Chapter 2 - Maintenance Procedures

Transcription

1 Chapter 2 - Maintenance Procedures chapter 2 page 1

2 Chapter 2 Maintenance Procedures 2.1 Supplier evaluation and subcontract control procedure Page Responsibilities Page Description Page Selection of new suppliers of aircraft parts Page Parts / Service Ordering Page Exceptions of PMA parts Page Supplier assessment, evaluation and risk assessment Page NAYAK suppliers / subcontractors lists Page Supplier audits Page Re-certification of suppliers / subcontractors Page Suspension of suppliers Page Supplier for FAA related customer Page Acceptance / inspection of aircraft components and Page 11 material from outside contractors Responsibilities Page Description Page Goods Receiving Page Receiving Goods Inspection / Incomming Inspection Page Electrostatic Sensitive Devices (ESD) Page Suspected unapproved Parts Page Discrepancies Page Return of spare parts to bin Page Storage, tagging and release of aircraft components Page 17 and material to aircraft maintenance Responsibilities Page Description Page Tagging and Storage Page Maintenance on Customer supplied parts Page Release of components and material to maintenance Page 18 chapter 2 page 2

3 2.4 Acceptance of tools and equipment Page Responsibilities Page Description Page Calibration of Tools and Equipment Page Responsibilities Page Description Page Internal control and calibration Page External calibration Page Marking of Calibrated Tools Page Quarantine Tools Page Tool out of tolerance procedure Page Interval Reduction Page Interval Extension Page Use of tooling and equipment by staff Page 23 (including alternate tools) Responsibilities Page Description Page Use of new and/or additional Tooling Page Additional tooling and equipment Page Alternative specific- or special tooling and equipment Page Procedure to approve the use of alternative tooling and equipment Page Loaned tooling and equipment Page Cleanliness standards of maintenance facilities Page Responsibilities Page Description Page Maintenace instructions and relationship to aircraft Page 28 component manufactures instructions including updating and availability to staff Responsibilities Page Description Page 28 chapter 2 page 3

4 2.9 Repair procedure Page Responsibilities Page Description Page Handling of Technical Defects Page Aircraft maintenance programme compliance Page Responsibilities Page Description Page Airworthiness directives procedure Page Responsibilities Page Description Page Optional modification procedure Page Responsibilities Page Description Page Maintenance documentation in use and completion Page 34 of same Responsibilities Page Description Page Entries in Technical Documentation / Correction of same Page Technical record control Page Responsibilities Page Description Page 37 chapter 2 page 4

5 2.15 Release to service procedure Page General Page Documentation Page RTS Statement (CRS) Page RTS on EASA Form One Page Records for the operator Page Responsibilities Page General Page Reporting of defects to the component authority / Page 41 operator / manufacturer Responsibilities Page Occurence Reports Page Non-Conformity-Reports Page External occurrence reports directed to the Quality Department Page Evaluation and retention period Page Processing of occurrence reports according Part 145.A.60 Page Return of defective aircraft components to store Page Responsibilities Page Description Page Return of parts to store Page Defective components to outside contractors Page Responsibilities Page Description Page Control of computer maintenance record systems Page Responsibilities Page Description Page 46 chapter 2 page 5

6 2.21 Control of man-hour planning versus scheduled Page 47 maintenance work Responsibilities Page Description Page Independent Inspections / Reinspections / Page 49 Detection and Rectification of Maintenance Errors Responsibilities Page Purpose Page Definition Page Description Page Documentation Page Referece to specific maintenance procedures Page Responsibilities Page Description Page Procedures to detect and rectify maintenance errors Page Responsibilities Page Description Page Shift / task handover procedure Page General Page Description Page Procedures for notification of maintenance data inac- Page 55 curacies and ambigities to the type certificate holder Responsibilities Page Description Page Production planning procedures Page Responsibilities Page Description Page AOG Support Page 59 chapter 2 page 6

7 2.1 Supplier evaluation and subcontract control procedure Responsibilities The individual person at purchasing department placing an order is responsible for the selection of the supplier. Purchasing department is also responsible for creation and update of the NAYAK CSC suppliers list, the continuous check and verification of the approval of all registered suppliers and to keep the list current. For further details refer to Working Place Procedure WPP 510. Safety Quality & Complinance Department is responsible for: the preparation, realisation and evaluation of the suppliers audits and the risk assessment of the suppliers the determination of the suppliers that have to be audited information of the management and of the affected team leaders The stores personnel is responsible for controlling the shipment according Part 145.A.42(a) Acceptence of Components which also integratet in detail to Working Place Procedure WPP Description Definitions: AMOS: Rotables: Consumables: Aircraft Maintenance and Engineering System; integrated software package, that manages the maintenance, engineering and logistic functions of NAYAK. Parts are time-controlled by flight-hours, flight-cycles, calendar days or special control dimensions. Rotables are always traceable because each unit is clearly identifiable by its serial number. They are often time-limited and can be repaired. Parts which are consumed and (usually) not repairable. They are used only once and then are thrown away. Traceability of consumables is possible to a certain, though limited extent with help of batch numbers. Some consumables have time-limitations. chapter 2 page 7

8 2.1.3 Selection of new suppliers of aircraft parts During the normal day to day business purchasing staff selects the supplier where aircraft parts, consumables, etc. should be bought. Prior order placement the selected supplier needs to be internally approved. This approvement will be done by the Safety Quality & Compliance Department after a vertification as per To start the approval process purchasing staff will contact the dedicated supplier and forward the Nayak Form QM 09 to the supplier. Additional information / documents are requested as well, to round out the supplier profile. A supplier can be approved if the supplier questionnaire (Nayak Form QM 09, postal audit) and additional information like actual certificates, etc. are available and found satisfactory. Suppliers located in the U.S. holding a current FAA approval have to provide a drug and alcohol prevention programm in addition Parts / Service Ordering If a supplier is approved, a part or a performance can be ordered without delay. When placing an order for spare parts the purchasing has to request a certificate according to the following chart. parts Rotables Repairables Consumables required / acceptable documentation FAA Form or EASA Form 1 or Transport Canada Form One or Form SEGVOO 003 for new parts. For all repaired parts a Dual release form is required. For further details refer to WPP 501. For serialized repairables: FAA Form or EASA Form 1 or Transport Canada Form One or Form SEGVOO 003 for new parts. For all reaired parts a Dual release form is required. For further details refer to WPP 501. For non-serialized repairables: Certificate of Conformance and Batch No. and manufacturer / suppliers history Certificate of Conformance and Batch No. and manufacture / suppliers history EASA Form 1 in dedicated cases, repaired under C-Rating Exceptions of PMA parts PMA parts may be used on the Aircarft-Components. PMA parts have to be delivered with a Parts Manufacture Approval (PMA) and Batch-No. Material Department has to be consulted before ordering due to special agreements in the contract with each individual customer or leasing contracts of the aircraft in question. chapter 2 page 8

9 Furthermore Material Department will ensure, that the PMA parts has been approved by the FAA and the necessary approval documentation (like DER Approval) is available. These Parts must delivered with FAA Form For details please refer to Procedure VA10 & WPP Supplier assessment, evaluation and risk assessment An evaluation on basis of NAYAK CSC Form QM 09 and additionaly provided information coming from the supplier/subcontractor has to be performed by Quality / Compliance Department before an internal approval may be issued to the new supplier / sub-contractor NAYAK suppliers / subcontractors lists Separate lists showing all approved suppliers and subcontractors. These lists are available at AMOS. NAYAK CSC can add following suppliers to the lists without an on site audit if following requirements (and / or) are met: suppliers, who send a complete and conclusive vendor questionary + requested documents suppliers, that have an audit report not older than one year of any other airline or maintenance organisation, after the report has been checked and evaluated by Safety Quality & Compliance Management suppliers, that are mentioned in the regularly published EASA list subcontractors, that have a certified / approved quality system Supplier audits Should there be systematic quality / safety problems resulting from goods receiving or the supplier evaluation or risk assessment, a supplier on site audit has to be accomplished in cooperation with the Safety Quality & Compliance Monitoring Manager and, if necessary, with relevant Department Managers. For the performance of an audit, the regulations and requirements of the procedure "Audit apply. As a result of a supplier audit the Safety Quality & Complinance Department generates an assessment of the supplier with the following steps: keeping the supplier without further action keeping the supplier by implementing actions at NAYAK to ensure proper deliveries keeping the supplier by imposing conditions to the supplier changing the supplier chapter 2 page 9

10 2.1.9 Re-certification of suppliers / subcontractors Purchasing surveys all listed suppliers / subcontractors in the AMOS data base and will contact the supplier / subcontractor for starting the re-certification process when the due date will be reached Suspension of suppliers Suppliers have to be suspended from further orders until further notice, if the following applies: loss of their approval audit result unsatisfied due to other reasons like but not limited to: unreliable, poor delivery performance, price, etc Supplier for FAA related customer Additional to the described requirements suppliers located in the U.S. holding a current FAA approval have to provide a drug and alcohol prevention programm. Purchasing keeps a current List of approved suppliers, for all approved suppliers for U.S. aircraft. chapter 2 page 10

11 2.2 Acceptance / inspection of aircraft components and material from outside contractors Responsibilities The Materials Manager, and the Maintenance Managers are responsible for the performance of the receiving goods process. They are responsible that only authorized personnel have access to the stores area. The proper trained stores personnel with special authorization are responsible for receiving and controlling the shipment. The proper trained stores personnel with special authorization is responsible for goods inspection acc. to WPP 501. The Safety Quality & Compliance Monitoring Manager is responsible for the approval and authorisation of personnel Description Definitions: Serviceable Parts: Components which are in a satisfactory condition, released with EASA Form 1 or equivalent (ref to 2.1.4). Unserviceable Parts: Unserviceable components which could be maintained / repaired. Scrap Parts: Components which can`t be maintained / repaired Rotables / Consumables: Standard parts which are specified in the manufacturer`s illustrated parts catalogue and / or the maintenance data. (ref to 2.1.4). Raw / Consumable Material: Material used in the course of maintenance, meets the required specification and has appropriate traceability. All material must be accompanied by documentation clearly relating to the particular material and containing conformity to specification statement plus both the manufacturing and supplier source. Expendable Parts: Shelf Life: Any component that is discarded at the end of its useful life, i.e is not worth repairing or cannot be repaired or overhauled due to it's construction. (refer to WPP 507) The legth of time of a product which can be stored with becoming unsuitable for use of consumption. A placard showing the expiry date is attached on the packaging or the part itself. If the expiry date is exceeded this parts / materials are Scrap Parts. chapter 2 page 11

12 2.2.3 Goods Receiving In principle, goods may only be accepted, if the delivery documents declare NAYAK CSC as the receiver. Parts must delivered with EASA Form 1 or equvivalent accordening Part 145.A.42(a) Acceptence of Components. The store personnel has to compare the delivery documents and, if available, the Air Way Bill (AWB) with the actual delivery. If differences are found, store personnel has to note this on the delivery documents and obtain a confirmation by the supplier Receiving Goods Inspection / Incomming Inspection All parts delivered from suppliers or customers have to be inspected. If external damages of the packaging material have been found, the delivery is only accepted with reservation, including a note concerning the assumed damage on the delivery documents. The supplier has to confirm this note. If it is suspected, that the contents have been damaged, the Store Personnel has to take photos of the package before opening. The delivered goods have to be unpacked and inspected for external damages. The Store Personnel has to inform the Store Team Leader. A note has to be completed by the Store Team Leader and forwarded to the Frightforwarder and / or Supplier for further processing. Until further clarification the damaged part will be stored into the Quarantine Area. A decision is made by the responsible Persons where the parts concerned are going to stay. Appropriate authorized personnel perform the acceptance inspection in accordance to inspection lists which include the items listed below. All inspection documentation and labels have to be archived with the incoming goods documentation. If the criteria are not fulfilled, a report has to be filed. The complete incoming inspection booking in the AMOS for this material is performed by the responsible persons. Store personnel should only perform the Goods Inspection and the corresponding data entry into the AMOS system if the following documents are available: order (from open order file) delivery document from sender shipping document (including customs number for non-ec-goods) AWB (Air-Way-Bill) conformity of all relevant data between part and documents For further information regarding Incoming Inspection please refer to WPP 501. chapter 2 page 12

13 Acceptance of components A document equivalent to an EASA Form 1 may be: a) a release document issued by an organization under the terms of a bilateral agreement signed by the European Community (Brazil, FAA, Canada) b) a release document issued by an organization approved under the terms of a JAA bilateral agreement until superseded by the corresponding agreement signed by the European Community; c) a JAA Form One issued prior to 28 November 2004 by a JAR 145 organization approved by a JAA Full Member State; d) in the case of new aircraft components that were released from manufacturing prior to the Part-21 compliance date the component should be accompanied by a JAA Form One issued by a JAR 21 Organization approved by a JAA Full Member Authority and within the JAA mutual recognition system; e) a JAA Form One issued prior to 28 September 2005 by a production organization approved by a competent authority in accordance with its national regulations. The EASA Form 1 or equivalent identifies the status of an aircraft component. Block 12 Remarks on the EASA Form 1 in some cases contains vital airworthiness related information which may need appropriate and necessary actions. It should be satisfied that the component in question is in satisfactory condition and has been appropriately released to service. In addition, it should ensure that the component meets the approved data / standard, such as the required design and modification standard. This may be accomplished by reference to the manufacturer s parts catalogue or other approved data (i.e. Service Bulletin). Care should also be taken in ensuring compliance with applicable airworthiness directives, the status of any life-limited parts fitted to the aircraft component as well as Critical Design Configuration Control Limitations. Standard parts: Certificate of Conformance from the manufacturer Raw Material and consumable: Certificate of Conformance from the manufacturer as minimum requirement The following types of components should typically be classified as unsalvageable: a. Components with non-repairable defects, whether visible or not to the naked eye; b. Components that do not meet design specifications, and cannot be brought into conformity with such specifications; chapter 2 page 13

14 c. Components subjected to unacceptable modification or rework that is irreversible; d. Certified life-limited parts that have reached or exceeded their certified life limits, or have missing or incomplete records; e. Components that cannot be returned to airworthy condition due to exposure to extreme forces, heat or adverse environment; f. Components for which conformity with an applicable airworthiness directive cannot be accomplished; g. Components for which maintenance records and / or traceability to the manufacturer can not be retrieved. The store personnel has to check during the incoming inspection if the data of the delivered material (P/N, S/N, etc.) complies with the data contained on the approval certificate / batch number as well as the order itself. In some cases it can be possible that the store personnel must produce a copy of the original certificates. Furthermore it has to be inspected if all necessary data are contained on the certificate. Further checks include the following: delivered quantity in compliance with delivery documents corresponding open order in AMOS individual packaging of consumables adequate shelf life large quantity of materials are complete correct and undamaged packaging physical inspection for obvious damage and properly installed blind plugs If a goods receipt can not be performed due to negative results, the store personnel has to tag the material with a Report / Tag and stores the part in the specially marked quarantine shelfs. The Supplier must be informed that this part are received but damaged or not in compliance with the Nayak CSC incoming procedures. Prior to installation of a component, NAYAK CSC ensures that the particular component is eligible to be fitted as instructed by IPC and CMM Electrostatic Sensitive Devices (ESD) Components that are considered sensitive to electrostatic discharges (ESD`s) are to be kept in their protective packing. When visual inspection is required, the ESD is handled using the conductive, earthen workbench and bracelet. For details refer to WPP 707. chapter 2 page 14

15 2.2.6 Suspected unapproved Parts A Suspected Unapproved Part (SUP) is a part, component, or material that is suspected of not meeting the requirements of an approved part. A part that, for any reason, may not be approved. Reasons may include findings such as a different finish, size, colour, improper (or lack of) identification, incomplete or altered paperwork. For details refer to FAA AC Unapproved Part An Unapproved Part is a part that does not meet the requirements of an approved part. This term also includes parts which have been improperly returned to service and / or parts which may fall under one or more of the following categories: (1) Parts shipped directly to the user by a manufacturer, supplier, or distributor, where the parts were not produced under the authority of (and in accordance with) a production approval for the part, such as production overruns where the parts did not pass through an approved quality system. Note: This includes parts shipped to an end user by a Production Approval Holder s (PAH) supplier who does not have direct ship authority from the Production Approval Holder. (2) New parts which have passed through a Production Approval Holder s (PAH) quality system which are found not to conform to the approved design / data. Note: Parts damaged due to shipping or warranty issues are not required to be reported as SUP. (3) Parts that have been maintained, rebuilt, altered, overhauled, or approved for return to service by persons or facilities not authorized to perform such services. (4) Parts that have been maintained, rebuilt, altered, overhauled, or approved for return to service which are subsequently found not to conform to approved data. Notes: 1. This would include parts produced by an owner / operator for the purpose of maintaining or altering their own product, which have been approved for return to service, and found not to conform to approved data. 2. This does not include parts currently in the inspection or repair process, such as, parts removed for maintenance. Parts in this status may be considered not acceptable for installation. 3. Suspected Unapproved Parts Notification can be found on FAA Internet address: Special Airworthiness Information Bulletins can be found on FAA Internet address: chapter 2 page 15

16 If case of suspect and / or unapproved parts being found the Safety Quality & Complinance Department shall be informed immediately for reporting unapproved parts to the authority Discrepancies If discrepancies are found the respective material is stored in the Quarantine Area. The purchaser will be informed who will take further action with assistance of Maintenance Manager when required. If the reason for rejection cannot be resolved by the supplier / manufacture the material will be returned to the supplier / manufacture Return of spare parts to bin Airworthy spare parts, handed over for maintenance, not used, could be returned to bin after performance of physical review by store staff. During that review it should be verified: that part(s) obviously not damaged that associated documentation (Authorised Release Certificate, etc.) available that packaging is suitable Return Pick slip After verification parts should be booked into storage system and stored again. chapter 2 page 16

17 2.3 Storage, tagging and release of aircraft components and material to aircraft maintenance Responsibilities Certifying staffs approved by Quality and Compliance Management are responsible for the release of aircraft components and material to maintenance under the Companies C- Ratings with EASA Form 1 or equvivalent accordening Part 145.A.42(a). Acceptence of Components The stores personnel is responsible for the correct and adequate storage Description Definitions: Quarantine Shelf: Interim area for storage of unserviceable components or repairables with EASA Form 1 or equvivalent accordening Part 145.A.42(a). Acceptence of Components Tagging and Storage All components and material passed the Goods Receiving Inspection (ref. to chapter 2.2) have to be tagged with a NAYAK CSC lable. To ensure that a part can be easily found, the store personnel performing the incoming inspection attaches the label to the outside of the packaging. Following indications should clearly state on the lable: listet Part Number listed Serial Number or Batch Number description ATA-Chapter, if necessary store-address Customs-Number (customs label only if customs goods) date (customs label only if customs goods) stamp of person performing the Goods Receiving Inspection (Rotable Tag only) marking dangerous goods (if applicable) In order to prevent damages and to ensure safe transport within the company, rotables and repairables are stored within their original packaging. The parts have to be protected from dust and other environmental influences in accordance with the manufactures recommendations or other acceptable industrial standards. For further details refer to Working Place Procedure WPP 405. chapter 2 page 17

18 Consumables principally remain in their individual packaging. Consumables are stored in special storage boxes, which are marked with the appropriate part number and batch number. Additionally the expiry data of these parts / materials are manually monitored by the store personnel in the AMOS system. There for a placard showing the expiry date is attached on the packaging or the part itself when it has been received. Under the responsibility of the Material Manager, store personnel checks this material / parts on a monthly basis. If an expiry date has been reached, the corresponding material is disposed off in accordance to the company procedures and current authority requirements. All rotables, repairables and consumables without a label must generally be regarded as unserviceable. Serviceable and unserviceable parts must strictly segregated and clearly marked / labled, to avoid any confusion or mix up in handling. Customers equipment and parts have to be separated from NAYAK CSC own parts. The storage of customer supplied parts requires the same procedures as NAYAK CSC owned parts. The standards for storage of aircraft parts are to be followed. Special instructions for storing delicate units requested by the customer have to be followed. Rejected and unserviceable parts will be identified and stored in a separate shelf, clearly identified. Material which cannot be repaired will be scrapped with the customes agreement. The scrapping of the parts will be documented in a scrap book. The scrap parts have to be destroyed, that they can not be reused. If the customer wants his scrap parts back, a delivery note has to be issued for the parts, stating that these parts are not to be used on aircraft again. For further details refer to Working Place Procedure WPP Maintenance on Customer supplied parts The maintenance on customer supplied parts is handled in accordance with the storing agreement and on behalf of the customer and there procedures Release of components and material to maintenance Release of stored components and material Before components or material will leave the storage area store personnel has to perform a Goods Outgoing Inspection. During this inspection it should be checked if the part / material was damaged during storagging, if the shelf life limit is overdue and if all necessary release certificates (EASA Form 1, C of C, etc.) are available (ref. to VA 10). When components or material will leave the storage area, the corresponding release certificates (EASA Form 1, C of C, etc.) must be attached to the part / material. If components or material will be send to outside maintenance facilities the parts / material has to be packed i.a.w. Working Place Procedure WPP 503 to prevent damaging during transport. chapter 2 page 18

19 2.4 Acceptance of tools and equipment Responsibilities The Maintenance Manager are responsible for the determination of adequate quantity of tools. If necessary he initiates the order of new tools. The Tool Keeper (Werkzeugbeauftragter) reports to the Maintenance Manager upon a regular basis (minimum once a month) the number of outstanding tools. The Tool Keeper must ensure that an adequate number of tools are always available and must be based upon planned maintenance activities (data supplied by planning department). He is also responsible for: control of tool flow composition of all tool orders and forwarding Maintenance Manager inspection of all tools in accordance with the valid laws and regulations to ensure serviceability preparation of tool lists for mechanics tools preparation and revision of tool catalogues / booklets clear and permanent identification labelling of all tools Every user of tools is responsible for the proper return of serviceable tools as well as for the reporting of unserviceable tools when they are returned and responsible for: visual control and check of completeness of every returned tool retention of unserviceable tools and forwarding to the NAYAK Tool Keeper Description Before an component will be released for service after maintenance work, each employee has to verify that no tools will stay within the component. If damages or a possible unserviceability is determined during this check, the tool has to be labelled as "unserviceable" and stored in the quarantine store location for unserviceable tools. Further measures are defined by the tool keeper. For maintenance work, general shop tools are provided. The contents of these tools are based solely upon the tool-lists generated by the tool keeper. Any excess and or private tools are not permitted in these areas, and have to be checked for serviceability and completeness. Unserviceable tools have to be labelled adequate and deposited in the store. Possible discrepancies have to be reported to the Maintenance Manager immediately. Once received, the respective staff is responsible for the completeness, serviceability and location of these tools. This person has to ensure at all times, that no tools remain on or in an component after the performance of maintenance activities. For further details refer to Working Place Procedure WPP 602. chapter 2 page 19

20 2.5 Calibration of tools and equipment Responsibilities Everyone at NAYAK CSC using precision tooling or test equipment is responsible, that the seal, showing the next due date, is attached to the equipment and that this due date has not expired. The Maintenance Manager are responsible for the complete shop Interieur Description Internal control and calibration The equipment which has to be calibrated is delivered to the Avionic Shop (AV) before the due date. All tools subject to a calibration interval may be used up until indicated by the calibration placard affixed to the tool. AV is responsible, to maintain the file for calibration of precision tooling and test equipment. All precision tooling and test equipment is registered in AMOS. All such equipment has a NAYAK CSC Serial Number under which the equipment is registered in the precision tooling and test equipment file. Calibration can only be performed, when the equipment used for calibration is of a higher standard and the calibration of this equipment can be traced to the national standard. Bases for the calibration procedure and interval is the manufactures documentation with the latest Revision. Calibrated equipment is marked with a plaque, showing NAYAK CSC Serial Number and the next calibration due date. The calibration-file includes all calibrated tools which have been registered in AMOS as well as the corresponding calibration certificates. Calibration software has to be checked at frequent intervals for completeness and function. This ensures that all relevant data can be supplied at any time if required External calibration Before sending equipment out for calibration, the organisation must be approved by Safety Quality & Compliance Department, after verifying, that this organisation complies with the requirements of this MOE. The organisation must show documentary proof, that the calibration can be traced to the national or other recognised standards. This requirement is satisfied, if the organisation is the manufacturer of the equipment, a Part-145 Organisation, or a recognized Quality Assurance Organization (like DKD). The control of the calibration due date and the filing of the calibration reports are still the responsibility of NAYAK CSC. For further details refer to Working Place Procedure WPP 602. chapter 2 page 20

21 Marking of Calibrated Tools All tools have to be marked with a calibration label. Tool issue may only be performed with a valid and readable calibration label. The label must show the next calibration date. Tool data such as Part-Number and Serial-Number must also be available on a readable type label, placard or engraving on all calibrated tools. New tools without a manufacturer calibration placard must be sent to the Avoinic Shop prior to its first use. The calibration shop evaluates the calibration and applies a corresponding placard Quarantine Tools Calibrated tools, which are not needed for a long period, are decommissioned due to economical reasons. These tools are locked at a special area and marked as unserviceable using the unserviceable tag / label. As a basic principle every quarantine tool has to be calibrated before reusing it Tool out of tolerance procedure If Avionic Shop detects during calibration process that the applicable tolerance has exceeded, an Out of tolerance notification (Form QM 40) will be created out of AMOS and forwarded to the individual department where the tool came from. If the affected tool is owned and / or used by Nayak the Form QM 40 will be forwarded to the responsible department head, Safety Quality & Complinance Department for further internal investigations. If the affected tool is a customer tool not used by Nayak the Form QM 40 will be forwarded to customers contact persons for general information. After that the Avionic Shop has to clarify what should happened to the affected tool. Depending on further investigations the tool could be separated in U/S condition, or send back to customer, or Avionic Shop will performing an adjustment of the tool. If necessary the calibration interval for this kind of tool has to be adapted. chapter 2 page 21

22 If the affectet tool is a Nayak owned / used tool the Maintenance Manager will receive an appropriate Out of tolerance notification (Form QM 40) issued by Avionic Shop. Further investigation is necessary! He has to check immediately which work has been performed with this particular tool since its last calibration. All aircraft, engines and components whose Release to Service (RTS) was based on the use that item of calibrated equipment are potentially noncompliant with the required specification. An analysis therefore needs to be carried out to determine the extent of any remedial action that may be required on those aircraft, engines or components that are affected by the event associated with the out-oftolerance item of equipment. Additionally all tools of the same kind have to be rechecked immediately. An investigation statement (formless) has to be created showing investigation results. All aircraft, engines or components affected by that event has to be listed in this statement. Form QM 40, the investigation statement and all additional records concerning the internal investigation has to be retained for a minimum period of three years in the calibration file of the affected tool. As a result of investigations the calibration interval may be reduced in cooperation with Avionic Shop. This has to be documented in the calibration file. For further details refer to WPP Interval Reduction If justified calibration intervals may be reduced to avoid inaccuracies in the field of operation of a tool. Therefore Avionic Shop has to be informed, they will change the calibration interval in tool tracking system Interval Extension For tools, whose interval had been reduced, the interval can be readjusted by a maximum of 100% in cooperation with the Avionic Shop, if two further calibration processes have been performed. However, this requires that the last two calibrations did not require readjustments of the tool and the tool was in flawless service. An extension of a calibration interval may only be performed for one single tool but not for several tools of the same kind. chapter 2 page 22

23 2.6 Use of tooling and equipment by staff (including alternate tools) Responsibilities The Maintenance Manager are responsible for the determination of adequate quantity of tools. If necessary he initiates the order of new tools. He is responsible for the complete return of all tools to Stores. They have to control of completeness and good condition of every tool used upon the basis of the store tool list. Every NAYAK CSC staff which is handling or using tools is responsible for: carefully handling of all tools immediate reporting to the Maintenance Manager in case of identified hazards or problems with tools, as well as reporting of every loss of tools check of completeness, proper function and check intervals after receiving and return to the store complete return of every tool before leaving NAYAK CSC Description The respective staff is responsible for the completeness, serviceability and location of the tools he received from the store. This person has to ensure at all times, that no tools remain on or in an component after the performance of maintenance activities. Tool controls have to be performed independently by this person after changing the work location from one component to another, after the performance of each task as well as at the end of a duty period. Before an component is handed over to flight operations, each individual staff has to ensure that no tools, equipment or other supplemental maintenance material remains on these component. Deviations from this procedure have to be reported immediately to the maintenance Manager. All tools must be handled in accordance with manufacturer requirements and procedure and in accordance with manuals and legal requirements. This may be ensured by additional instructions or training and employment of suitable personnel. Should a tool be found to be in an unuseable condition the tool has to be taken out of service by that personnel. The details of unserviceability have to be recorded on an unserviceable label. Unserviceable tools may only be brought back to service if appropriate inspections or repairs have been performed. chapter 2 page 23

24 Should any tool be lost, an immediate search has to be performed of the respective work areas, questioning of other staff, or a complete tool check for the whole shift or even all staff present. If a tool cannot be found or retrieved, the respective person has to file a tool loss report (Form HL 02). On this form the person concerned has to confirm, that the search has not been successful and no hazard or danger exists for flight operation. This report has to be countersigned by the Maintenance Manager, via the Safety Quality & Complinance Department and forwarded to the Tool Keeper, for tool replacement. Tools have, if applicable, to be returned to the store completely and in a serviceable condition. Upon return of tools to the store, an additional visual check is performed by store personnel for completeness and serviceability. The return booking has to be performed by the staff who initially received the tools in conjunction with store personnel. After the return to the store, all tools have to be appropriately stored. If tools should not be returned properly or not returned at all, the tool store personnel has to inform the respective Department Manager. He will initiate the return of the tool in accordance to the requirements Use of new and/or additional tooling All new and / or additional tooling will be implemented into AMOS: Before first use to make sure that: the needed calibration / safety at work related data will be tracked the Instruction Manual will be linked to Tool Administration the tool can be verified by allocating an Asset number the tool will be linked to respective work cards technical personnel will be informed about availability and use if not documented in a manual If a new Tool needs specialized Training; the affected technical personnel will be trained as required Additional tooling and equipment If during maintenance process there is a need for the use of tooling and / or equipment not recommended by the manufacture, the Maintenance Manager will review the request and will take care of delivery of the tool and / or equipment after approval Alternative specific- or special and equivalency tooling and equipment Specific- or special tooling and equipment specified by the manufacturer shall be used as much as practicable. If specific- or special tooling specified by the manufacturer is unavailable, alternative / and equivalency equipment may be used. chapter 2 page 24

25 The term "equivalency" as used means functionally equivalent to that recommended by the aeronautical product or aircraft manufacturer. For determining equivalency, a comparison should be made between the technical specifications of the tooling or test equipment recommended by the manufacturer and those proposed by the maintenance organization. The tooling or test equipment may look different, be made of different materials, be a different color, etc. However, as long as the tool or test equipment is functionally equivalent for the specific test or check, the tool may be approved for use. The level of accuracy should be equal to or greater than that recommended by the manufacturer. A finding of equivalency can only be made based on an evaluation of the technical specifications and sometimes the demonstrated functionality of the proposed tooling or test equipment. The substantiation may include, but not be limited to data, drawings, specifications, instructions, photographs, templates, certificates, description of any software, the revision status of that software and reports. In the case of calibration equipment the substantiation should also include data sheets attesting to the accuracy. An assessment of a finding of equivalency must be made by persons with appropriate skills or qualifications. For further details refer to Form (Tool Test Card) QM 41. This Form should be linked and recorded in the tool register of AMOS indicating that the source of the data that the tooling or test equipment was manufactured from. An Assessment of the maintenance instructions may be required to determine the need for change as a result of using alternative equipment. The approval of work instructions can only be made based upon an evaluation of technical data. Typically the substantiation would contain a breakdown of the step by step instructions required by the manufacturer and the equivalent process proposed by the maintenance organization. The substantiation may include, but not be limited to data, drawings, specifications, instructions, photographs, templates, certificates, description of any software, the revision status of that software and reports. Where the tooling or test equipment is locally made from data provided by the equipment or aircraft manufacturer then no approval is required. Notes: The use of highly specialized test equipment and tooling is often required to support the continued airworthiness of aircraft or aeronautical products to the manufacturer's specifications and tolerances. Critical Design Configuration Control Limitations (CDCCL) are airworhtiness Limitations. When the manufacturer provides or recommends specific equipment they may not condone any tooling or test equipment other than what they recommend. However if a substantiated claim supporting the use of alternate test equipment is provided to the aircraft or aeronautical product manufacturer they may support the application. chapter 2 page 25

26 2.6.5 Procedure to approve the use of alternative tooling and equipment after manufacturing The Maintenance Manager shall evaluate if alternate tooling or equipment for specific- or special tooling and equipment is recommended by the manufacture is equivalent. To determine equivalency, the proposed alternative tooling shall meet the same criteria for the tooling or equipment as specified by the manufacture in the maintenance manual. The following subjects will be investigated: comparison of original specifications with proposed alternative in: Material Ref. Drawings Pressure (if applicable) Loads Safety Working Requirements in case specifications of the originally required equipment are not available, the Maintenance Manager will evaluate what manufacturers test requirements are, including accuracy, and will check if alternate equipment will meet those requirements as above. Before the tooling can be used into production a safe evaluation check will be made acc. to Form WS 17. Alternate tooling which meets not the requested requirements are not allowed to be used. For further details refer to WPP Loaned tooling and equipment Tooling and equipment for single maintenance activities can be leased for short time use. Only Part-145 approved maintenance organisations shall be used for the loan of calibrated related aircraft tooling to ensure that calibration criteria met. Also the criteria of equivalency have been met as listed in Production Planning will have the responsibility to ensure that these criteria will take place. For further details see Working Place Procedures WPP 602 chapter 2 page 26

27 2.7 Cleanliness standards of maintenance facilities Responsibilities All NAYAK CSC staff are responsible for a clean and tide work area during maintenance Description As a general all facilities are cleaned at regular intervals (ref. to WPP 102). For Foreign Object Debris / Foreign Object Damage (FOD) prevention all work and workshop area has to be cleaned after completion of maintenance or at the end of the work. Also all vehicles (e.g. forklifters) have to be checked and cleaned. All tools have to be cleaned, checked for completeness and returned to their position/area. All equipment (e.g. trolleys, etc.) have to be put to their designated areas (ref. to WPP 602). Eating and drinking in working areas is not allowed. Special lables installed on the entrance doors substantiate the prohibition. chapter 2 page 27

28 2.8 Maintenance instructions and relationship to aircraft / aircraft component manufacturers instructions including updating and availability to staff Responsibilities The Maintenance Manager is responsible for the availability of the latest amendment of the needed manuals. He / she has to ensure that work will be performed in accordance to this technical documentation. It needs to be assured that: registration of incoming documentation acquisition and control of documentation inventory distribution of documentation if needed information of the users of available documentation inventory and location complete and up-to-date documentation which has been published for use archiving of technical documentation All publishers and users of technical documentation have the responsibility of the proper and careful use of documentation Description Technical Documentation represents all quality-, legal- or safety-relevant documents and data which are necessary for NAYAK. Technical documentation is issued by manufacturers, aviation authorities and maintenance organisations. It can be available in various media, such as printed form or electronic data. All maintenance documentation (e.g. AMM, IPC, SRM, etc.), required by technicians for performing work, are available as hardcopy, on CD-Rom, at NAYAK Intranet or via Internet by online access. New technical documentation supplied has to be registered and a decision is made about the method of ordering, control, distribution and administration by the Maintenace Manager shops. chapter 2 page 28

29 If technical documentation will be received, which is not applicable or not readable in an electronic format or not distributed in such a format, the Maintenace Manager has to ensure, that this documentation is not accessible for users, and that the documents do not reach the revision process. Documents, which are subject to revision, the Maintenace Manager has clearly marked and distributed them to dedicated personnel. Documents and data, which are not subject to revision, had to be separated and clearly marked with a statement (stamp, label or hand written) declaring "NO REVISION SERVICE, FOR INFORMATION ONLY" If not defined otherwise, changes on documents or data are not permitted. Otherwise they have to be checked and approved by the same person who was responsible for the initial issue. In order to ensure a current revision status, new revisions have to be incorporated as soon as possible, the incorporation has to be documented and reported back to the Maintenace Manager. As a principle, technical documentation may only be destroyed with the consent of the Maintenace Manager. A distribution list is included in the current documentation inventory list. This serves as a record for the actual storage location of technical documentation. For further details see Working Place Procedure WPP 407. chapter 2 page 29