AeroEd Inspection Services, LLC. (AIS)

Transcription

1 AeroEd Inspection Services, LLC. (AIS) FAA Repair Station # O64R443Y Repair Station And Quality Manual Printed: 24-Oct-06

2 BLANK 13-Sep-06

3 Table of Contents List of Effective Pages Section...1 Effective Pages...1 Document Distribution List...2 Repair Station Manual...1 Compliance, Approval & Acceptance Record...2 RSM 01 - Introduction...3 RSM 02 - Organization and Responsibilities...4 RSM 03 - Personnel and Roster...6 RSM 04 - Operations, Facilities, Equipment, Materials, and Data...7 RSM 05 - Capability List RSM 06 - Certification, Training, Drug and Alcohol RSM 07 - Work Away From Station RSM 08 - Air Carrier Maintenance (Parts 121,125,135, & 129) RSM 09 - Contract Maintenance RSM 10 - Records RSM 11 - Repair Station Manual Revisions and Control System Quality Manual...1 QM 01 Inspections...2 QM 02 - Continuity of Maintenance and Inspections...6 QM 03 - Inspection Personnel...7 QM 04 - Technical Data...8 QM 05 - Tools and Equipment Calibration...9 QM 06 - Taking Corrective Actions on Deficiencies QM 07 - Reporting Failure, Malfunctions & Defects QM 08 - Operations Compliance Auditing & Corrective Action Process QM 09 - Capability List and Process for Making Changes QM 10 - Quality Control Manual Revision and Control System QM 11 - Control of Inspection Records QM 12 - Repair Station Forms Index FAA Form 337 Major Repair/Alteration FAA Form Authorized Release Certificate FAA Form Suspected Unapproved Parts Report FAA Form Malfunction or Defect Report FAA Form Airman Certificate Application Approved Contractors - AIS Form Work Instruction Sheet - AIS Form Equivalency Tooling Acceptance Form - AIS Form Training and Needs Assessment Record - AIS Form Red/Green Tag System AIS Forms 18 and 18A Shipping & Receiving Inspection Log AIS Form Corrective Action Request Form - AIS Form Vendor Inquiry/Audit Form - AIS Form Calibrated Tool Data Sheet - AIS Form AIS Roster of Supervisory and Mangement Personnel - AIS Form Repair Station Return to Service / Stamp Roster - AIS Form Inspector Roster - AIS Form Capabilities List Change Checklist AIS Form Workstation Turnover Log - AIS Form Instructions for Collecting Multimedia Borescope Inspection Assets Sep-06

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5 Document Distribution List Revision # Date Assigned To (Person or Location) Title/ Organization Contact Information Original 8-May-06 FSDO FAA Original 8-May-06 File Cabinet, Director of Operations AeroEd Aug-06 FSDO FAA Aug-06 File Cabinet, Director of Operations AeroEd Sept-06 File Cabinet, 145 Room AeroEd Sep-06

6 BLANK 13-Sep-06

7 Repair Station Manual Page Effective: 8-May-06 Repair Station Manual - Page1 of 1

8 Compliance, Approval & Acceptance Record By signing this page you are officially recognizing you have read, understand and approve the contents of this manual and will personally comply with the requirements of this manual and provide the leadership and guidance to assure all employees of this facility receive proper training, tools, supplies required to comply and when necessary will take the appropriate actions to assure the company is in compliance with this document and all applicable regulatory requirements. Managing Dir.: Date: Dir. of Operations: Date: Chief Inspector: Date: Employees of this company by attending and signing the training record has agreed to comply with the requirements of this document and understands that any intentional violations to State, Local and Federal Laws and these company operational procedures will result in disciplinary actions and possible termination of employment. The following FAA Flight Safety District Office of Rochester, NY has accepted this manual for use by AeroEd Inspection Services, LLC Flight Standards District Office #23 One Airport Way, Suite 110 Rochester, NY FSDO Representative: Date: Page Effective: 8-May-06 Repair Station Manual - Page 2 of 22

9 RSM 01 - Introduction IMPORTANT NOTE: All records, technical data and files will be made fully available to the administrator and / or any law enforcement official during audits and / or inquiries and all personnel associated with this facility will be professional and cooperate during these audits and inquiries. Any employee not fully cooperating will be subject to disciplinary action and / or termination of employment. This Repair Station and Quality Control Manual (RSM/QM) have been prepared in accordance with the current Federal Aviation Regulations Part 145 for the operation of this Repair Station operated at this location: AeroEd Inspection Services, LLC 90 Air Park Drive Suite 306 Rochester, New York Phone Inspections are issued out of this office by the Director of Operations and may be performed at this location or at the customer s facility. The requirements of this manual are applicable for all work performed by the Repair Station (RS) in the base facility or away from station. 1.1 Scope of Operations and Limitations This Repair Station is authorized to do inspections, and is limited to engines and related components on various aircraft in accordance with FAA Operations Specifications. These inspections are performed to documented procedures approved by the Air Carrier, Owners, Manufacturer s operating and maintenance manuals or other acceptable / approved technical data documents to include, when applicable, Airworthiness Directives and FAA DER approved procedures. Inspections are performed by the following nondestructive methods as listed on the Operations Specifications: Visual Borescope Inspection AeroEd Inspection Services will not operate as a certificated repair station without, or in violation of, a repair station certificate, ratings, or operations specifications; and once the certificate and operations specifications are issued to AeroEd Inspection Services they will be kept on the premises and made available to the public and the FAA. This Repair Station operates as a contracted Repair Station agency performing inspections and repairs as directed by the aircraft owner or authorized aircraft operator. This Repair Station is limited to only performing the inspections and repairs as specified on the Operations Specifications. This Repair Station WILL NOT authorize or perform any maintenance, inspections or repair functions not authorized by the Operations Specifications and Capability List. The responsibility for an Aircraft s Continuous Airworthiness and Maintenance Program resides with the aircraft owner, aircraft operator or designated authority. The customer is responsible for identifying all maintenance, repairs, inspections, and other operations necessary for the safe operation of the aircraft. The work scopes contracted to AeroEd Inspection Services may provide a portion of the needed operations to administer an effective program however; this should not be considered as a substitute for the Air Carrier or Operator s maintenance program. Page Effective: 8-May-06 1-Aug-06 Repair Station Manual - Page 3 of 22 1

10 RSM 02 - Organization and Responsibilities Organizational Chart Managing Director (585) Accountable Manager Chief Inspector (585) Primary: Calibration & Scrap Director of Operations (585) Primary: Drug & Alcohol, Tech Data Director of Training (585) Primary Quality and Training Inspectors/Technicians Office and Facilities Instructors 2.1 Managing Director Responsibilities of the Managing Director include providing the adequate resources (funding, tools, material, personnel, training etc) necessary for complying with all applicable regulatory and customer requirements. This position can delegate responsibility to other positions throughout the organization however; it does not relieve this position of the overall responsibility for total compliance to regulations, state and local laws applicable to this facility. 2.2 Director of Operations The Director Operations is the accountable manager designated by the Managing Director as responsible for and having the authority over all repair station operations that are conducted under FAR Part 145. Director of Operations is in charge of all Inspection and Maintenance work. These duties include: 1. Ensuring that personnel follow regulations and serving as the primary contact with the FAA. 2. Reviewing and authorizing work scopes inspections 3. Providing and obtaining adequate training, equipment, material and competent personnel pertinent to the operations of the Repair Station in order that it may comply with all applicable Federal Aviation Regulation (FAR) requirements and manufacturer recommendations 4. Assuring that proper inspection records, reports and forms used by the Repair Station are properly completed 5. Assuring the customer receives all reports and records applicable for the work performed 6. Assuring completed work scopes are given to the Chief Inspector for review and filing 7. Administering the FAA Drug and Alcohol Abatement Program 8. Maintaining personal FAR 65 certification 2.3 Chief Inspector The Chief Inspector is directly in charge of all Inspection work and is responsible for administration of quality assurance activities within the organization. These duties include: Page Effective: 8-May-06 Repair Station Manual - Page 4 of 22

11 1. Assigning qualified Inspectors to perform work 2. Providing technical authority for manual and specification interpretation 3. Maintaining a database of inspection equipment and generating the necessary recall notices. 4. Maintaining calibration system with traceable records 5. Maintain revisions and distribution of this 6. Providing assistance to the Director of Operations 7. Maintaining quality records as required to comply with customers and regulations 8. Control and distribution of inspection documents and forms 9. Final Review / Audit of the work package for accuracy and compliance prior to filing 10. Performing operational audits and leading the Root Cause & Corrective Action process 11. To ensure findings / infractions will not re-occur 12. Maintaining personal FAR65 certification 2.4 Technician/Inspector The Inspector is responsible for: 1. Reviewing customer requirements and completing a Work Order 2. Obtaining assignment or authorization from the Director of Operations for work to be performed 3. Performing necessary equipment calibrations, checks and verifications prior to doing work 4. Properly performing inspections according to the owners / operators / air carrier s technical data or designated procedure and applicable approved technical data 5. Compliance to all technical data and Instructions for the work scope being accomplished 6. Accurately recording the results of all inspections performed 7. Completing all documentation required for the customer 8. Maintaining full knowledge and compliance to this manual 9. Maintaining personal training and qualifications as required by the company and maintaining personal FAR65 certification 2.5 Back-Up Responsibility The Chief Inspector can delegate responsibility among the organization personnel based on their training, experience and qualifications shall this person be unavailable to perform the role. This delegation must be authorized in writing and communicated to the organization. In the absence of the Chief Inspector the Director of Operations can delegate the Chief Inspector s responsibilities to qualified Inspectors only. 2.6 Director of Training The Director of Training is responsible for maintaining the required level of training for the entire organization, and for maintaining a staff of training personnel or contracting outside sources to satisfy the requirement. The Director of Training can delegate responsibility among the organization personnel based on their training, experience and qualifications shall this person be unavailable to perform the role. This delegation must be authorized in writing and communicated to the organization. In the absence of the Director of Training the Director of Operations can delegate the Director of Training s responsibilities to qualified Instructors. Page Effective: 8-May-06 Repair Station Manual - Page 5 of 22

12 RSM 03 - Personnel and Roster 3.1 The Chief Inspector will maintain the personnel rosters in a separate file in the quality office. All rosters will have the name, certificate number, qualifications and indicate the air carrier for which the individual is qualified Return to Service when applicable. The Chief Inspector will submit any changes of the roster to the Director of Operations within 5 working days. This facility will maintain the following Rosters: Return to Service Roster: This Roster will indicate the Name, certificate number of the employee. No person can be listed on this Roster without being FAA CFR Part 65 certified, active in the Drug & Alcohol program and have an active, up-to-date training record according to the RSM/QM. Management, Supervisor and Inspection Roster: Qualifications This Roster will indicate the name of the personnel who are trained and authorized to supervisor and / or perform work for this repair station. This roster will show the name, certificate number, authorizations issued by the Chief Inspector. No person can be listed on this Roster without being FAA Part 65 certified, active in the Drug & Alcohol program and an active, up-to-date training record on file with this facility. Supervisors and Inspectors listed on this roster that are authorized return to service will be given a qualifications card indicating the authorization no person can perform return to service for this facility without proper documented proof FAR, Manual, Form and Return to Service training. This training will be done on a bi-annual bases. Inspectors must be qualified according to this Repair Station s Training Manual; see separate Training Manual document addressing FAA FAR Part Employment Summary Each person listed on the rosters will have a file in the Director of Operations office containing an employment summary according to FAA FAR Part A summary of the employment of each individual whose name is on the personnel rosters required by paragraphs (a)(1) through (a)(3) of this section. The summary will contain enough information on each individual listed on the roster to show compliance with the experience requirements of this part and will include the following: a) Present title, b) Total years of experience and the type of maintenance work performed, c) Past relevant employment with names of employers and periods of employment, d) Scope of present employment, and e) The type of mechanic or repairman certificate held and the ratings on that certificate, if applicable. Example of Rosters are located in section QCM 12 of this Manual. Page Effective: 8-May-06 Repair Station Manual - Page 6 of 22

13 RSM 04 - Operations, Facilities, Equipment, Materials, and Data The repair station fixed location is in a brick/steel building located at 90 Air Park Drive, Rochester, NY, The facility is approximately 1350 square feet of floor / office space with 120 square feet dedicated to Repair Station Activities. This facility has heating, air conditioning, security, and a fire sprinkler system incorporated into the building. The AIS offices are located in Suite 306 on the 3rd floor of the building on the east side. Access the front door by turning left out of the elevator, proceeding through a glass door to the end of the hall and then turning left. The front door is clearly labeled. The facility houses the procedures, files and Borescope Inspection Equipment used to perform the work scopes for the repair station. If the repair station changes location, the FAA will be notified within 30 days. If the layout of the repair station is significantly changed so as to affect the procedures defined in this manual, the FAA will be notified within 30 days of the change. Shop / Office Layout (Not to Scale) Page Effective: 8-May Sept-06 Repair Station Manual - Page 7 of 22 1

14 The following steps are performed to complete customer inspections: 4.1 Receipt of customer parts (for parts shipped to the fixed location) 4.2 Contract Review 4.3 Inspection Process 4.4 Inspection Documents 4.5 Returning Parts to the Customer 4.6 Purchasing Inspection Materials 4.7 Shipping 4.8 Technical Data 4.1 Receipt of Customer Parts Upon receipt of items being sent by the customer to the Repair Station, the following shall be reviewed: a. Shipping Damage -- Shipping containers and received parts shall be inspected for any evidence of mishandling and instances where any aircraft parts may have been lost or damaged in the shipping process. b. Identification of Parts All tags, packing lists, certifications, prints, etc. shall properly identify the received items. c. The Shipping/Receiving Inspection Log shall be completed and any discrepancies noted at this time on the Shipping/Receiving Inspection Log (AIS Form 22). The customer shall be contacted and notified. The customer will determine the disposition of the items Identification and Traceability of Parts a. Prior to beginning a customer order, the operations will assign a unique job number. Job numbers may be obtained from network computer terminals. b. The Job Number contains the letters prefix AIS for the appropriate department or activity involved then a sequential digit numbers issued sequentially. c. Administration shall maintain the Job Numbers database listing the number issued along with the corresponding customer name, location, and date the parts were received. If known at the time, the Purchase Order Number and type of test to be performed will be included. d. A job folder labeled with the Job Number to be used for identification information to the Director of Operations. e. All reports, data sheets, and other quality records generated specific to a customer order shall be identified with the AIS Job Number and be maintained with the items or job folder Handling of Parts All items or components undergoing inspection shall be handled in such a way as to prevent damage while under the control of the Repair Station Storage Aircraft parts that are not being immediately inspected shall be placed in a secure or locked area. Page Effective: 8-May-06 Repair Station Manual - Page 8 of 22

15 4.2 Contract / Job Acceptance Procedure AIS Representative will open a job order in the computer database system and enter the information as required on the form AIS representative will accept the customer request and obtain the contact persons name, phone number, serial number of the engine to be inspected, hours and cycles of the engine, date work is being requested and location where work is to be accomplished Customer will acknowledge their responsibility to provide a work area that is protected from the elements, has available electricity, compressed air and any lifts, ladders, work benches, or other equipment requested by AeroEd Inspection Services. Customer will acknowledge their responsibility to provide the current maintenance manual and AD notes for the article to be inspected. It is highly unlikely that a remote visual inspection will require any Hazmat considerations, however, the Customer will acknowledge their responsibility to inform AIS about any possible Hazmat issues related to the inspection according to FAA FAR Part AD Notes should be verified on the FAA Website at: Currency of Technical Documentation should be verified by the Director of Operations, his delegate, or the Inspector with the OEM; or, if the customer is under FAA Part 121 Regulations, the Air Carrier's responsible person. Operations will then develop a quote for the job and when required, review with the quality department to ensure compliance to the operator and company procedures. The quote will be sent to the customer for review and acceptance. The company will use either , fax, or postal methods for delivery of all correspondence. The customer will acknowledge and enter into the contract by signing and returning the quote back to AeroEd Inspection Services using any of the above methods of delivery. Once AeroEd receives the signed quote back from the customer the Director of Operations will enter the job start in the database, obtain any necessary foreign clearances with respect to D100, work away from station, and notify the appropriate departments to ensure a smooth job process. Once the job is completed the job file will be closed in the computer database and kept as record for as long as required by this manual Review of job requirements Contracts and purchase orders are reviewed to ensure that job requirements are defined and meet customer requirements prior to beginning work. Contracts and purchase orders may be reviewed by the Director of Operations or Chief Inspector. Before accepting all contracts and purchase orders, the following items must be reviewed and agreed upon by both AIS and the Customer: 1. Availability of the procedure or specification (including revision) 2. Inspection procedure approvals procedures must be FAA approved or provided as part of the aircraft s operations manual 3. Availability of qualified inspection personnel 4. Availability of inspection equipment and calibration current, if required 5. Job Folder, tools and technical data to be supplied by the customer / air carrier will be available before work begins Requirements of the customer s Repair Station Manual or other operating documents When performing work for a customer under the authority and/or supervision of another FAA approved authority (such as those operating under FAA Part 121, 125, and 135), the AIS Inspector must consult with the customer s authorized personnel and comply with the operator s inspection requirements including receiving specific training on the inspection of the component Page Effective: 8-May-06 Repair Station Manual - Page 9 of 22

16 when required, completion of the customer s paperwork, and receiving authorizations. If any requirements are conflicting with this Repair Station Manual, the requirements of the customer s Repair Station Manual and supporting documentation shall take precedence. The AIS Inspector will contact the Chief Inspector for any guidance in this situation Completion of the Work Order If AIS is capable of completing the work as requested, acceptance of the contract shall be documented by completion of the Work Order. The work order shall include: Inspection procedure that was used including revision and/date of revision Details of the actual procedure used where the procedure allows for variables Special instructions provided by the customer will be noted Engine hours and cycles will be verified and noted on the work order prior to the Inspector closing the work order and issuing the release document Engine serial number and tail number of aircraft, if applicable Contact information for responsible customer personnel Once the Work Order is complete, the Director of Operations shall review and approve by initialing. The Director of Operations is then responsible for assigning qualified personnel to perform the inspection. All assignments must use a job package with a minimum of the following: Customer work order / instructions Turnover log Copy of the Copy of the Instructions for Collecting Multimedia Borescope Inspection Assets Safety tags Copy of the Operator and/or OEM work instructions, i.e. Engineering Orders (EOs), Routers, Technical Manual (TM), Maintenance Manual (MM), Job Cards, etc. the required items (minimally the current Maintenance Manual) will be obtained from the customer per contractual agreement. The inspector should verify current maintenance manual and AD notes for the article to be inspected by contacting the OEM or 121 responsible person Contract or Purchase Order Amendment Contracts or purchase orders may be amended as necessary to resolve any problems and to ensure requirements may be met. When agreed upon by the customer, the Inspector shall make revisions and amendments to the work order upon acceptance and, if applicable, notify any other personnel involved with work-in-progress. Acceptable methods of this documentation include obtaining a revised contract or purchase order from the customer or having the customer issue an amendment referencing the purchase order number and describing the changes. Page Effective: 8-May-06 Repair Station Manual - Page 10 of 22

17 4.2.6 Performance of Inspection at a Location Other Than the Repair Station AIS will perform its remote visual inspection services under the D100 Op Spec, Section (c) Recurring Basis. Specific information on performing work away from station on a continuing basis is defined in this RSM/QM, Section RSM 07 Work Away from Station. AIS will provide services for customers on an on-call basis at a place away from the repair station. According to Op Spec D100 this will be accomplished by moving facilities, material, equipment, and technical personnel to perform specific maintenance functions. AIS can only provide this service for work for which the repair station is rated. Only the Director of Operations and Chief Inspector or delegates thereof are authorized to initiate a Work Order for such work. 4.3 Inspection Materials Only materials that meet the requirements specified per the inspection method are allowed for use. 4.4 Material Storage The Director of Operations is responsible for maintaining the inspection materials storage areas. Storage areas for inspection areas shall be in-doors, controlled and not subject to freezing temperatures. 4.5 Shelf Life The Director of Operations shall be responsible for the shelf-life program. Age-sensitive materials shall be marked with expiration dates. This expiration date shall be in accordance with manufacturer s recommendation unless specifically approved by the Chief Inspector. The Chief Inspector shall review the storage areas quarterly to ensure all inspection materials have not exceeded the expiration dates and that all materials remain in good condition. 4.6 Purchasing of Inspection Materials This requirement is for the purchase of materials used as necessary to complete inspections and NOT for any materials or parts that are part of the maintenance or operation of the aircraft such as lubricants, coolants, etc. AIS shall not purchase, distribute, or provide any materials other than those used by AIS to perform inspections Purchase Order A purchase order shall be completed providing a description of the materials, including any catalog numbers or positive identification of the item to be purchased. Any technical specifications shall also be included, when applicable. The Chief Inspector shall approve purchase orders for the purchase of materials Upon receipt of materials, the following shall be performed: a. Purchased inspection materials shall be reviewed for any shipping damage. Materials shall be inspected for any evidence of mishandling and instances where any materials may be damaged or contaminated. b. Identification Materials and/or containers shall be properly identified with batch numbers. c. All incoming material shall be inspected for quantity, quality, conformity to Specifications and the status of preservation. d. Material Shelf Life Any materials used for inspections that may degrade or expire after time shall be identified with the expiration date. Page Effective: 8-May-06 Repair Station Manual - Page 11 of 22

18 4.6.3 Inspection Materials Inspection materials shall be kept in established areas for use. Materials shall be placed so that older stock is used first provided it is not beyond manufacturer s specifications. 4.7 Shipping and Transportation of Tools and Inspection Equipment When inspection equipment and tools are shipped, they shall be shipped via a qualified carrier with the equipment and tools insured for full replacement value. Any exception to this can only be made by the Director of Operations. Any calibrated tool that has been shipped or transported must be checked by the inspector or other qualified individual for damage and out-of-calibration according to the manufacturer's recommendation and specification immediately upon receipt. 4.8 Technical Data AIS will use technical data obtained from customers, storage programs, and air carriers to ensure that the inspection is carried out in accordance with the most current technical documentation available. See section QM04 for information of storage of Technical Data. This repair station manual requires that appropriate technical documentation for the inspection be provided by the customer, storage program, or air carrier. Page Effective: 8-May-06 Repair Station Manual - Page 12 of 22

19 RSM 05 - Capability List 5.1 Capability List The capability list will be updated / revised maintained by the Chief Inspector. No additional capability changes can be made without first performing an audit of the following items and ensuring the proper requirements are in place. This is accomplished using the capability list change checklist in section QM 12 of this manual. Once the Chief Inspector has completed the audit and is satisfied the proper qualified personnel, tooling, technical data, RSM & QM revisions are in place and the local administrator finds the changes acceptable, the change official and the repair station is then allowed to perform that work. The audit form will be attached to the new capability list as a permanent record and kept on file in the quality department. This repair station will not accept or authorize its employees to perform any work that is not listed as part of the capability listing. The capability list will be maintained under separate cover in the Quality Department. See section QM09 for procedures. Page Effective: 8-May-06 Repair Station Manual - Page 13 of 22

20 RSM 06 - Certification, Training, Drug and Alcohol 6.1 Training and Certification of Personnel Training and certification of personnel shall be in accordance with AeroEd Inspection Services training and certification program which meets all requirements of FAA. Current records of employee training and certification will be maintained by the Director of Operations. The records will indicate the type of training (detailed), method, duration and date of completion. Certification will based on previous training, work experience (documented) and the Chief Inspector may request written testing, on job observations or oral reviews to determine an individual s proficiency level prior to issuing a certification card. A roster of management and inspection personnel will be maintained by the Chief Inspector. This roster will indicate the employee s certifications and expiration dates and will be kept current at all times. All changes to the roster will be communicated to the FSDO within 24 hours of the change. Inspectors will be issued a card to show proof of the work scopes and qualifications authorized to perform for the repair station. Return to Service employees will be trained on the use of All employees will receive RSM & Quality Manual, Human Factors and FAR immediately upon new hire, or prior to performing any work for the repair station. 6.2 Training Program Summary See separate Training Manual for more Details Initial Training (To be completed immediately upon new hire, or prior to performing any work for the repair station) a. Repair Station & Quality Manual b. Integrity & Quality requirements c. Human Factors d. Federal Aviation Regulations & other applicable regulations e. Airworthiness Release (8130-3) f. HAZMAT (According to 14 CFR ) Note: AIS will review past work experience and training provided as part of the hiring process, when employees have previous experience and training they will be required to prove job proficiency through OJT and / or oral testing with the AIS quality department. Once a candidate successfully meets AIS requirements the quality department will list the individual on the roster with tasks the individual is authorized to perform for the repair station Recurrent training (24 month period) a. Repair Station & Quality Manual b. Applicable regulatory training (FAR s, Local, State other governing bodies) c. Human Factors d. Aircraft & Engine models (job / task specific) Note: AIS may provide OJT / Classroom training on the above listed requirements and will adjust the 24 month requirement date to show currency for the individual. If the employee has performed the job a minimum of two (2) times within the past 24 month time frame, recurrent training is not required. If the job has not been completed (2) times within the past 24 month time frame, the person is required to complete re-currency training. Page Effective: 8-May-06 Repair Station Manual - Page 14 of 22

21 6.2.4 Training Program Revisions See also Section 7 of AIS Training Manual The person responsible for making and submitting training program revisions is the Director of Training. Revisions are to be submitted to the FAA and the Director of Operations. Revisions are to be submitted to the FAA after final determination and internal approval of the actual training needs based on review, audit, or other. The process for submitting changes is to submit the reason for the change, the proposed change, and an effective date to the local FAA FSDO. Documents are to be submitted on printed hardcopy and/or on CDROM in Adobe PDF format. Revisions to this document will be recorded and indicated using the same methods as specified in RSM Section Training Program Procedures AIS has procedures that establish and maintain proficiency and familiarity of inspection personnel in the following: Applicable regulations Inspecting the articles they are assigned to inspect As a part of AIS Initial training, see RSM Section 6.2.1, inspectors are provided with training materials that cover the basic regulatory information they need to do their job. This includes general knowledge of applicable sections of 14 CFR Part 145 from this manual. The director of Operations will review Title 14 CFR Part 145 on a yearly basis, usually upon release of changes to the code, for changes to applicable regulations and will facilitate notification of inspection personnel on the regulatory changes. Tools for finding current regulations can be found on the internet at: List of CFR Sections Affected. Before inspectors can appear on the inspection roster for a specific assigned article to inspect, they must satisfy section 3.1 of this Repair Station manual and have applicable training and/or work experience within the specified limits for recurrence. If not, needs analysis will indicate the requirement for initial or recurrent training. Training must then be provided and successfully completed via instructor-led, computer-based training, or other means deemed acceptable by the chief inspector before that inspector may perform an inspection on such article. 6.3 Drug & Alcohol Program All personnel performing inspections under this repair station shall be covered under AIS s or other FAA Approved Drug and Alcohol Abatement Program. Administration of this program is performed by an approved testing service and the Director of Operations maintains all records. The Director of Operations will notify employees randomly selected to report to the collection center. The procedure for this process is maintained by the collection center Employees failing or refusing to comply with these requirements are automatically suspended and will be removed from the inspection roster immediately. Any work performed by this individual will be recalled and reviewed by the Chief Inspector and any issues will be discussed with the Local FSDO. Employees will only be returned to Roster status after all investigations have been completed and the FAA is agreeable all conditions are acceptable to the administration. Page Effective: 8-May Sept-06 Repair Station Manual - Page 15 of

22 RSM 07 - Work Away From Station 7.1 AeroEd Inspection Services performs Borescope Inspections on turbine engines and this work typically takes place on the aircraft or in the customers storage / maintenance facility. This requires AIS to travel to the location with equipment and required job records. All work accomplished away from the station will done in the manner outlined in this Repair Station and Quality Control Manual. The Director of Operations and / or Chief Inspector will assure the location where the work is to be accomplished satisfies the requirements outlined in Section RSM 4. The customer / operator is responsible for providing the applicable technical data in its most recurrent revision to AeroEd Inspection Services prior to any inspection / repairs being accomplished. If there is any confusion or misunderstanding between the customer requirements and / or AeroEd procedures the AeroEd employee will report these issues to the Chief Inspector and /or the Director of Operations immediately. The Chief Inspector and / or the Director of Operations will work through the issues with the customer. OpSpec D100 Since this repair station's primary mission is to perform remote visual borescope inspections on a recurring basis, its procedures, found in section 4.2 of this manual, are designed to satisfy the requirements of the D100 OpSpec. AIS will furnish its own equipment for performing the inspections. Where additional or specialized tooling is required, AIS will obtain the necessary items through lease agreement or customer arrangement. If it is not possible to obtain the necessary or equivalent tooling, it is not permissible to conduct the inspection until that requirement is satisfied. AIS will maintain a permanent fixed location in the country of domicile even though its work will be done inside and outside the country at customer locations, storage facilities, and other facilities where engines are located. a. Tools and equipment will be shipped according to procedures stated in Section 4.7 of this manual. b. Tools and equipment will have calibration maintained according to procedures stated in Section 4.7 of this manual. c. Procedures to ensure that only qualified personnel perform inspections are found in section 3 of this manual. d. Procedures to ensure that all air carrier maintenance programs are followed are found in section 8 of this manual. e. Procedures to ensure that all forms are properly completed are found immediately following each form example in the forms section of this RSM/QC manual. This repair station will perform work away from its fixed location on a recurring basis. This work will be performed under the procedures set forth in this manual. Only the Accountable Manager or Chief Inspector may initiate the forms associated with performing work at a location other than the repair station. It should be noted, however, that the Work Order Package may be initiated and completed after the maintenance has been accomplished and will include only those forms applicable to the job work scope. The work scope shall be limited to those maintenance or inspection actions that can be accomplished with personnel, equipment, material, tooling, and technical data that can be transported to or are available where the maintenance will be performed. Therefore, upon Page Effective: 8-May-06 Repair Station Manual - Page 16 of 22

23 initiation of a request for off-location work, the Accountable Manager or Chief Inspector shall request that the customer provide as detailed a description as possible of the discrepancy(ies), as well as the location of the article. This information shall be recorded along with a list of the required personnel, equipment, tooling, and data needed to accomplish the anticipated work scope. Only technicians specifically familiar with and capable of performing the work scope anticipated shall be assigned to perform the maintenance requested. The Accountable Manager or Chief Inspector will assign the technicians. The Accountable Manager or Chief Inspector shall ensure that the personnel, equipment, tooling, and data necessary to accomplish the requested work scope (including the pertinent sections of this manual) are made available to the technicians. The Accountable Manager or Chief Inspector shall ensure that there is adequate and continual communication between the technicians in the field and the repair station. Upon arrival, the technicians shall determine that the location where the work is to be performed is safe and protected from the elements as required by the applicable maintenance data. The exact location of where the work is actually performed shall be documented. If any equipment is used during maintenance other than that originally listed by the Accountable Manager or Chief Inspector, the technicians will record the use of that equipment by listing that equipment by nomenclature, type, manufacturer, and date of last calibration, as applicable. Documentation of the work performed may be recorded in the aircraft and/or propeller log in accordance with 14 C.F.R However, a record of the work performed shall also be entered for inclusion into the Work Order Package which will be generated, to the extent necessary, in accordance with the procedures outlined in this manual. Normally, a Form will not be generated for work performed at a location other than the repair station. However, if a Form is generated, it will be completed as outlined in this manual. Section (b) permits work away from a repair station s fixed location when it is necessary to perform such work on a recurring basis. Examples of a recurring need are found in AC 145-9, page 27. Under section (a). When it is necessary to perform work outside this repair station's domicile country, AIS will obtain any required approvals or clearance from the country where the work is to be performed. When it is necessary to perform work outside its domicile country, the repair station will obtain any required approvals from the country where the work is to be performed. AIS will notify the local CHDO when these special circumstances arise in order to obtain the FAA s approval in each instance. The same procedures for regular work away from station will be observed. The Director of Operations or his delegate will inform the CHDO via telephone or , whichever is most expedient. The approval or denial will be recorded on the job quote form that is part of the work order process. Page Effective: 8-May-06 Repair Station Manual - Page 17 of 22

24 RSM 08 - Air Carrier Maintenance (Parts 121,125,135, & 129) This facility does provide work for air certificate holders under parts 121, 125, and 135, and foreign air carriers or foreign persons operating a U.S.-registered aircraft in common carriage under part 129. This work will be carried out in accordance with the continuous airworthiness maintenance program instructions / technical data provided by the air carrier at the time the maintenance agreement is requested by the operator. Using the air carriers procedures / technical data will ensure the work is done in accordance with the carrier's approved airworthiness and maintenance program and applicable regulations. Once the work request has been accomplished and meets the requirements outlined in the approved technical data / instructions provided by the air carrier. The inspector will review the work, work instructions to ensure the work has been accomplished as required and issue a return to service only for the work performed and provide this to the air carrier. Instructions for completing FAA are in section 12 of the QCM. If there were discrepancies that fall outside the requirements of the air carriers technical data the operator will be notified of the condition and a report issues. AeroEd will not provide a release (8130-3) in this situation until the proper repair has been accomplished and a re-inspection yielding compliance to the requirements has been completed. If the Air Carrier issues a deviation under their authority to accept the condition then AIS will issue the documenting the inspection data used as well as the number of the deviation record stated in block 13 of the form and attach a copy to the release and in the job folder maintained by AeroEd Inspection Services. In cases where the operator requests AIS to sign their logbooks and / or complete Return to Service Inspections then the air carrier is responsible to provide the GMM (General Maintenance Manual), Return to Service (Required Inspection Items) and other necessary training needed to properly comply with their program. The names and approvals of the employees trained for Return to Service inspections under the air carriers program will be listed on the specific Air Carrier's Return to Service Roster located in the Chief Inspector s office. If the work request is urgent and there is not time for the carrier to provide the necessary training then the carrier will provide the necessary qualified personnel to supervise, review and complete the Return to Service Inspection to ensure the work complies with their program. This will be coordinated with the carrier quality department at the time the work request initiation and prior to any work being accomplished The air carrier is responsible for completion of the work necessary under their maintenance program and the final aircraft release. Prior to performing work for or on behalf of a part 121 or part 135 operator, AIS will notify its employees, contractors, or subcontractors that handle or replace aircraft components or other items regulated by 49 CFR parts 171 through 180 of each certificate holder's operations specifications authorization permitting, or prohibition against, carrying hazardous materials. The Air Carrier will provide all Return to Service training and / or approve a trained trainer of this facility to train Return to Service as applicable for this facility and the work the repair station will perform under contract. Page Effective: 8-May-06 Repair Station Manual - Page 18 of 22

25 RSM 09 - Contract Maintenance Not applicable, AeroEd will not contract maintenance tasks. Page Effective: 8-May-06 Repair Station Manual - Page 19 of 22

26 RSM 10 - Records All Maintenance records will be maintained for a minimum of 24 months as required by FAR145. These records / files will be kept in storage in the repair station. The records can consist of hardcopy files / papers or digital media stored on computer disc. The operations department will maintain this records storage and have then readily available for audits / review. Shall it be necessary to store these records off site due to lack of space or other unforeseen reasons then the Operations Department will maintain a list of the records which were moved to off site storage and the location of the storage facility. See Quality Control Manual section QCM 11 Records will be organized using the Job Number system. This job number is issued by the computer database at the time a job request is initiated. The numbers run in sequence and the operations department will maintain a history of the numbers. There will be gaps in the completed job numbers on file because all job requests will not get an agreement / contract due to various reasons (costs, personnel availability etc.) Readily available means 24 hours or one business day whichever is greater - less retrieval time. Page Effective: 8-May-06 Repair Station Manual - Page 20 of 22

27 RSM 11 - Repair Station Manual Revisions and Control System The Repair Station manual for this facility will be maintained in the electronic format by the Chief Inspector. The Chief Inspector is the only person authorized to make manual changes and distribute the manual. Changes / Revisions to the Manual will be noted by the use of a highlighter to make it easy to see what has changed since the last revision. All manual revisions will be submitted to the local FSDO for review and acceptance within 5 working days of the change. This facility will not implement any changes until we have received the FAA acceptance either by or telephone. When a change has been accepted by the FAA the Chief Inspector will make a CD with the new manual revision in a PDF format and distribute it to each person listed on the manual distribution list. This repair station will not use or issue a manual that does not conform to Federal Code Of Regulations. Should this facility determine there is a violation to the FAR s, the Chief Inspector will immediately notify the local FSDO to inform them of the finding and the corrective actions / change which were implemented. The new change will be submitted, accepted and distributed as stated above. All computers use by this facility will have the capability of reading PDF files. It is the responsibility of each recipient of a revised manual CD to open it immediately, contact the Chief Inspector and verify receiving by revision number and return the old revision to the Chief Inspector. The Chief Inspector will collect the old CD manual Version from the employees signifying they have received the new version. The old version CD will be erased / destroyed to prevent retrieval of the old document. Only the Chief Inspector will have all the old revisions of the manual on electronic media for purpose of documenting revision history. Page Effective: 8-May-06 Repair Station Manual - Page 21 of 22

28 BLANK Page Effective: 8-May-06 Repair Station Manual - Page 22 of 22

29 Quality Manual Page Effective: 8-May-06 Quality Manual - Page 1 of 68

30 QM 01 Inspections Inspection Process 1.1 Engine Inspection All required inspections shall be performed as documented on the Work Order using the air carrier s approved Technical Data and / or job cards, Engineering Orders, AD notes, etc. Any special conditions, deviations, or other conditions that arise during the inspection shall be brought to the attention of the Chief Inspector and customer. Deviations to inspection procedures may not be made unless approved by Air Carrier representative or the FAA or authorized customer representative. For more information see the forms section of the Quality Manual Section 12, Authorized Release Certificate Instructions Receiving Inspection Receiving Inspection of articles must check for proper documentation, identification and traceability, shipping damage and contamination, conformity to specifications and acceptable quality, shelf life and state of preservation. All incoming parts and material will under go a receiving inspection process looking for proper release documents (8130-3, Final release under Production Certificate (OEM), customer airworthiness release tag signed / issued by Inspector. Inspection will look for shipping damage, ensure the part numbers, serial numbers match the accompanying documentation. The paperwork will be stamped RECEIVED with signature and date. If there are discrepancies noted during the receiving inspection they will be noted on the reject tag and the material will be quarantined to prevent the use until the issue is resolved. Pictures will be taken and use to show the Shipper and / or customer of the condition so they can assist with resolution. Once the issue is corrected the reject tag can be cleared and removed by the inspector and material issued to the job or stored. Pictures, Documentation will be kept in file for the job number material was received to support. 1.2 Verification of Calibration The Inspector shall ensure that all equipment is calibrated according to the appropriate procedure in the Quality Control Manual prior to performing inspections. The Inspector shall review stickers for due dates, logs, or other indicators showing the calibration status of the equipment. If at any time, the equipment is past its calibration interval or does not appear to be operating correctly, the equipment shall be identified as such and taken out of service until the equipment can be calibrated and/or repaired. The Chief Inspector will keep a Calibration Master log listing all company owned or leased calibrated tools, the current status of the calibration and the date the next calibration is due. Equipment / Tooling which require calibration before use will be calibrated by the user prior to use and any discrepancies will be reported to the Chief Inspector immediately. Equipment / Tooling with discrepancies will be tagged with a reject tag stating the problem and returned to the facility for evaluation and repairs. 1.3 Preliminary Inspections Preliminary Inspection of standard parts and materials must check for proper documentation, identification and traceability, conformity to specifications and acceptable quality shipping damage, contamination, state of preservation, life limits, airworthiness directives and services bulletins, functional test or teardown inspections, FAA approval of new articles, and / or determination of what repairs are necessary. A preliminary visual inspection will be done upon arrival to the job site and prior to performing Page Effective: 8-May-06 Quality Manual - Page 2 of 68

31 customer requested work-scope on the item to determine the condition, state of preservation, or any defects on the items involved. Any observations found during this inspection will be recorded on the applicable Inspection Report when completed. These issues must be resolved before the release form (8130-3) can be issued. 1.4 Inspection for Hidden Damage When inspection is required on a damaged aircraft or component, a thorough and searching inspection in the areas adjacent to the areas for inspection shall be made for hidden damage. The OEM will be consulted to receive the appropriate inspection direction for parts / units involved in accidents, The scope of this inspection will be governed by the type of unit involved with special consideration accorded previous operating history, Malfunction or Defect Reports, service bulletins and AD notes applicable to the unit involved. The inspector is responsible for listing any areas of suspected damage noted during inspection on the Inspection Report and reporting this information to the customer. 1.5 Suspected Unapproved Parts detection and reporting If for any reason the Inspector has reason to suspect that a part, component, or material does not meet requirements and/or has not been approved by the FAA, must report the fact to the AIS Chief Inspector immediately. Reasons for suspicion may include characteristics such as improper (or lack of) identification, incomplete or altered paperwork, a different finish, size, or color. The Chief Inspector will discuss with the owner / operator and assure the proper action is taken. Reporting of Suspected Unapproved parts shall be done by completion of FAA form , which is included in the forms section of this manual. Additional information and details regarding Detecting and Reporting Suspected Unapproved Parts is provided in Advisory Circular AC-21-29B. 1.6 Inspection Documents These documents shall be completed upon finishing the inspection, as applicable to the inspection / repair performed. Sample forms are included in the Forms section in the Repair Station documentation. All these documents shall be provided to the customer and a copy maintained by the repair station as part of the job folder. When noted and applicable, documents shall be sent to the FAA. Copies of blank forms are stored on the central AIS file server. 1.7 Tagging and Identification of Parts After inspection, parts being returned to the customer from the Repair Station shall be tagged as Accept (Green) or Reject (Red). The tags shall be attached directly to the part, where practical, but may be affixed to the container in cases of small parts and/or large quantities. Examples of these Tags and instructions for completion can be found in the forms section of this manual. 1.8 Inspection Reports The Inspector shall be authorized and responsible to complete the appropriate Inspection Report for the inspection performed and issuing a copy to the customer and AeroEd Inspection Services. All reports will state the condition on the article inspected / repaired to the limits set forth in the Technical Data used to complete the work. The report will show the revision number and date of the technical Data used. All discrepancies outside the limits set by the technical Data will be documented in the report pictures of the discrepancies will be included if and where practical. The report can be on either Hardcopy or digital media as requested by the customer. The inspector must report defects to the customer, and report them according to section QM07 of this manual. Page Effective: 8-May-06 Quality Manual - Page 3 of 68

32 1.9 Inspection Release Forms The Inspection Release form shall be reviewed and approved by a FAA Part 65 certified FAA Repairman or Airframe & Power plant mechanic. This may be the same as the inspector who performed the work if meeting this requirement Returning Parts to the Customer The Inspector is responsible for ensuring that all parts, both Accepted and Rejected, are returned to the customer for Work Done accomplished both in the base facility and in the customers locations. The Work Order shall be completed showing that the parts were returned to the customer Rejected / Scrapped Parts When specifically directed by the customer, rejected parts may be scrapped. The Chief Inspector shall be responsible for mutilating the part (sawing, grinding, etc.), such that it cannot be repaired or used in any way. The Chief Inspector or Inspector shall identify the part along with serial numbers and the date of destruction on the Work Order Packaging and Delivery Inspectors are responsible for the return of inspected items to the customer. Parts shall be packaged in such a way to prevent any reasonable damage that may occur during shipping. When customer parts are supplied in special packaging, (i.e. Wooden Crate, Foam casing, etc.) the parts shall be returned in the same packaging as received. All Items shall be packaged to prevent their susceptibility to damage. If necessary, the Inspector shall apply any protective coatings/oil necessary to prevent damage or corrosion during the return to the customer. The Shipping/Receiving Inspection Log shall be completed with the shipping information and kept as part of the job folder Major Alterations This repair station will not perform any maintenance, preventive maintenance, alterations or alteration approvals. Only inspections will be performed. Completion of FAA Form 337 per FAR 43.9 and FAR Part 43, Appendix B will not be required. Major alteration or approvals will not be a part of the job instruction sheet Final Inspection and Return to Service As required by AC 145-9, the return to service procedure is as follows: The return to service form FAA is to be completed by an inspector that appears on the repair station Inspector roster and that meets all qualifications required by this manual. The instructions for completing this form are located in section QM12 of this manual. Prior to return to service the chief inspector or authorized inspector will review the records package and the inspection job package to determine that all work has been inspected as required for compliance with this inspection system. When approval has been given to the above review, either the Chief Inspector or the authorized inspector will approve the article for return to service by signing work order and/or the airworthiness release certificate (FAA Form ). The approval will be appropriate for the work done, the article involved, the records available with the article, and the instructions from the customer or owner of the article. Care will be exercised to comply with FAR Part 43. Page Effective: 8-May-06 Quality Manual - Page 4 of 68

33 Whenever the logbooks are available, a record of the work accomplished is expected to be made therein. If aircraft records are not provided, the airworthiness release statement on the work order (AIS Work Instruction Sheet - Form 14) will serve as the necessary release to service statement and the customer's copy of the Work Order will indicate that it is to be retained as a permanent part of the maintenance records. This does not waive and FAR Part 145 records requirement Special case visual inspection (Non-Airworthiness Release) If the customer does not require a completed or an airworthiness release statement, then the inspection is considered a video and/or photograph inspection only. The inspector will provide a report to the customer, but will not issue the or airworthiness release statement in the Job Pack. If any defects are detected, the inspector must report them according to section QM07 of this manual. Page Effective: 8-May-06 Quality Manual - Page 5 of 68

34 QM 02 - Continuity of Maintenance and Inspections 2.1 In Progress Inspections (Work Station Turnover) If an inspector is unable to complete all work directed by the Work Order prior to the end of his shift and the work is to be carried on with change of inspectors, then prior to leaving, the inspector shall clearly identify which components or areas have been inspected using AIS Form 57 - Workstation Turnover Log and identify with accept/reject tags, when appropriate and any other required documentation for those items that were completed. During the course of the inspection, any parts removed should be bagged-and-tagged so that they can be returned to their proper place. The inspector will circle the work tasks completed, sign and date indicating completion. The Inspector shall provide this documentation to the relieving inspector. The relieving inspector will finish the tasks and claim the rest of the tasks by signing and dating. Page Effective: 8-May-06 Quality Manual - Page 6 of 68

35 QM 03 - Inspection Personnel 3 Training Certification See section RSM 06 of the AIS Repair Station Manual, and the separate Training Manual. Page Effective: 8-May-06 Quality Manual - Page 7 of 68

36 QM 04 - Technical Data 4.1 Technical Data This facility will maintain all Technical Data (OEM Manual, Air Carrier Manuals, FAA Approved Data) in the most current revision used. All Technical Data (Hardcopy or Digital Media type) will be maintained in the Tech Library and there will be a master log to show what manual, manual revision number and revision date of all data in the Library. All Technical Data revisions will be accomplished through the Chief Inspector or designee. When a revision is posted the Master Log will be changed and the old revision of the data will be destroyed by rendering unusable (shredding, tearing or incineration). The Master Log revisions will be kept on file for 24 months by the Chief Inspector. Air Carrier supplied Technical Data will listed on the Master Log and revisions posted and destroyed as outlined above. Any notification of receipt will completed and returned to the air carrier. In Cases where the Air Carrier provides a direct access to their Technical Data base using computer connections with ID and Password access this facility will not maintain this Data in our Library. The record of what Data was used to complete the repairs / Inspections will be documented on the Airworthiness Release (FAA Form ) Block 13 of the form will indicate the Manual section /sections, manual revision, and revision date. Page Effective: 8-May-06 Quality Manual - Page 8 of 68

37 QM 05 - Tools and Equipment Calibration Inspection, Measuring, and Test Equipment 5.1 Identification AIS inspection equipment shall be identified with an AIS asset number. This number shall be affixed to the equipment or container. A log shall be maintained by the Operations department of the AIS asset number along with a description of the equipment. 5.2 Control of Inspection and Test Equipment Inspection and test equipment, including equipment used in the Repair Station operations are subject to periodic checks and calibrations. This equipment shall be calibrated in accordance with the applicable documented calibration procedure and a record kept of the calibration. This record shall be provided for the file and the Chief Inspector will maintain the file and have it available for review. The item shall be identified with its calibration status. This may be accomplished using calibration stickers affixed to the item or container, a log book, or by other means such that the information is readily available to the user. When an item is returned, it will be checked in and verified against the inventory list per case numbers verified and to be in good working order and not in need of repair. If repair is necessary it will indicated out of service and repaired before being used. Where available, standards used to calibrate test equipment shall be traceable to the National Institute of Standards and Technology (NIST) or other nationally recognized body. Where no such standards exist, the method of calibration and/or method used to ensure the equipment is producing valid results shall be documented. 5.3 User Calibration The inspector is required to perform prior to use calibration in accordance with the OEM recommendations prior to using the equipment. 5.4 Equipment Calibration and Recall Test equipment shall be calibrated at periodic intervals established on the basis of equipment s history of stability, purpose, degree of usage and manufacture s recommendations. Each month the Chief Inspector shall review the AIS Calibration Control Database and issue a recall notice on equipment that is coming up for recalibration to the Director of Operations when required. The Chief Inspector is responsible for removing equipment from service and ensuring the equipment is calibrated as necessary. Calibration records will be maintained by the Chief Inspector. If upon recall of equipment, it is found to be significantly outside of allowable tolerances, an investigation shall be performed by the Chief Inspector to assess the validity of inspections performed with the equipment. Customers shall be notified if the condition may have had a negative effect on the inspections. Page Effective: 8-May-06 Quality Manual - Page 9 of 68

38 5.5 Expired Calibrations At no time will any person be permitted to perform work on aircraft or components using test equipment which is past the calibration due date. If at any time a piece of test equipment exceeds its calibration due date, it will immediately be taken out of service and Red tagged until such until calibration has been performed. 5.6 Calibration Extensions A request for extension to the due date may be made by submitting a written request to the Chief Inspector. If upon review of the equipment s calibration records, the equipment has shown consistency in maintaining tolerances, then the sticker and calibration records shall be amended to show the extended due date. Calibration Extensions can only be authorized by the Chief Inspector. Calibration Extensions must be approved by the FAA local FSDO by the Chief Inspector. Page Effective: 8-May-06 Quality Manual - Page 10 of 68

39 QM 06 - Taking Corrective Actions on Deficiencies The Director of Operations is responsible for the Discrepancies and Corrective Action Program Root cause of an operational problem should be determined through the following outline: For Each Causal Factor Determine the following: 1. Equipment Difficulty a. Equipment Design Problem i. Design Input ii. Design Output b. Equipment Reliability Problem i. No Program ii. Corrective Maintenance iii. Preventative Maintenance iv. Predictive Maintenance v. Inappropriate Maintenance vi. Risk acceptance criteria c. Equipment Records i. Design ii. Maintenance History d. Installation i. Administrative and Management Systems e. Misuse i. Procedures 2. Personal Difficulty a. Company Employee/Contractor i. Human Factors 1. Workplace Layout 2. Workplace Environment 3. Workload 4. Error not correctable ii. Training 1. No Training 2. Training Records 3. Training a. Task Analysis b. Lesson Content c. OJT d. Testing e. Continuing Training f. Exceptions/Emergency Training iii. Supervision 1. Preparation 2. Supervision during work 3. Teamwork iv. Communications 1. Misunderstanding a. No Verification b. Non- standard Terminology c. Too long Page Effective: 8-May-06 Quality Manual - Page 11 of 68

40 2. Wrong instructions 3. Work Turnover Intra-shift / Inter-shift v. Personal Performance 1. Sensory Capability 2. Reasoning Capability 3. Motor/Physical Capability 4. Attitude/Attention 5. Rest/Sleep 6. Personal/Medication 3. Other Difficulty a. Natural Phenomenon b. Sabotage/ Horseplay c. External Event d. Other The Discrepancies and Corrective Action Investigation can be initiated by the Director of Operations, Chief Inspector, or Managing Director. The amount of time allowed to implement corrective action will be determined by the root cause and practical considerations for making a timely and effective corrective action. Where appropriate, the FAA voluntary disclosure reporting program should also be used according to Advisory Circular AC The Director of Operations will conduct a follow-up audit of the corrective action to ensure that it was effective. The Director of Operations will maintain records of the action taken, why the action was taken and what the results and conclusions of the follow-up audit are. Page Effective: 8-May-06 Quality Manual - Page 12 of 68

41 QM 07 - Reporting Failure, Malfunctions & Defects 7.1 Reporting to FAA This Repair Station will report to the Federal Aviation Administration (FAA) within (96) hours after it discovers any serious defects in, or other recurring un-airworthy condition of, an aircraft, power plant, or propeller, or any component of any of them. The report will be made on a FAA Form , (Malfunction or Defect Report) describing the defect or malfunction completely without withholding any pertinent information. 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 flight, the Repair Station will use the most expeditious method it can to inform the Administration and Operator. When work is being accomplished for a certificated air carrier and a defect as described is found, the air carrier will be notified as well as this repair station s Chief Inspector. The Chief Inspector is responsible for preparing and submitting a Malfunction or Defect Report (FAA Form ) to the regional FSDO office. Page Effective: 8-May-06 Quality Manual - Page 13 of 68

42 QM 08 - Operations Compliance Auditing & Corrective Action Process 8.1 The Chief Inspector is responsible for performing facility audits and ensuring Corrective Action is initiated as a result of an audit finding or as a result of human error. The compliance audit will be accomplished using the FAR 145 checklist. The Chief Inspector will maintain this checklist under separate cover. All completed audit checklist will kept on file in the quality department. 8.2 The Chief Inspector shall provide a description of deficiencies which will be documented on the Corrective Action Request. A brief description of the CAR will be entered on the Corrective Action Request Log. 8.3 The Director of Operations shall initiate Root Cause and Corrective Action (RCCA) process: 1. Immediate action to contain and / or correct the deficiency. 2. Prevention of nonconforming product being delivered to the customer as a result of the deficiency. 3. Identification and elimination of the root cause of systematic deficiencies to prevent the deficiency from recurring. These actions shall be documented on the CAR. 8.4 After completion of Corrective Action Request by the affected department/individual, the Chief Inspector shall verify that the corrective action specified has been accomplished shall determine the effectiveness of the Corrective Action. 8.5 The CAR shall be considered closed after verification of effectiveness by the Chief Inspector or delegate. Completed Corrective Actions will be kept on file in the quality department. 8.6 Corrective Actions Requests will be issued against customer audit findings to ensure the facility uses the same process to address all findings against the facility. These corrective actions will be summarized in a letter of response to findings back to the customer for final closing. AeroEd Inspection Services Compliance Audit Schedule for 2006 June 2006 September 2006 December 2006 March 2007 Quality System Initial X X Work Package Initial X X X Operations Initial X Page Effective: 8-May-06 Quality Manual - Page 14 of 68

43 QM 09 - Capability List and Process for Making Changes This repair station has elected to maintain a dynamic repair station maintained capability list. When it is necessary to add / change the capability list the Chief Inspector will perform the Capability Self evaluation using the checklist provided in Section QM 12. Once the checklist has been completed and all areas meet the requirements the Chief Inspector can then change the Capability Listing and send a revised copy to the FAA Local FSDO certificate holding office. Page Effective: 8-May-06 Quality Manual - Page 15 of 68

44 QM 10 - Quality Control Manual Revision and Control System All Quality Control Manual Revisions will be accomplished by the Chief Inspector. All revisions will be done in draft form, reviewed for compliance to the regulations and submitted to the administrator for acceptance. See Repair Station Manual Section 11 for process on manual revision and distribution. Once acceptance has been received the Chief Inspector will train the organization on the changes and distribute new approved copies to all personnel listed on the manual distribution list in accordance with the requirements in section RSM11 of the Repair Station manual. Page Effective: 8-May-06 Quality Manual - Page 16 of 68

45 QM 11 - Control of Inspection Records 11.1 Retention Times Records are retained according to the following chart. The specified retention times are minimums. The retention period for the record begins when it no longer an active document (i.e. procedure superseded, supplier becomes inactive, etc.). Retention period for job folders begins at time of job opening. Quality Record Ret. Period Maintained by Job Folders (includes the documents below) 24 Months Operations Mgr Shipping/Receiving Report 24 Months Operations Mgr Work Order 24 Months Operations Mgr Inspection Reports, FAA Reports, Certifications, Releases, Data, and all other documentation specific to the inspection performed 24 Months Operations Mgr Documents and Data Repair Station Manual 24 Months Chief Inspector Quality Control Procedures 24 Months Chief Inspector Forms 24 Months Chief Inspector Equipment Calibration Records 24 Months Chief Inspector Corrective Actions 24 Months Chief Inspector Personnel Training/Qualification Files 24 Months after employment Operations Mgr 11.2 Documents shall be recorded neatly and legibly in black non-water soluble ink. Pencils shall not be used to complete and / or correct documents Records shall not contain erasures, correction fluids, tape, or other means of changing information. Corrections shall be accomplished by placing one line through the portion to be corrected, make correction as needed, and then initial the change Employees shall use Out Cards indicating the record removed, the date, and the employee s initials, when removing quality records from storage areas Records shall indicate page numbers and number of pages (i.e. Pg. 1 of 3) when more than one page and there is no method of determining if the document is complete, such as item numbering or otherwise. Page Effective: 8-May-06 Quality Manual - Page 17 of 68

46 11.6 When records are to be moved to any of the record storage areas, the Director of Operations is responsible for historical records and shall indicate the series of job orders stored in on the box: a. Department Responsible for the records b. Contents of the box, including job numbers, dates, etc. c. Destroy date for the records 11.7 Disposal of Quality Records The Chief Inspector shall identify records which have exceeded their required retention periods, and remove the records from the storage area. Records shall be reviewed to ensure accurate labeling and retention requirements have been met The Chief Inspector is responsible for arranging pickup of Quality Records. Disposal may be performed by shredding locally or through a commercial disposal service. This repair station will keep record of method used to destroy the records. Page Effective: 8-May-06 Quality Manual - Page 18 of 68

47 QM 12 - Repair Station Forms Index FAA Form 337 Major Repair/Alteration FAA Form Authorized Release Certificate FAA Form Suspected Unapproved Parts Report FAA Form Malfunction or Defect Report FAA Form Airman Certificate Application Approved Contractors - AIS Form Work Instruction Sheet - AIS Form Equivalency Tooling Acceptance Form - AIS Form Training and Needs Assessment Record - AIS Form Red/Green Tag System AIS Forms 18 and 18A Shipping & Receiving Inspection Log AIS Form Corrective Action Request Form - AIS Form Vendor Inquiry/Audit Form - AIS Form Calibrated Tool Data Sheet - AIS Form AIS Roster of Supervisory and Mangement Personnel - AIS Form Repair Station Return to Service / Stamp Roster - AIS Form Inspector Roster - AIS Form Capabilities List Change Checklist AIS Form Workstation Turnover Log - AIS Form Instructions for Collecting Multimedia Borescope Inspection Assets Page Effective: 8-May-06 Quality Manual - Page 19 of 68

48 Form Approved OMB No United States Dept. Of Transportation For FAA Use Only Federal Aviation Administration INSTRUCTIONS: Print or type all entries. See FAR 43.9, FAR 43 Appendix B, and AC (or subsequent revision thereof) for instructions and disposition of this form. This report is required by law (49 U.S.C. 1421). Failure to report can result in a civil penalty not to exceed $1,000 for each such violation (Section 901 Federal Aviation Act 1958) 1. Aircraft Make Serial No. Model Nationality and Registration Mark 2. Owner Name (As shown on registration certificate) Address (As shown on registration certificate) 3. For FAA Use Only 4. Unit Identification 5. Type Unit Make Model Serial No. Repair Alteration AIRFRAME ~~~~~~~~~~~~~~~~~~~~(As described in item 1 above)~~~~~~~~~~~~~~~~~~~~ POWERPLANT PROPELLER APPLIANCE Type Manufacturer 6. Conformity Statement A. Agency s Name and Address B. Kind of Agency C. Certificate No. U.S. Certified Mechanic Foreign Certified Mechanic Certified Repair Station Manufacturer Limited Powerplant D. I certify that the repair and/or alteration made to the unit(s) identified in item 4 above and described on the reverse or attachments hereto have been made in accordance with the requirements of Part 43 of the U.S. Federal Aviation Regulations and that the information furnished herein is true and correct to the best of my knowledge. Date Signature of Authorized Individual 7. Approval for Return to Service Pursuant to the authority given persons specified below, the unit identified in item 4 was inspected in the manner prescribed by the Administrator of the Federal Aviation Administration and is APPROVED REJECTED FAA Flt Standards Inspector Manufacturer Inspection Authorization Other (Specify) FAA Designee Repair Station Person Approved by Transport Canada Airworthiness Group Date of Approval or Rejection Certificate or Designation No. 064R443Y Signature of Authorized Individual FAA Form 337 (12/88) Page Effective: 8-May-06 Quality Manual - Page 20 of 68

49 NOTICE Weight and balance or operating limitation changes shall be entered in the appropriate aircraft record. An alteration must be compatible with all previous alterations to assure continued conformity with the applicable airworthiness requirements. Page Effective: 8-May-06 Quality Manual - Page 21 of 68

50 8. Description of Work Accomplished (If more space is required, attach additional sheets. Identify with aircraft nationality and registration mark and date work completed.) Page Effective: 8-May-06 Quality Manual - Page 22 of 68

51 FAA Form 337 Major Repair/Alteration INSTRUCTIONS FOR COMPLETING Purpose: The FAA form 337 is used when performing major repairs and alterations. This is used to capture the maintenance that was performed and to provide a record for return to service. For AIS purposes this form will be used when separating or splitting major flanges or when requested to do so by the customer. This form must be used every time a major flange or module separation takes place as part of the work scope. Examples: The separation of engine modules, splitting of flanges or any other scenarios defined by FAR 43.9 appendix A will constitute a major repair/alteration and therefore will require completion of the 337. Proper Form Completion: The date will be entered on this form as follows: DD, MMM, YYYY 1. Aircraft: If available enter the information necessary to complete make, model and serial number of A/C which can be found on the Mfg. ID plate. 2. Owner: If available enter the A/C Owners complete name and address. 3. Note: When major repair/alteration is made on a spare or the information above is unavailable then steps one and two will be left blank. In this case the original and duplicate copy of the 337 will remain with the part (given to the customer/operator) until such time that is installed on the A/C. Make a separate three to keep with the work package. It will be the responsibility of the customer/operator to ensure that this form is filed with local FSDO. 4. For FAA Use Only: Not to be completed by AIS personnel. 5. Unit identification: Enter the make and Model and Serial Number of the article repaired or altered this information is obtained from the data plate. In this case the article will be the engine repaired or altered in the Powerplant section. 6. Type: Enter the applicable check mark in the appropriate box, repaired or alteration. 7. Conformity Statement: Agency name and address will be the name and address of the AIS site completing and approving the major repair or alteration. The kind of agency will always be a repair station; the certificate number block should contain the repair satiation air agency certificate number and the rating by which the repair station used to perform the major repair or alteration. In many cases this will be limited Powerplant. Finally, sign and date the conformity statement block inspectors are the only persons authorized to sign the conformity statement on behalf of the repair station. 8. Approval for Return for Service: Check the block as being approved or rejected as applicable and check the repair station block signifying that the article be repaired or altered has been approved by the AIS repair station. Finally, sign, date and enter the repair stations air agency certificate number. Inspectors are the only persons authorized to sign the approval for return to service on behalf of the repair station. 9. Description of Work Accomplished: A clear, concise and legible statement describing the work performed should be entered in item 8 on the reverse side of FAA form 337. At the very minimum, it will be required to make reference to the technical data used, the part number and serial number of the article/engine repaired/altered, AIS work order number (AIS1234) and a description of the work performed. Some carriers may require additional information such as cycles, TSR, PO# and AD status which can be entered as necessary. When entry has been completed draw a single line diagonally across the remaining portion of the page and write the word END to signify that this was the last entry. If additional pages are required, check the box at the bottom and attach additional pages as necessary. Always ensure that the revision number and date of all publications being used for major and or alteration is included on the reverse side of the 337 in section 8 description of work performed. This includes service bulletins, ADs, customer EOs, OEM data, etc. When revising the 337 the following will apply: Enter Rev. 1 or 2 as applicable as well as the date in the date blocks of section 6, conformity statement and section 7, approval for return to service as well as the dates. Enter a brief description of the revision on the back of the 337 in section 8. Always use the date the revision was made not Page Effective: 8-May-06 Quality Manual - Page 23 of 68

52 the date the work was originally performed. Page Effective: 8-May-06 Quality Manual - Page 24 of 68

53 Page Effective: 8-May-06 Quality Manual - Page 25 of 68

54 FAA Form Authorized Release Certificate INSTRUCTIONS FOR COMPLETING: Purpose: The purpose of the is to provide a record for return to service after performance of FAA covered maintenance, preventative maintenance, rebuilding, alteration and/or inspection. This serves as a clear concise description of the work that was performed and coincides with the maintenance record entry requirements specified by FAR 43.9 (a). The is the form that AeroEd Inspection Services, LLC (AIS) uses to ensure consistency in how the maintenance record is documented. Proper Form Completion: Block 1: This is the approving National Aviation Authority/Country and will be pre-printed on the tag. Block 2: This is the title of the form (Authorized Release Certificate, Airworthy approval tag) and will be pre-printed. Block 3: Form Tracking Number. This is a unique number assigned and issued by the AIS system. This number cannot be duplicated and is used to track and identify specific maintenance that was performed under that tracking number. For example, AIS456 would be placed in block 3 of the if the job number were AIS456. Block 4: Organization Name and Address. For AeroEd Inspection Services, LLC. purposes this will be preprinted on the form including Repair Station Number. Block 5: Work order, Contract, Invoice No. For AIS purposes this will be the customer issued PO or reference number. Typically, each operator/customer will reference a repair order number when requesting maintenance services. This is the customer/operators unique internal tracking number to archive the work that was requested / performed. When no customer reference number is provided the AIS number will be again written in this block. Block 6: Item. This will be pre-printed in the form as Item 1 for AIS purposes. Block 7: Description. This will be the description of the part being overhauled, repaired, inspected, tested, etc. For example, if the engine were being worked on then the word engine would be entered in block 7. Where as if we were performing an NDT inspection of a fan disk and the fan disk was removed from the engine then we would enter the word Fan Disk in block 7. Block 8: Part Number. This will be part number or model of the item identified in block 7. For example, if it were an engine model JT8D then JT8D would be entered in block 8. Alternately, if it were a, Engine with a part number of then would be entered in block 8. Block 9: Eligibility. When issuing an for approval for return to service enter N/A in block 9. Block 10. Quantity. Enter the quantity of the part / parts Block 11: Serial/Batch No. Enter the serial number of the part identified in block 7. Note: When an LLP is identified in block 7 and 8 then the serial number MUST be included. Block 12: Status/Work. Enter one of the following: Overhauled, Repaired, Inspected, Altered or Modified. For AIS purposes this will be repaired or inspected. Block 13: Remarks. Enter a clear concise description of the work performed including: Technical data used (Shop manual, AMM, EMM, CDRs, EOs, Operator Specific Manuals, etc.) including revision No. and date, repair No. s performed, (01, 005, 07, etc) ADs complied with or the statement No ADs Complied Page Effective: 8-May-06 Quality Manual - Page 26 of 68

55 With, as specified by Operator, service bulletins performed with revision No. and date as required/specified by customer, other information such as results of inspection /repair or major parts/assemblies removed and replaced with part number and serial number listed. Time and Cycle information must be listed for Life Limited Parts when they are being inspected, repaired and/or replaced. This block must also reference any duel release statement such as the EASA145 maintenance release. Note: If approved as a EASA145 maintenance facility the following statement must be entered in block 13 when issuing in the Domestic United States. Certifies that the work performed has been accomplished IAW JAR 145, EASA acceptance certificate No.. This statement may NOT be entered when issuing an outside of the Domestic United States. Any items, which are being left open as a result of the maintenance performed, will be identified and documented on the carry forward sheet. When items are left open a statement will be made on the in this block calling out the Carry Forward Sheet, for ex. See Carry Forward Sheet for open items. Block 14: Not Completed By AIS Block 15: Not Completed By AIS Block 16: Not Completed By AIS Block 17: Not Completed By AIS Block 18: Not Completed By AIS Block 19: Return to Service. Check the appropriate block based on the work performed. This indicates the regulations followed in performing the work. For AIS purposes domestically the return to service IAW 43.9 will be checked off. Only when NOT performing work IAW with FAR 43.9 would you check the other block and identify how the work was performed in block 13. See block 13 for EASA dual release statement which will be entered in block 13 by US repair stations when performing the work within the United States and the work meets the requirement of EASA 145 regardless of block 19. Block 20: Authorized Signature. This is the individual authorized by the repair station to sign and provide return to service documentation. This block must be signed; the use of an inspection stamp or initials is prohibited. Block 21: Approval/Certificate No. Repair Station number will be listed here and will be pre-printed on the form. Block 22: Name (Typed or Printed). This will be the same name as entered in block 20 only printed. Block 23: Date (Month Day and Year). This is the date the form was signed, should be completed and signed the day the maintenance is completed and the return to service is being provided. For AIS purposes the date should be entered as follows: 1 December Revising the Purpose: In cases of omission or an error entry the FAA form will require revision to ensure the appropriate corrections are made and to properly document and certify the work that was performed. 1. The original form may not be amended once issued, this holds true with reach revision. 2. The form will be completed as instructed above except for the following additions: a. Add Rev No. to form tracking No. in block 3. (it will be the original number with a dash and then 1 for first revision and -2 for second, etc.) b. Include brief description and/or reason of revision in block 13. c. Enter Rev No. after the date in block 23. Note: The date must be the date the form was revised not the date the work was performed. Page Effective: 8-May-06 Quality Manual - Page 27 of 68

56 d. The original must be kept as part of the work package and should not be discarded. e. The original revised copy should be forwarded along with a copy of the old to the Customer/Operator with copies of both remaining as part of the job package. Page Effective: 8-May-06 Quality Manual - Page 28 of 68

57 FAA Form Suspected Unapproved Parts Report Page Effective: 8-May-06 Quality Manual - Page 29 of 68

58 Page Effective: 8-May-06 Quality Manual - Page 30 of 68

59 Page Effective: 8-May-06 Quality Manual - Page 31 of 68

60 FAA Form Page Effective: 8-May-06 Quality Manual - Page 32 of 68

61 FAA Form Malfunction or Defect Report Follow these Instructions to fill out the form and return to Chief Inspector for FAA Submission ITEM, OPER.Control No. Primarily to be used for FAR Part 135 and 121 operators. Example: ABCD , BCDE ITEM, ATA Code Four-digit code used primarily by the FAA. Example: ITEM 1. A/C Reg. No.: Enter the complete aircraft registration number. Example: 7523Q, 8304Q NOTE: The registration number is not mandatory; however, it is of use when there is a need to trace the aircraft model by series. ITEM 2 AIRCRAFT. NOTE: Always supply aircraft data if available. MANUFACTURER: Enter the aircraft manufacturer s name. Any meaningful abbreviation will be acceptable. Example: Boeing MODEL/SERIES: Enter aircraft model as identified on the aircraft data plate. Example: 172A. 180 SERIAL NUMBER: Enter the serial number assigned by the manufacturer. Example: 81RK, 94RK ITEM 3. POWERPLANT: MANUFACTURER : Enter the engine manufacturer s name. Any meaningful abbreviation will be acceptable. Example: Lvc., Cont. MODEL/SERIES: Enter engine model as identified on the engine data plate. Example: , O-470R SERIAL NUMBER: Enter the serial number assigned by the engine manufacturer. Example: 4700, 230O ITEM: 4. PROPELLER: Complete only if pertinent to the problem being reported. MANUFACTURER: Enter the manufacturer s name. Any meaningful abbreviation will be acceptable. Example: GE, PW MODEL/SERIES: Enter propeller model as identified in FAA type certificate data sheet/propeller specifications. Example: DHCC2Y SERIAL NUMBER: Enter the serial number assigned by the propeller manufacturer. Example: D800, D900 ITEM 5. SPECIFIC PART (of component) CAUSING TROUBLE: Part Name: Enter the name of the specific part causing the problem. The appliance or component is the assembly which includes the part. For instance: When the part is a burned wire, the component would be the system using the wire, such as VHF communication system. When the part is a bearing, the appliance should be the unit using the bearing, such as starter, alternator, generator, etc. When the part is a stringer, the component name should be fuselage, wing, or stabilizer, etc. Example: crankcase, wire MFG. Model or Part No.s: Enter the manufacturer s part number. Example: 14542,23893 NOTE: If same as aircraft engine, or propeller, leave blank. NOTE: If the aircraft, engine, or propeller manufacturer is the component manufacturer, leave blank. Serial No.: Enter the serial number assigned by the manufacturer. Example: WA, W5489 Part/Defect Location: Enter the location. Example: left half, right wing ITEM 6. APPLIANCE/COMPONENT (Assembly that includes part): Comp/Appl Name: Enter the manufacturer s nomenclature for the component or appliance of the specific part causing the problem. Example: engine, starter Manufacturer: Enter the part manufacturer s name. Example: Lvc.. Lear Model or Part No: If supplied by the manufacturer. Example: 0-362~01, 0473GH-2 Serial Number: If supplied by the manufacturer. Example: CH9693, DE8549. Part TT Enter the service time of the part in whole hours. (If Part TT is unknown, use aircraft, engine, propeller, or appliance/component total time, whichever is applicable.) Example: 02756, Part TSO: Enter the service time of the part since it was last overhauled, in whole hours. (If part TSO is unknown, use an aircraft, engine, propeller, or appliance/component time since last overhaul, whichever is applicable.) Example: 00351, Part Condition: Enter the word(s) which best describe the part condition. Example: cracked, disintegrated ITEM 7. Date Sub: Enter the date of submission, day, month, year. Example: 08/15/92, 11/15/92 ITEM 8. Comments (Describe the malfunction or defect and the circumstances under which it occurred. State probable cause and recommendations to prevent recurrence.) Continue on reverse side if needed. Powerplant TT and TSO should be shown in this box when it is a secondary item. Example: "During a scheduled inspection of the landing gear, the mechanic found the left main landing gear support was broken completely in half. It is suspected that fatigue or an unreported hard landing could be the cause." ITEM Optional Information Accident; Date: Accident where substantial damage to aircraft or property and/or serious injury. Enter the date of the accident (day, month, and year). Example: Ol/22/93, 02/13/93 Incident; Date: Anything less than an accident. Enter the date of the incident (day, month, and year). Example: 01/14/93, 02/12/93 NOTE: This information may be used to trace data to accident or incident records. Page Effective: 13-Sept-06 8-May-06 Quality Manual - Page 33 of 68 Revision: 1.1 Original

62 FAA Form Airman Certificate Application Repairman Application under FAA Part 65 AIS will submit an application to the FAA local FSDO for a Repairman Certificate using the following suggested form letter or similar correspondence. The letter will be submitted with a completed form , as follows: Page Effective: 8-May-06 Quality Manual - Page 34 of 68

63 FAA Form Page Effective: 8-May-06 Quality Manual - Page 35 of 68

64 Page Effective: 8-May-06 Quality Manual - Page 36 of 68

65 Approved Contractors For AeroEd Inspection Services, LLC. Name / Address Repair Station Number Services Last Audit Date AIS Form13 Page Effective: 8-May-06 Quality Manual - Page 37 of 68

66 Approved Contractors - AIS Form 13 To be completed by the Chief Inspector: Purpose: This form establishes a listing of all approved facilities performing maintenance and/or subcontract work for AIS. This form provides the name, address, repair station number, services provided and the date the last audit was performed. Only contractors, which have met the approval process of AIS, are eligible to be added to this list. The approval process consists of and may include: 1. A vendor inquiry form sent to that facility requiring completion as well as a copy of their quality package, which includes (Air Agency Certificate, Operations Specifications, and Drug/Alcohol Program Approval) if applicable. 2. An on-site audit performed by an approved auditor of AeroEd Inspection Services, LLC. Proper Form Completion: 1. Once the facility has been audited and approved add them to the approved contractors list by entering the physical name and address where the work is being performed on the left side of the form. 2. If the facility being approved is a FAA certificated source add the agencies certificate number in the second column. If the organization being approved is not certificated enter N/A, for example this may apply to a calibration facility, which is NIST traceable but is not governed by the FAA. 3. Enter a brief description of the services performed by the approved facility in the third column. 4. Enter the date the audit was accepted and approved in column four. 5. Each time a revision (add/remove) is made to the list make the necessary changes to the bottom of the form. 6. Attached additional pages as necessary. Page Effective: 8-May-06 Quality Manual - Page 38 of 68

67 Page Effective: 13-Sept-06 8-May-06 Quality Manual - Page 39 of 68 Revision: 1.1 Original

68 Work Instruction Sheet - AIS Form 14 version 1.1 Router Purpose: Guide used to document step-by-step procedures or tasks that must be taken to complete work and is used to identify the individuals who performed and inspected that work as well as the date the work was performed/inspected. The router is a guide drafted IAW and to be used in conjunction with approved technical data. Each router is specific to a particular task outlined in the approved technical data and is issued, revised and controlled by AIS engineering. Routers are issued for each top-level work scope and must remain as part of the work package. When a router cannot be drafted in time to respond to a particular job it is acceptable to use and claim the procedure pages outlined in the approved technical data. These pages serve as a temporary router and become part of the work package. This is accomplished by the technician claiming each procedure and the inspector claiming each inspection immediately after each task. Proper Form Completion: 1. Complete the six job identifiers located at the top of each router. 2. Enter serial number. Use one form per engine, do not list multiple serial numbers on the form. 3. Date and Location; enter the date the router was initiated and the geographic location where the inspection/job will be conducted. 4. AIS No., Enter the AIS work order Number assigned to the job. 5. Customer work scope reference, enter the customer/operator work scope reference No. as provided by the customer/operator. 6. Engine Model; enter the full engine model or part, which the router covers, for example JT8D. 7. Tail Number/Engine Position, Enter the Aircraft Tail number, if not applicable, enter "None" - and the engine position, if on wing. If not, enter off wing for position. 8. List any applicable AD notes provided by the customer or OEM. 9. List the tools assigned for the inspection by serial or case number, as applicable. Indicate that manufacturer's recommended verification of calibration was performed prior to inspection. 10. Have the customer, air carrier, or storage facility accountable person that provided the technical documentation sign and date the indicated box. 11. List the task(s) to be performed, use additional sheets if necessary and observe page numbering at the bottom of each page. 12. Return to Service Statement: Inspector must enter an airworthiness release statement with regard to the work performed and that the inspection satisfies the specification of the maintenance manual. Otherwise, state that there is no return to service indicated. 13. Sign and date the form upon completion. Each router will contain the individual task No., manual reference and task description. 1. All work performed must be claimed immediately after completion of that task. 2. Technicians shall claim completion of a task by entering their badge number, initials and date. 3. Inspectors working as technicians for any particular job shall claim completion of that task by entering their stamp and date. Caution: Inspectors may not inspect work on a job where they have worked on that same job as a technician. 4. Inspectors assigned to jobs will work as inspectors and may not claim technician steps throughout that particular job. Note: The Inspector assigned to any particular job may ASSIST the technician in the performance of any given task. Assistance includes, but is not limited to the following: Holding, lifting, handing, advising, showing, etc. 5. If a step cannot be performed as described or specified in the router or is not applicable a discrepancy MUST be noted in the Fault Items / Discrepancies block. The task on the router will be claimed in this situation by the inspector entering the words See Fault Items Discrepancy Item No._ in the space/s provided along with their stamp. It is not acceptable to enter any other term or information in the sign-off blocks of the router like N/A, void, unable to complete, etc. It is also not acceptable to leave the sign-off blocks blank. Fault Items / Discrepancies block must also reference the task. Page Effective: 13-Sept-06 8-May-06 Quality Manual - Page 40 of 68 Revision: 1.1 Original

69 6. When performing an out of sequence operation it is necessary to identify that an out of sequence operation has been performed on the workstation turnover log identifying the steps, which have been skipped. This lets the next shift or reminds the person who skipped those steps that those tasks remain OPEN. It is not acceptable to perform an out of sequence operation when the operation is sequence sensitive. For example, when an assy. is reassembled and measurements are called out after assembly. It is not acceptable to take the measurements prior to assembly. This will be considered a work stoppage and may NOT progress. 7. Routers must be obtained in original copy format for that particular job and may not be copied or reproduced for future application and/or use. All routers must have an approval signature from AIS as well as the effective date and the revision number of the router. 8. Typos and obvious errors such as incorrect manual references, page number or title errors, which can be easily reconciled by the approved technical data shall be identified by the inspector by entering the words See Fault Items / Discrepancies block Item No._ along with their stamp for that step and a fault generated on the Fault Items / Discrepancies block. This fault must reference the step in the router and be corrected by entering the correct information for completion of that particular task or subject. Routers will be corrected by the AIS Operations and/or Quality Departments. Page Effective: 13-Sept-06 8-May-06 Quality Manual - Page 41 of 68 Revision: 1.1 Original

70 EQUIVALENCY TOOLING ACCEPTANCE FORM 15 Part Number: Description: Manufacturer/Vendor: Blueprint Drawings/Technical Data Reference: Calibration Requirement: Equivalent to: Part Number: Description: Manufacturer/Vendor: Blueprint Drawings/Technical Data Reference: Calibration Requirement: Tool Used For/Application: AIS Engineering (Evaluated) Date: Chief Inspector Date: (Accepted) Page Effective: 8-May-06 Quality Manual - Page 42 of 68

71 Equivalency Tooling Acceptance Form - AIS Form 15 Instructions for completing Equivalency Tooling Acceptance Form Purpose: The purpose of this form is to document and identify a tool as being equivalent to that called out for by the manufacturers approved technical data. Precision measuring and test equipment specified in the respective manual may not be procurable or practical. Therefore, this form becomes necessary to document the approval from the AIS Engineering Department to use such a tool or fixture. This form does not have to be completed for special tools used for ease of lifting, holding, removing and installing. Items such as these used must meet the intent of the tool called for in the manual. Example: Manual calls for a precision measuring or testing tool, which AIS does not have, and can not obtain. A suitable equivalent will be sought and approval obtained from the AIS Engineering Department to use an alternate tool. 1. Enter the OEM specified tool part number as well as the description, mfg., technical data reference page and whether or not the tool requires calibration. 2. Enter the information provided with the potential equivalent tool including part number, description, mfg., pertinent blue print drawings or manual reference concerning the potential equivalent and any calibration requirements. 3. Enter the application for which the tool is to be used. 4. Engineering must use the criteria below to evaluate the tools equivalency and sign acknowledging the fact that the tool meets the specifications set fourth in the applicable manual and called for by the Mfg. 5. Chief Inspector must approve the tools use and will accept based on data provided and engineering disposition. 6. This form must be retained on file and a copy kept with the job package for which the tool was used. The following information should be maintained on file with the equivalent tooling form for establishing equivalency approvals for each particular tool: 1. The rationale and data used to determine equivalency including: 2. Specifications or standards used, 3. Descriptions of tests, trials or other methods used to assist in making the equivalency determination, 4. Manufacturers approvals (if appropriate), 5. Preliminary sketches, 6. Final drawings and parts lists (these should be kept under revision control), 7. Calibration requirements (if applicable), 8. Special maintenance instructions (if applicable), Page Effective: 8-May-06 Quality Manual - Page 43 of 68

72 Page Effective: 8-May-06 Quality Manual - Page 44 of 68

73 Training and Needs Assessment Record - AIS Form 17 Instructions for completing: Purpose: To document and provide a record of individual training received which may include but is not limited to classroom training, on the job training, recurrent training, RS&QM and regulatory, etc. This record becomes part of the individuals training record and is incorporated into the individuals training matrix. Accumulation and documentation of this training highlights the individuals experience level at the same time helping to define the repair stations capabilities. Proper Form Completion: 1. Each individual is responsible for completing and turning into the site quality leader each training record as training is received. 2. Indicate the type of training received by checking the appropriate box at top of form. When learning something new and being taught by someone else always document the training as OJT and when completing work scopes which, by virtue of previous experience you are already trained, document that training as recurrent. 3. Enter the needs assessment information based on training assignment by the accountable manager. Once this information is entered, it will remain in the employee file for sign-off upon successful completion of the training. 4. AIS No.: Enter the AIS number under which the OJT training was received. When classroom or RS&QM or Regulatory training is received the AIS Job number is entered as N/A. 5. Training Name/Certificate Number: Enter the trainee s name and Part 65 certificate number. 6. Aircraft/Engine Model: Enter the aircraft and/or engine model for training received. If classroom, not dealing with engine or aircraft instruction enter N/A. 7. Location of Training: Enter the geographic location where the training was received. For classroom training be more specific with respect to the location, for example OEM Pratt & Whitney, Atlanta, GA. 8. Start Date/Finish Date: Enter the date the training commenced and the date the training ended. 9. Duration: Enter the duration of training received in hours. Note: Do not count prep and/or travel time associated with the training. 10. Scope of Training Accomplished: Provide a detailed account and description of the training received. Be specific as to the work scope or type of classroom training attended (B737 Engine Removal, Installation and Pylon Inspection). Identify the course number if applicable (Boeing Course #123XXX) 11. Trainers Name/Business Address/Certificate Number: Enter the individual conducting the training as well as their business address and certificate number as applicable. 12. Trainers Signature: Have the individual conducting the training sign the form after completion of the course/training. 13. Trainee Signature: The signature of the person receiving the training. This establishes that the individual has acknowledged that they have been trained. 14. Date: Enter the date the trainee acknowledges by signature that he/she has been trained. 15. Reviewed By/Date: This is to be completed by the AIS quality leader or designee and should be reviewed for completeness and accuracy, then signed and dated. Note: It is the responsibility of the individual being trained to accurately document the training, which they have received. Page Effective: 8-May-06 Quality Manual - Page 45 of 68

74 Red/Green Tag System AIS Forms 18 and 18A Red Tag AIS Form 18 To be used when a component is determined Unserviceable. Tag should be placed on the Component and / or tooling and placed in the quarantine area at the Repair Station, or given to the owner for disposition when away from the Repair Station. Instructions for filling out a Rejected Tag: Part Description: (Description of part) Part No. (Part No. of rejected part) Serial No. (Serial No. of rejected part) Work Order No. (W/O of which the rejected part is being worked on) Reason for Rejection (Brief description of discrepancy) Inspector (Signature or stamp of Authorized Inspector) Note: Make copy of tag to remain as part of the work package identifying the parts, which were rejected. Green Tag - AIS Form 18A To be used when a component is determined to be serviceable. Tag should be placed on the Component and / or tooling before being returned to the customer. Instructions for filling out a Accept Tag: Part Description: (Description of part) Part No. (Part No. of rejected part) Serial No. (Serial No. of rejected part) Work Order No. (W/O of which the rejected part is being worked on) Inspector (Signature or stamp of Authorized Inspector) Note: Make copy of tag to remain as part of the work package identifying the parts, which were accepted. Page Effective: 8-May-06 Quality Manual - Page 46 of 68

75 Shipping & Receiving Inspection Log AIS Form 22 Date Shipped / Rec d Part Number For AIS Job # or Shipped Purchase Order Discrepancies Inspector AIS Form 22 Page Effective: 8-May-06 Quality Manual - Page 47 of 68

76 Shipping & Receiving Inspection Log AIS Form 22 Date Rec d or Shipped column enter the date the part was received or shipped by AeroEd Inspection Services LLC. Part Number column enter the part number off the part / paperwork (verify paperwork & part match) AIS Job # or Shipped column - enter the AIS job number for which the part was ordered if the part/s was ordered for stock enter the word stock If part is being shipped enter word Ship Purchase order column enter the purchase order number assigned to the order if part is shipped enter carrier (UPS, FedEx, DHL, etc) Discrepancies column enter any faults that were noted by the receiving inspector if faults can not be corrected then quarantine the part(s). Receiving Inspector column - enter the signature or stamp of the inspector completing the inspection Page Effective: 8-May-06 Quality Manual - Page 48 of 68

77 Corrective Action Request Form - AIS Form 23 Issue Date Due Date Site/Location Control Number To From Element Reviewed Finding (Cat) Major/Minor Contact Root Cause Corrective Action Product Impact: No Yes (If yes, what action was taken) Implementation Date Issuer Reply Approved Issuer Sign-Off Receiver Sign-Off Signature Date Signature Date Answered By Manager Approval Page Effective: 8-May-06 Quality Manual - Page 49 of 68

78 Instructions for Completing Corrective Action Request Form 23 Purpose: This form is used in conjunction with the internal audit program defined in section six of the QM. The purpose is to document a finding, which resulted as part of an internal audit as well as its root cause and corrective action. This form assigns ownership to a problem found during the review of a certain part of the repair stations maintenance program. The from also allows the business to understand where it s weaknesses are and provides an opportunity to learn from these weaknesses and fix them. Proper Form Completion: 1. Once a finding requiring corrective action has been identified as a result of an audit this form should be completed. 2. The corrective action request form must reference the audit by giving it a control number in the upper right hand corner of the form. This control number can be the date of the audit proceeded by a sequential number or any other acceptable method of matching the corrective action form to the audit itself. 3. The auditor should enter the issue date as well as a due date for the satisfactory correction of the problem. In addition the site or location should be entered. The site or location should be the repair station or facility being audited. 4. The auditor should identify a person or owner responsible for ensuring corrective action is taken and properly documented on this form. Furthermore the auditor should identify him or herself in the from block. 5. The element reviewed will be the area where the problem was encountered. This might be the technical publications library or a particular workstation aspect like calibrations or housekeeping. 6. The auditor should then determine whether or not the finding is major or minor. This will depend on the severity of the problem, such as product impact or safety of flight, which should constitute a major and expired shelf life, which may only be considered minor. 7. The auditor should enter a detailed description of the finding as well as an additional contact person who may have been a party to the problem but may not have been directly involved. This entry will only be required as considered necessary by the auditor. 8. The auditor should then check the block product impact yes or no as applicable and sign and date the issuer sign off block. 9. The auditor should then explain in great detail what is expected of the owner with respect to root cause and corrective action. This part of the form is to be completed by the owner or to party. The owner must also include an implementation date and if product impact explain what was done to fix the item. The owner or receiver should then sign and date the receiver section after the items above have been addressed. 10. At this point the auditor must determine if the action taken was sufficient to correct the problem, identify the root cause and prevent re-occurrence. If the auditor determines that the action taken is sufficient then the reply will be signed as approved along with business leader approval to be filed with that audit report. 11. If the corrective action is not sufficient the auditor may take one of two approaches. a. The auditor may decide to issue a follow-up to the original audit to see if the problem persists and either close the finding at that point or issue another corrective action form referencing that number in the space provided. b. The auditor may choose to completely reject the corrective action and require additional action be taken before closing the finding. If this approach is taken the form should be returned to the owner for re-evaluation. 12. Once satisfactory correction of the finding has been taken the form should be filed along with the audit report. Again, these records are to remain on file for at least two years. Page Effective: 8-May-06 Quality Manual - Page 50 of 68

79 Vendor Inquiry Form 31 VENDOR NAME: ADDRESS: TELEPHONE: FAX: DATE: I. GENERAL INFORMATION 1. Type of Business: Manufacturer s Maintenance Facility ( ) Air Carrier ( ) Repair Station ( ) Distributor ( ) Surplus Parts Dealer ( ) Other ( ) Specify 2. List primary services performed or supplied for AIS: YES NO N/A 3. Is the agency authorized by the FAA to perform the above services under a Repair Station Certificate? Provide Cert. & Ops Specs ( ) ( ) ( ) 4. What is the Repair Station Certificate Number: 5. Are you approved by any other governing agencies or standards, i.e. JAA, CAA, CAAC, ISO, ASA, etc. ( ) ( ) ( ) 6. If yes, please list your approval number and return copies of certifications: 7. Have facilities previously been audited by: Month/Year YES NO N/A AIS Air Carrier FAA 8. Is there a drug/alcohol testing program currently in effect conforming to the Department of Transportation as well as FAA NOTE : Please attach your Drug/Alcohol Program Letter ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) Page Effective: 8-May-06 Quality Manual - Page 51 of 68

80 9. Key Personnel: President/Owner: Phone: Director/Manager: Phone: Quality/Manger: Phone: 10. Total number of employees: # of Production: # of Quality: 11.Number of buildings Type of Construction: Square Footage YES NO N/A Air Conditioned ( ) ( ) ( ) Humidity Controlled ( ) ( ) ( ) Security in Place ( ) ( ) ( ) Fire Fighting Equipment Available ( ) ( ) ( ) II. QUALITY SYSTEM AND MANUAL PROCEDURES YES NO N/A 1. Is a written Quality/Inspection Procedure Manual available and maintained for use by all inspection personnel? ( ) ( ) ( ) 2. The Quality Control System is derived from (Circle) FAR Part 21 FAR part 145 MIL-Q-9858 MIL-I C.A.S.E. Other 3. The Quality manual is revised/reviewed continually to the industry/government specification as required? ( ) ( ) ( ) How Often? 4. Is the Quality Manual available upon request? ( ) ( ) ( ) 5. Is the Quality Inspection organization separate from production? ( ) ( ) ( ) 6. Name and title of Senior Q.A. Official: 7. To whom does the Senior Q.A. Official report: 8. To whom does the Chief Inspector report: 9. Do the following inspection functions exist? Receiving Inspection ( ) ( ) ( ) Preliminary ( ) ( ) ( ) n-process ( ) ( ) ( ) Hidden Damage ( ) ( ) ( ) Vendor ( ) ( ) ( ) Final ( ) ( ) ( ) NDT ( ) ( ) ( ) 10. Is there a documented internal audit program? ( ) ( ) ( ) Page Effective: 8-May-06 Quality Manual - Page 52 of 68

81 11. Is there a policy to correct discrepancies revealed during the audit? ( ) ( ) ( ) 12. Are internal audit results compiled and reported to upper management? ( ) ( ) ( ) 13. Is there a program in place for performing Vendor or Supplier audits? ( ) ( ) ( ) 14. Is there a policy to correct discrepancies revealed during the audit? ( ) ( ) ( ) 15. Are training records maintained for each inspector? ( ) ( ) ( ) 16. Are inspectors required to have FAA certificates? ( ) ( ) ( ) 17. Does the Quality Dept. maintain an up-to-date signature roster? ( ) ( ) ( ) 18. Are training records maintained for at least two years after the employee leaves the company? ( ) ( ) ( ) 19. Are Serviceable Parts Tags/FAA Form being attached to all repaired/overhauled items with at least the following data: a. Airworthiness Release stating that the component identified was repaired and inspected in accordance with current FAA regulations and is approved for return to service. b. Condition of Part (Serviceable, Overhauled, Repaired, Etc.) c. Part Number d. Serial Number (when assigned) e. Pertinent details of the repair or reference to the work order on which the details are recorded f. Date of Repair/Overhaul g. Air Agency Certificate Number (Repair Station or Manufacturer s Maintenance Facility) h. Signature of an authorized representative of the Repair/Overhaul agency ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) 20. Are repair/overhaul actions accomplished on the referenced components at locations other than the address referenced at the beginning of the form? ( ) ( ) ( ) 21. How long are inspection records kept: 22. Are the records available for examination by customer representatives? ( ) ( ) ( ) III. TECHNICAL PUBLICATIONS: YES NO N/A 1. Are the applicable manufacturer s repair/overhaul manuals, ADs, and service bulletins available at the Agency s facility? ( ) ( ) ( ) 2. Are the manuals in item III (1.) kept up to current revision status? ( ) ( ) ( ) Page Effective: 8-May-06 Quality Manual - Page 53 of 68

82 3. Are repairs/overhauls being accomplished in accordance with the applicable manufacturer s current specifications? ( ) ( ) ( ) 4. Is there a system to control working copies ensuring they are revised with the masters? ( ) ( ) ( ) 5. Are the manuals properly identified and available to the mechanics? ( ) ( ) ( ) 6. Are manuals in use, which deviate from the OEM specifications? If yes, what manuals: ( ) ( ) ( ) IV. MEASURING AND TEST EQUIPMENT: YES NO N/A 1. Are procedures in effect, which describe the method and frequency of calibration of measuring, test equipment and master gauges or standards? ( ) ( ) ( ) 2. Is measuring and test equipment marked to designate certification and indicate when next calibration is due? ( ) ( ) ( ) 3. What specification is the calibration program controlled by? 4. Is adequate measuring equipment available to inspection for verifying conformance? ( ) ( ) ( ) 5. Are procedures in place to control personal tools? ( ) ( ) ( ) 6. Is a system of recall established to prevent test equipment and tools from being used after overdue calibration? ( ) ( ) ( ) V. DISCREPANT AND SCRAPPED PARTS: YES NO N/A 1. Are all serviceable and unserviceable parts/components physically segregated? ( ) ( ) ( ) 2. Is there an area designated for discrepant/scrapped parts awaiting disposition? ( ) ( ) ( ) 3. Is there a documented procedure to assure that scrapped parts are either returned to the customer or mutilated beyond repair? ( ) ( ) ( ) Page Effective: 8-May-06 Quality Manual - Page 54 of 68

83 Vendor Inquiry/Audit Form - AIS Form 31 Instructions Purpose: To obtain general information concerning a sub-contractors business and their quality program as it relates to the work they perform for this repair station. This form allows this repair station to have on file a copy of that company s contact information, air agency certificate and operations specifications as applicable and a copy of the companies drug/alcohol program. In addition it allows the vendor to answer questions about it s quality organization and the maintenance it performs and allows this repair station to review this information to determine if it will indeed add the vendor to it s approved sub-contractor list. Proper Form Completion: 1. This form should be sent with a letter to the potential vendor or to an existing vendor explaining what is required to complete and re-submit back to this repair station. 2. The letter should consist of instructions for completion as well as a time frame of when the form should be returned with the requested support documentation. 3. Once completed and returned by the vendor, the Chief Inspector should review the information provided to see if the vendor meets the quality requirements set fourth by this repair station in this RSQM. 4. Once considered approved, the Chief Inspector will add this vendor to the list of approved sub-contractors and retain the information provided on file. Page Effective: 8-May-06 Quality Manual - Page 55 of 68

84 Calibrated Tool Data Sheet Asset/Tag No./OWS No. MFR/PART No. NOMENCLATURE MFR S/N DATE CALIBRATED CALIBRATED BY REPAIRS MADE? Y N DUE CALIBRATION REMARKS: DATE CALIBRATED CALIBRATED BY REPAIRS MADE? Y N DUE CALIBRATION REMARKS DATE CALIBRATED CALIBRATED BY REPAIRS MADE? Y N DUE CALIBRATION REMARKS DATE CALIBRATED CALIBRATED BY REPAIRS MADE? Y N DUE CALIBRATION REMARKS AIS Form 32 Page Effective: 8-May-06 Quality Manual - Page 56 of 68

85 Calibrated Tool Data Sheet - AIS Form 32 Purpose: Provides documentation of the tool's life as well as any repairs that were made or changes in its calibration cycle. Proper Form Completion: 1. This form is to be completed at the introduction of a new tool/gauge requiring calibration or when an additional form must be attached. The form should be updated each time a calibration or repair takes place. 2. Asset Tag No/AIS No.: This is a unique number assigned by AIS to identify the tool/gauge and cannot be duplicated. The numbers are sequential preceded by three letters. 3. Mfg./Part No.: Enter the Mfg. and model number of the tool/gauge if applicable or part number for the tool if the Mfg. is unknown. 4. Enter the description of the tool/gauge next to nomenclature. 5. Enter the Mfg. unique serial number found or gauge or tool if applicable if none is present enter N/A. 6. Upon entering service or re-releasing to service enter the date the unit was calibrated. 7. Indicate whether or not repairs were made. 8. Remarks: Enter the date the unit was returned to service as well as any changes to its calibration cycle or any other pertinent information concerning the tool or gauge calibration status. 9. Enter the source for the calibration, note only those organizations listed as approved facilities may perform calibrations and those calibrations must be traceable to NIST. 10. Enter the date in which the gauge can no longer be used based on frequency of calibration for that particular tool. The due date will be specified on the calibration certificate and calibration sticker supplied by the calibration lab. 11. This form will remain as part of the permanent calibration file for each particular piece of calibrated tooling. Page Effective: 8-May-06 Quality Manual - Page 57 of 68

86 AIS Roster of Supervisory and Management Personnel Name Title Certificate Type and Number Notes AIS Form 37 Page Effective: 8-May-06 Quality Manual - Page 58 of 68

87 AIS Roster of Supervisory and Management Personnel - AIS Form 37 Instructions Purpose: This roster is required by FAR and lists the repair stations supervisory and Management personnel. The roster includes the individuals name, title, certificate type and number as well as their authorizations held at the facility. The authorizations held may reference another form or program governed by the repair station and covered under this RSQM. Proper Form Completion: 1. Enter the full name of the person being added. 2. Enter their title as defined by Section RSM 2 of this manual 3. Enter the certificate type and number held by the individual being added to the roster. Note, to be eligible for addition to the roster, as an inspector the individual must meet the requirements set fourth in FAR part 65 and QCM 3 of this manual. 4. As revisions are made update the information at the bottom of the roster. 5. Add additional pages necessary and complete the page _ of _ at the bottom of the form. Page Effective: 8-May-06 Quality Manual - Page 59 of 68

88 Repair Station Return to Service / Stamp Roster AIS Form 50 Page Effective: 8-May-06 Quality Manual - Page 60 of 68

89 Repair Station Return to Service / Stamp Roster - AIS Form 50 Instructions for Repair Return to Service / Station Stamp Roster Purpose: This form is used to document return to service authority / inspector stamp control and the owner of each stamp. It provides the signature, initials, name, stamp number, date and RSQM number of the individual being issued a stamp, which defines who that person is with respect to the repair station. Proper Form Completion: 1. Enter the individual s full name. 2. Enter the RSQM control number for the RSQM being issued. 3. Date stamp is being issued. 4. Stamp number should be entered here by stamping in the block provided and must be clear and legible. 5. Enter initials, as they would appear in claiming when a stamp has been lost. 6. Enter full signature. 7. This roster should be completed in dark colored ink. 8. When revising this roster (making additions, deletions, lost stamp, etc) circle the corresponding revision number. This is necessary to show the proper revision of the roster without having to re-complete by everyone each time there is a revision. The date should be handwritten and then once revised one single line drawn through and the date re-written. The record of stamp issue shall be maintained for 24 months. AeroEd can not assign Return to Service Inspectors to a job if the Return to Service authorizations are not current. Page Effective: 8-May-06 Quality Manual - Page 61 of 68

90 AIS Form 55 Page Effective: 8-May-06 Quality Manual - Page 62 of 68