

5

Rework

5

Aircraft (Logbook) Records

6

Major Repairs/Alterations

6

Previously Approved Data

6-7

Non-previously Approved Data

7

Aircraft Flight Manual Revision

7

Maintenance Release

7

Maintenance Release Statement

8

SECTION 6: SUBCONTRACTED MAINTENANCE (VENDORS)
Subcontracted Maintenance

1-2

List of Subcontracted Maintenance Functions (Vendor)

3

SECTION 7: PRECISION TEST EQUIPMENT
Specialized Tests, Calibrations and Inspections

1

Control of Precision Tools and Test Equipment

1-2

Test Equipment Calibration Requirements

2-3

SECTION 8: Corrective Action
Overview

1

Program Responsibility

1

Corrective Action Resolution

1-2

)




Section 1

Page 5

Title: Table of Contents

Revision No. Original

Date: May 11, 2011

SECTION 9: FORMS
Forms

1

Forms Index

2

Manual Status Report (Form #1)

3

Manual Revision Report (Form #2

4

Authorized Inspection Personnel (Form #3)

5

Instructions for Form #3

6

Personnel Training Record (Form #4)

7

Employment Summary (Form #5)

8

Work Order (Form #6)

9

Preliminary/Hidden Damage Inspection (Form #7)

10

Component Tag (white)(Form # 8)

11

Repairable Tag (green) (Form #9)

12

Serviceable Tag (yellow) (Form #10)

13

Rejected or Condemned (red) Form #11)

14

Shelf Life Limited Material (blue) (Form #12)

15

Test Equipment Calibration Log (Form #13)

16

Test Equipment Calibration Tab/Label (Form #14)

17

Altimeter Test Guide (Form #15)

18

Altimeter Certification (Form #16)

19

Altitude Certification (Form #17)

19

Incoming Inspection Form (Form #18)

20

Transponder Certification (Form #19)

21

Capability List (Sample)















REPAIR STATION MANUAL

CONTROL NO.________________________


FAA APPROVED REPAIR STATION

{Your Name}

{Your Address}

FAX:

Number:






Title: Record of Revision

Page No. 1

Revision No. Original Issue

May 11, 2011





RECORD OF REVISION

DATE

REVISION NO

SECTION NO

PAGE NO


















Approved___________________________________________(Manager)














SECTION: I

INTRODUCTION
























.Section I

Page No: 1

Title: Introduction

Revision No: Original

May 11, 2011

Section I INTRODUCTION

  1. Purpose

This manual serves as the primary guideline for the operation of {Your Company Here}within Federal Aviation Regulations for the Repair Stations Manual (RSM) and Quality Control Manual (QCM) under 14 CFR Part 145. It is specifically created in accordance with 14 CFR 145, Advisory Circular 145-9, and the policies of {your name} certificate number{here}
  1. Scope

This introduction is the controlling document for all manuals listed below in accordance with 145.207, 145.209 and 145.211. The manual contains all required information in four volumes:
Repair Station Manual (RSM)
Quality Control Manual (QCM)

Table of Contents
List of Effective Pages
  1. Revisions

Revisions- It is the responsibility of the Accountable Manager to initiate, write, and submit revisions for all manuals to the FAA for review and acceptance. These tasks may be delegated, but responsibility remains with the Accountable Manager.

Distribution – The Accountable Manager will initiate contact with the FAA Certificate Holding District Office (CHDO) to coordinate incorporation of the revision into the manual within 5 working days from the date that a change is approved by the Accountable Manager.

The Accountable Manager will assure the Master Manual is updated and that revisions are included into all other local copies of the manual within 5 working days from the date that a change is accepted by the CHDO. The CHDO will incorporate revisions per Introduction, Section 6 “Distribution”.

Acceptability – In the event that a proposed revision is not found acceptable to the FAA, the Accountable Manager will coordinate the necessary changes to the manual with the CHDO in agreement with applicable Federal Aviation Regulations and the policies of  {Your Company Here}
This repair station will not incorporate a proposed revision into its operation until it has been coordinated and accepted by the CHDO.





Section I

Page No: 2

Title: Introduction

Revision No: Original

May 11, 2011

  1. Identification

All pages will be identified by section, page number, revision number and date. Revised pages will be noted by the Revision Date on each page. Revised text will be noted by a bar in the margin of the page by the affected lines.

The List of Effective Pages (LEP) will indicate what pages are to be contained in the manual and the most current revision date for each page. A new LEP will be issued with each revision.

A Record of Revisions page will be provided in each manual. Upon receipt of a revision, each manual holder will be responsible for noting on this page the revision number and the date of insertion. This is to be completed and returned to the Accountable Manager showing that the applicable manual has been revised.

Notification of FAA – The Accountable Manager will provide revisions to the FAA in accordance with RSM Section 7 for Distribution.
  1. Control

The Accountable Manager will review the manual once each quarter to insure the manual is current. This review will confirm that the manual is still current, or identify needed revision(s).

A follow-up file will be maintained by the Accountable Manager showing on a continuous basis the disposition of each identified need for revision.

The Master List of manuals is controlled per RSM Section 1, Item 7.

The Accountable Manager will have those revisions he finds necessary produced in final form for coordination with the CHDO.

Approvals and acceptance will be per RSM Section 1, Item 6.

Distribution and insertion will be per RSM Section 1, Item 7.







Section I

Page No: 3

Title: Introduction

Revision No: Original

May 11, 2011

  1. Acceptance/Approval

Approval – The accountable manager will sign the list of effective pages.

There is no need to revise the entire manual just for approval signatures in the event of a change in Accountable Manager. Signatures of previous Accountable Managers will remain effective until such time as a revision for that specific page is incorporated.

Acceptance – FAA acceptance will be noted on applicable pages by their current method.

(Your Name), LLC will allow the FAA to inspect its facility to determine its compliance with its Repair Station Certificate, Repair Station Manuals and CFR Part 145.
  1. Distribution

Distribution – The Accountable Manager is accountable for distribution of the manuals and revisions.

Each manual will have a Title page containing the Control Number of the manual and its location per this paragraph.

Two printed copies of this manual will be distributed as:
Master 1 – located in the repair facility shop/office
Control 2 – located at the Certificate-holding District Office CHDO, currently at the
(Your FSDO)
An electronic version of this manual will be maintained in the repair station computer with suitable backup provided. The file will be password protected to prevent inadvertent or unauthorized changes.

The Accountable Manager will insert revisions into all manuals assigned to the repair station.

The FAA/CHDO is responsible for incorporating revisions into their copy of the manual once received from the Accountable Manager.
  1. Method of Application

The Accountable Manager is responsible for seeing that the items contained in the manual are applied to all applicable functions carried out by the Repair Station Certificate.

The Accountable Manager will assure that each supervisor and inspector will have access to a current copy of the manual, and that they thoroughly understand its contents.




.Section I

Page No: 4

Title: Introduction

Revision No: Original

May 11, 2011

The Accountable Manager will assure that all other Repair Station employees are provided the opportunity to familiarize themselves with the manual and its application.
  1. Contract Maintenance

The Accountable Manager will determine when a revision of the contract maintenance information on the vendor list is needed. Also see the Quality Control Manual (QCM) for further Contractor information.

When the revision is finalized, it will be submitted to the CHDO for approval of the maintenance function included in the vendor listing. The listing will include the maintenance function contracted, the name of the outside facility, the type of certificate(s) held, and ratings held.

The revision will be transmitted to the CHDO by mail, fax or E-mail within five working days after finalization of the revision. The revision will not be incorporated into the repair station operation until approval is received from the CHDO.

The Accountable Manager is responsible to maintain the listing and keep it on file in the repair station office files.

This repair station will only contract maintenance to vendors who are certificated repair stations.
  1. Capability List

The capability list will be maintained by the Accountable Manager and will be filed in the inspection section of the repair station. The list will contain a cover sheet with date and the Accountable Manager’s approval block. Each page will have a revision date and Accountable Manager approval block.

The capability list will identify each article by make and model and will be revised by the Accountable Manager when it becomes necessary to add additional makes/models that may be maintained under the existing ratings issued by the CHDO.

The list will only be revised after a self-evaluation checklist contained in the capability list has been accomplished to determine if the repair station is capable of maintaining additional models under existing ratings issued.

The evaluation will be conducted using a checklist identifying as adequate, at least, the following items: tools, equipment, materials, technical data, housing, facilities, and qualified personnel.




Section I

Page No: 5

Title: Introduction

Revision No: Original

May 11, 2011



Once the evaluation process is complete and the capability list revised, the evaluation checklist and revised capability list will be forwarded by the Accountable Manager to the CHDO. The revised list and checklist will be forwarded to the CHDO within five (5) working days of approval by the Accountable Manager.
  1. Technical Specifications

This manual is created electronically using Microsoft Word.


















































SECTION: II

HOUSING, FACILITIES, EQUIPMENT AND MATERIALS


















Section II

Page No: 1

Title: Housing, Facilities, Equipment and Materials

Revision No: Original

May 11, 2011

Section RSM 2 – Housing, Facilities, Equipment and Materials

  1. Location

 {Your Company Here}, maintenance is conducted at {Your address here.  {Your Company Here}has the housing and facilities for performing maintenance, preventive maintenance and alterations of articles for which it is rated.
  1. Hangar

{Your Company here} has a designated maintenance hanga{(Measurements of Hanger} for a total of { } square feet located on the { Airport, Address Here} {.Discreption of the space}
  1. Repair Station Building {Example}

The repair station building is a free standing portable building located within the hangar in the southeast corner. The building measures 12'x16' and contains a total of 192 square feet. The repair station building houses all repair station P.M.E, work bench space, inventory associated with repair station functions, and all repair station documents and records.
  1. Environmental {Example}

The repair station building is cooled and heated. No materials are used in the facility requiring any special environmental controls beyond normal central heating and cooling provided in the shop/office.
  1. Special Use {example}

Painting and spraying are accomplished in an area segregated from the assembly areas, or outside of the repair station building.
  1. Material {Example}

Materials received into the repair station building are processed IAW procedures specified within the RSM. Materials are received and processed through an incoming inspection where they are tagged if necessary for shelf life limits and stored in the shop area in separate bins labeled with the part numbers until the parts are required for maintenance.
  1. Equipment {Example}

The equipment in the shop is sufficient to maintain any item the repair station is rated to maintain. The limited radio, limited instrument and limited airframe ratings is supported by voltmeters, amp meters, pitot static test sets, hand tools and various specialized test equipment are kept to maintain instruments in support of the limited airframe ratings. No actual instruments requiring opening sealed instruments are repaired in this facility.
The equipment to support the ratings held by this repair station may be owned, rented, leased,



Section II

Page No: 2

Title: Housing, Facilities, Equipment and Materials

Revision No: Original

May 11, 2011


or lease purchased. Any equipment from whatever source will be in place when needed and will be maintained and/or calibrated IAW manufactures requirements or other approved data. Equipment will be controlled and calibrated in accordance with procedures located in the Quality Control Manual (QCM).
  1. Change of Location

{Your Company Here},  will apply for a change to its certificate in writing to the FAA prior to changing its location, add or amend a rating, or change the location of its housing, without written approval from the FAA. If {Your name} sells or transfers its assets, the new owner must apply for an amended certificate in the manner described in CFR Part 145.51.
  1. Diagram of the Shop and Hangar







NORTH



WEST EAST





SOUTH

















SECTION: III

COMPANY ORGANIZATION



































Section III

Page No: 1

Title: Company Organization

Revision No: Original

May 11, 2011



Section RSM 3 – Company Organization

  1. Organization Chart


Accountable Manager


Director of Maintenance


Chief Inspector


Repairmen































Section III

Page No: 2

Title: Company Organization

Revision No: Original

May 11, 2011

  1. Roster of Authorized Management and Inspection Personnel

The Director of Maintenance shall maintain a master List (Form #3) containing each manager, supervisor and inspector’s full name, initials and area of responsibility assigned within the repair station. The listing will be signed and dated by the Director of Maintenance to indicate approval. When a change is made in management, supervisory or inspection personnel caused by termination, reassignment, change in duties or scope of employment, or addition of personnel the Director of Maintenance will revise the appropriate section of the roster within five (5) business days of the change. Sufficient copies will be made and distributed to appropriate personnel within the repair station. It will also be made available to the CHDO in a method mutually acceptable to this repair station and the CHDO. The list (Form #3) will identify the area of responsibility listed at the end of the roster. The code will be listed in a column labeled authority in the row of the appropriately designated person. See authority delegation code below:

MAC 01 – Supervisor authorized to sign:
Final Inspections
Maintenance Release and
Approval to Return to Service

A sample of the list along with further instructions is maintained in the form section of this manual. The master list (Form #3) of management, and inspection personnel list required by 145.161 is maintained in the repair station files by the Director of Maintenance. The authority roster (Form #3) is posted on the inside of the repair station building..




























SECTION: IV

PERSONNEL















Section IV

Page No: 1

Title: Personnel

Revision No: Original

May 11, 2011

Section RSM 4 – Personnel

  1. Summary of employment

A summary of employment will be maintained on each person listed on a personnel roster required by 14 CFR 145.161. The Director of Maintenance will maintain the summaries, which will be filed in the individuals training folder located in the repair station.
The Director of Maintenance will collect information for inclusion in a summary within five (5) business days of employment of personnel required to keep a summary of employment and produce a summary for inclusion in the files. The Director of Maintenance will sign and date the summary. The individual named in the summary will also sign the summary. The signatures will indicate the summary is an accurate representation of experience and employment of the named individual. The summary will contain enough detail of experience to show compliance with the experience requirements of 14 CFR 145.161. The summary must also contain:
  1. Present title
  2. Total years of experience and type maintenance performed
  3. Past relevant employment and names of employers and periods of employment
  4. Scope of present employment
  5. Type of mechanic or repairman certificate and the ratings on that certificate, if applicable

A sample of this summary is maintained in the forms section. Summaries of employment may be provided to the CHDO through a method mutually agreeable to this repair station and the CHDO.
  1. Repairmen Certificates

The Director of Maintenance will determine when additional Repairmen are needed for the efficient and safe operation of the repair station. When additional repairmen are needed the Director of Maintenance will write a letter of recommendation for a repairman in the form and manner required by the administrator and forward it along with a completed FAA Form 8610-2 Airman Certificate and/or Rating Application to the CHDO for processing. When additional ratings are needed on a repairman certificate, the Director of Maintenance will forward the required information requesting additions to the certificate. Upon the termination of employment of any repairman, the Director of Maintenance will make reasonable effort to recover the repairman certificate for surrender to the CHDO. A letter stating the reason for surrender will be forwarded to the CHDO along with the certificate. When any certificate is not recovered, the Director of Maintenance will forward a letter to the CHDO explaining the Repairman’s employment is terminated and the certificate is unrecoverable.












SECTION: V

DUTIES AND RESPONSIBILITIES















Section V

Page No: 1

Title: Duties and Responsibilities

Revision No: Original

May 11, 2011

Section RSM 5 – Duties and Responsibilities

  1. Accountable Manager

The Accountable Manager is responsible for the complete overall operations of the Repair Station, including assuring adequate housing and facilities and the continued maintenance thereof. In addition, the Accountable Manager is also responsible:
  • For providing adequate training, equipment, materials, and competent personnel pertinent to the operations of the Repair Station that it may comply with all applicable Code of Federal Regulations (CFR) and manufacturer’s recommendations.
  • To ascertain that adequate firefighting equipment is available at the Repair Station.
  • To establish standards to ascertain that adequate safety precautions are observed.
  • For contracting and maintenance of the repair station Drug/Alcohol Abuse Detection/ Surveillance program.


2.0 Director of Maintenance
The Director of Maintenance is responsible to the Accountable Manager for the daily operation of the repair station and direct supervision of repair station personnel. In addition, the Director of Maintenance's duties include:
  • The development of initial and recurrent training of personnel consistent with the work to be performed.
  • Maintaining a roster containing management, supervisory and inspection personnel IAW policy and procedures contained in this manual and 14 CFR 145.161.
  • Maintaining a summary of employment for each individual listed on the roster of management supervisory and inspection personnel IAW policy and procedures of this manual and 14 CFR 145.161.
  • In the absence of the Chief Inspector, he may delegate authority to qualified personnel as dictated by CFR Part 145 and CFR Part 43, to release aircraft for service after repair or inspections.
  • The Director of Maintenance will ensure application is made for additional repairmen as necessary for the efficient operation of the repair station.
  • The Director of Maintenance is also responsible to make a reasonable effort to retrieve repairman certificate of former employees and surrender them to the CHDO or to notify the CHDO or to notify the CHDO in writing the certificates are not recoverable.
  • Formulation and implementation of action plans to resolve notices of deficiencies reported by the Chief Inspector.

The Director of Maintenance may delegate all duties assigned to any qualified assistant as necessary. Such delegation does not relieve the Director of Maintenance of overall responsibilities.



Section V

Page No: 2

Title: Duties and Responsibilities

Revision No: Original

May 11, 2011

3.0 Chief Inspector
Chief Inspector Responsibility and Authority:
The Chief Inspector is responsible to the Director of Maintenance for the overall operation of the Repair Station and is the primary contact with the FAA. As such, the Chief Inspector will have the final authority for releasing to service within the ratings authorized to this Repair Station, Limited Radio, Limited Airframes, and Limited Instruments for final inspections, maintenance releases and approvals for return to service. The Chief Inspector is responsible for directing, planning, and laying out details of inspection standards, methods, and procedures used by the Repair Station in complying with all applicable Federal Aviation Regulations, manufacturer’s specifications, and recommendations.

Chief Inspector Duties
  • Personnel and Personnel Safety

The Chief Inspector (CI) shall train, assist, supervise, and direct all inspection personnel assigned to the Repair Station in matters pertinent to airworthiness, quality control and FAR compliance. In addition the CI shall ensure that proper work procedures and practices are followed. That supervisors and inspectors have sufficient proficiency of the English language. The CI shall Indoctrinate and train personnel in observing the safety precautions relevant to the functions for which they may be utilized. The CI shall see that periodic drills for the purpose of indoctrinating personnel in the location and proper use of firefighting equipment are performed and that fire safety equipment is periodically checked for serviceability and adequacy. He/she shall assure that the repair station has a sufficient supply of fire fighting and safety equipment.
  • Rules, Technical Data and Manuals

The Chief Inspector shall ensure that the Repair Station maintains a current FAA federal library containing pertinent Federal Aviation Regulations, specifications, type certification data sheets, and airworthiness directives. The CI is responsible to stay current and knowledgeable of the Federal Aviation Regulations pertinent to the ratings and limitations of the repair station and shall see that the repair station remains compliant with the applicable parts governing its operations. The CI shall ensure that the repair station makes available the required technical data necessary for job tasks and functions of the repair station. The CI shall ensure that required technical data is current with respect to the latest revisions. This data will include the Repair Station’s process specification for: Manufacturer’s Overhaul Manuals, Service Bulletins, Part Specifications, Related Federal Aviation Administration Approved Data, or other Technical Data used by the Repair Station. In addition, the Chief Inspector will assure that any military technical orders used in the overhaul and repair of components that have been evaluated and approved by the FAA.
  • Records and Reporting

The Chief Inspector shall submit reports of defects or un-airworthy conditions in accordance with CFR Part 145.221. The CI shall assure the proper execution of FAA Form 337 when required, and/or a maintenance release.


Section V

Page No: 3

Title: Duties and Responsibilities

Revision No: Original

May 11, 2011


The CI shall maintain the files of completed Work Orders and inspection forms in such a manner that the file pertaining to a specific item repaired can be readily located for review. The CI shall ascertaining that all necessary maintenance entries on maintenance forms and Work Orders used by the Repair Station are properly executed.
  • Material Processing and Inventory Control

The Chief Inspector shall conduct the preliminary, hidden damage, in-progress, and final inspection of all articles processed by the Repair Station and record results as outlined in this manual. The CI shall determine that no defective, unserviceable, or un-airworthy parts are installed in any component or articles released by the Repair Station. The CI shall assure that repairable parts are segregated by work order and serviceable parts are segregated from un-serviceable parts and shall oversee the proper tagging and identification of all parts and components as outlined in this manual. The CI shall ensure that rejected and unserviceable parts are handled in such a way as to prevent their reuse as serviceable parts. The CI shall ensure that materials, parts and supplies used by the repair station are properly stored and segregated and that procedures will be implemented and used to monitor the preservation status of such and that items reaching shelf life limits will be discarded or reinspected as required. The CI shall assure replenishment of needed materials and/or equipment that have been expended or have been rendered unservicable due to normal wear and tear.
Repair Station Tooling, Precision Measuring and Test Equipment (PME)
The Chief inspector shall assure that periodic calibration checks are made of the inspection tools, test equipment and precision measuring equipment used by the Repair Station. The CI shall assure that a current record of those inspections and test is maintained and that equipment is taken out of service when calibration is due, its accuracy is suspect or if articles have been damaged. The CI shall see that all shop equipment and tools necessary for the functioning of the repair station are maintained in a serviceable working condition.
  • Inspection Processing

The Chief Inspector shall determine the final acceptance of all incoming material, including new parts and supplies. The CI shall ascertain that all inspections are performed properly on all completed work and that the proper inspection records, reports and forms used by the Repair Station are properly executed prior to executing a maintenance release approving an article for return to service.
  • Quality Control

The Chief Inspector shall assure that only acceptable parts and supplies will be issued for any job. The CI shall assure that the personnel in the maintenance department perform quality work. The CI shall verify the airworthiness of articles on which work has been performed outside the Repair Station under contract. The CI shall inspect all work that requires the qualifications of an A&P Mechanic, such as airframe structures, airframe electrical wiring, and weight and balance.



.Section V

Page No: 4

Title: Duties and Responsibilities

Revision No: Original

May 11, 2011

  • Human Factors

The Chief Inspector shall oversee the implementation of continuity of inspection systems including pass down logs, assuring completion of required task and inspection when personnel shift or assignment changes occur. The CI shall ensure that the Repair Station has a sufficient number of supervisors to direct work performed and that the Repair Station is maintained in a clean and orderly manner conducive to quality work standards.
  • Responsibility and Reporting to the Director of Maintenance

The Chief Inspector shall report to the Director of Maintenance any concern or deficiency he or she finds. This report shall indicate the deficiency and how it impairs the repair station with respect to ratings and limitations.
  • Delegation

The Chief Inspector may delegate duties to any qualified assistant as necessary but such delegation does not relieve the CI of the overall responsibility.











































SECTION : VI

REPAIR STATION OPERATIONS



























Section VI

Page No: 1

Title: Repair Station Operations

Revision No: Original

May 11, 2011

Section RSM 6 – Repair Station Operations

  1. Operational Overview

The Director of Maintenance is responsible for receiving any item into the repair station for Maintenance. A work order form (#6) will be filled out prior to anything being done to an aircraft or article. The work order accompanies all items throughout the maintenance cycle.
The Chief Inspector will accomplish inspections on any item coming into the repair station for maintenance (preliminary inspection) or use as spare or repair parts (incoming inspection.)
No item must be placed in stock or inducted into the repair station for maintenance without a preliminary inspection, hidden damage inspection, and or incoming inspection as stated in this repair station manual. Items are tagged or otherwise identified as to their condition and segregation:
Repairable items tagged with a Form #9
Unrepairable items tagged with Form #11 and quarantined until disposed of
SUPS items are tagged with Form #FAA 8120-11 and quarantined until disposed of
Items with a shelf life are tagged with Form #12 to indicate its shelf life limit
Repaired items are tagged with a serviceable tag Form #10 and placed in a segregated are
Reserved for repaired parts awaiting pickup, installation or shipping.

After preliminary inspection and work order and status tags are attached, the item is repaired or altered and the appropriate paperwork is accomplished, the item is ready for inspection.

The Chief Inspector accomplishes the final inspection and checks that all paper work is accomplished. After final inspection is successfully completed, the item is ready for a maintenance release.

The maintenance release may be signed by an authorized inspector and the item is ready for approval for return to service. The approval for return to service may be accomplished by completing a serviceable tag Form #10.

Articles will be inducted using preliminary and hidden damage inspections and will progress through the maintenance process, in process inspection, final inspection, maintenance release and approval for return to service. The articles will also be provided a maintenance record (aircraft logbook) sign off if the records are available or an insert will be provided to the customer. Madison Air Center, LLC, Form #10 will be used to return articles to service.








Section VI

Page No: 2

Title: Repair Station Operations

Revision No: Original

May 11, 2011

  1. Maintenance Records

The Chief Inspector has the responsibility to maintain the required record system for this repair station. This repair station will provide active storage for required maintenance records IAW CFR 145.219 for at least (2) years. After two years, at the direction of the Accountable Manager, the records may be moved into archival status for an undetermined period of time. Disposal of records will be determined solely at the discretion of the Accountable Manager after the required active storage period of two (2) years. Record packages for each job will be accumulated as the component progresses through the maintenance process. A records package may be comprised of:
  1. Work order(s)
  2. Specific functional test
  3. Teardown inspections
  4. In process inspection checklist
  5. Specialized tests and or calibrations
  6. Vendor maintenance records
  7. Approval for return to service records produced by this repair station
  8. Other records as deemed necessary for maintenance or inspection

The records will be filed in the inspection section office space. They will be in English. They will be filed by calendar year completed and in work order sequence.

{Your Company} will make all required records available for inspection by the FAA and NTSB.
  1. Malfunction or Defect Report Procedures

The Director of Maintenance is responsible for preparing and submitting a Malfunction or Defect Report to the FAA Flight Standards District Office.

MALFUNCTION OR DEFECT REPORT:
This Repair Station will report to the FAA within 96 hours after it discovers any serious defect in, or recurring un-airworthy condition of, an aircraft, power plant, or propeller, or any component of any of them.
The report will be made on FAA Form 8010-4 “Malfunction or Defect Report”, describing the defect or malfunction completely without withholding any pertinent information. The M or D may be electronically submitted through the FAA website.
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 whether it must be reported.
If the defect or malfunction could result in an imminent hazard to fight, the Repair Station will use the most expeditious method available to inform the Administrator.




Section VI

Page No: 3

Title: Repair Station Operations

Revision No: Original

May 11, 2011

  1. Mechanical Reliability Reports

This Repair Station will not perform maintenance on CFR Part 121, Part 125, and Part 129 carriers. When required under Part 135 the Chief Inspector will coordinate with the Director of Maintenance of the applicable Part 135 entity to ensure that all required information is furnished for the timely submission of required MRRs. A written record of that communication (preferably by fax or email) will be retained in the applicable work order file.
  1. Detecting and Reporting Suspected Unapproved Parts (SUPS)

The Chief Inspector is responsible for the repair station Suspected Unapproved Parts (SUPS) program.
Suspected Unapproved Parts will be detected and reported in accordance with FAA AC 21-29 as revised. The FAA form 8120-11 including instructions included in the Advisory Circular and or the FAA Aviation Safety Hotline may be used as determine by the urgency needed for the report.
The Chief Inspector will forward a report to the FAA or call the FAA Hotline concerning A SUPS within five (5) working days after determining within reason a SUPS has been detected. Any additional information discovered may be reported in the same manner as an original finding and within the same time periods as the original report.

A file containing a copy of all information and reports will be maintained and filed in the Inspection Section of the repair station. Any additional information will be filed as it is received.

On a monthly basis the Chief Inspector will review the file for follow-up if necessary and any significant progress or results.
  1. Performance of Maintenance at a Location Other than the Repair Station

{Your Company} may provide maintenance service for its customers on an emergency on-call basis at a location other than the Repair Station IAW CFR 145.203.
{Your Company} will only provide maintenance for which the Repair Station is rated and can be conducted to the same level of quality and safety as maintained at the repair station.

The repair station will contact the CHDO and request permission to perform maintenance at another location prior to performing any maintenance away from the repair station location.

Only the Director if Maintenance is authorized to initiate a request to perform maintenance at another location, the request will be in a written format and may be transmitted by E mail, fax, mail or hand carried to the CHDO.
The CHDO must affirmatively endorse the request and transmit it back to the repair station in one of the methods mutually acceptable to the repair station and the CHDO.
Only the Director of Maintenance is authorized to issue a Work Order for such work.

.Section VI

Page No: 4

Title: Repair Station Operations

Revision No: Original

May 11, 2011


The Director of Maintenance will assure that all required forms and work are complete as necessary. The Chief Inspector will be responsible for returning the article to service.
The Director of Maintenance will:
Ensure that the article to undergo maintenance and the workforce will be in an area: Safe for the work to be performed and protected from the elements.
Be responsible for providing all the necessary manpower, work forms, technical data, tools, and equipment necessary for the accomplishment of the maintenance.
Establish a system of communications between the field force and the Repair Station.

The Director of Maintenance is responsible for providing 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 parts receiving process: 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 CFR Sections 145.109 and 145.201, 145.157 and 145.213 and 145.219.

This Repair Station does not conduct maintenance on a recurring basis at another location at this time (CFR Part 145.203 (b). The RSM must be revised to meet the requirements of CFR Part 145.203 (b) to perform such work on a recurring basis.






























SECTION: VII

TRAINING
















Section VII

Page No: 1

Title: Training

Revision No: Original

February 15, 2011

SECTION RSM – 7 TRAINING

  1. Training

A training program is maintained in a separate manual.













































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