UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC 433 Breesport San Antonio, Texas 78216 ELECTRONIC REPAIR STATION MANUAL Including: QUALITY CONTROL SYSTEM ELECTRONIC MANUAL: This manual is maintained and revised to be up to date and valid while posted on this internet based link. Aeroweld authorizes no other electronic copies. Users are prohibited from saving or copying this electronic file onto computers or other storage devices. Printed copies of this file are uncontrolled and the user must validate the revision. Please contact Aeroweld at 210-590-7888 with any questions concerning this manual.
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC 433 Breesport San Antonio, Texas 78216 REPAIR STATION MANUAL Including: QUALITY CONTROL SYSTEM FAA Certificated Repair Station W2XR853X Manual Number: Assigned To:
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm REVISION LOG AND TRANSMITTAL Manual Number: Revision Number: 10 Revision Page Number Instructions Page Number Instructions all insert Follow the instructions in the table above to incorporate this revision into your manual. For pages not included previously, you will be instructed to add the page. When you remove pages, those pages are to be discarded. After you have completed inserting this revision into your manual, sign and date this page in the space provided below. Make a copy of this page and insert it in front of the previous Revision Log and Transmittal pages in your manual. This will provide a chronological revision history. Return the original signed copy of this page to the Chief Inspector. Aeroweld RSM Rev 10 i
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm HIGHLIGHTS OF CHANGE Revision 9 Complete Rewrite 10 All pages reprinted for convenience. Changes made to the following pages: 2-1 Electronic Manuals Wording Clarified 2-2 Electronic Manuals Wording Clarified 3-10 Employee summary data requirements explained 4-1 Policy on rental equipment defined 5-1 Capabilities List yearly review explained Section 9 Contract Maintenance Explained 10-11 New Maintenance Defect form and web site listed 10.14 Self disclosure discussed. A-1 Housing Facilities Updated Aeroweld RSM Rev 10 ii
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm TABLE OF CONTENTS And LIST OF EFFECTIVE PAGES Title Page Rev Date COVER PAGE n/a REVISION LOG AND TRANSMITTAL i 10 9/14/12 HIGHLIGHTS OF CHANGE ii 10 9/14/12 TABLE OF CONTENTS/LIST OF EFFECTIVE PAGES iii 10 9/14/12 iv 10 9/14/12 v 10 9/14/12 PREFACE vi 10 9/14/12 SECTION 1: GENERAL POLICY AND PROCEDURE 1-1 10 9/14/12 1.1 Introduction 1-1 10 9/14/12 1.2 Definitions and Acronyms 1-1 10 9/14/12 1.3 Changes to the Repair Station 1-2 10 9/14/12 1.4 Capabilities List 1-2 10 9/14/12 SECTION 2: MANUAL REVISION AND CONTROL 2-1 10 9/14/12 2-2 10 9/14/12 SECTION 3: ORGANIZATION AND PERSONNEL 3-1 10 9/14/12 3.1 General 3-1 10 9/14/12 3.2 Organizational Structure 3-1 10 9/14/12 3.3 Personnel Duties and Responsibilities 3-2 10 9/14/12 3.3.1 Accountable Manager 3-2 10 9/14/12 3.3.2 President 3-2 10 9/14/12 3.3.3 Director Quality 3-2 10 9/14/12 3-3 10 9/14/12 3.3.4 Quality Assurance Manager 3-4 10 9/14/12 3.3.5 Chief Inspector 3-5 10 9/14/12 3.3.6 Maintenance Manager 3-6 10 9/14/12 3.3.7 NDT Manager 3-6 10 9/14/12 3.3.8 NDT Level III 3-7 10 9/14/12 3.3.9 NDT Level II Technician 3-7 10 9/14/12 3.3.10 NDT Level I Technician 3-7 10 9/14/12 3.3.11 Welder 3-7 10 9/14/12 3.3.12 Technician 3-8 10 9/14/12 3.3.13 Machinist 3-8 10 9/14/12 Aeroweld RSM Rev 10 iii
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm 3.4 Personnel Qualifications 3-9 10 9/14/12 3.4.1 Supervisors 3-9 10 9/14/12 3.4.2 Repairmen 3-9 10 9/14/12 3.4.3 Inspection Personnel 3-9 10 9/14/12 3.5 Personnel Records and Roster 3-10 10 9/14/12 3.5.1 Inspection Personnel Roster 3-10 10 9/14/12 3.5.2 Supervisor Personnel Records 3-10 10 9/14/12 3-11 10 9/14/12 SECTION 4: HOUSING AND FACILITIES 4-1 10 9/14/12 SECTION 5: CAPABILITIES LIST 5-1 10 9/14/12 5.1 Capabilities List Self Evaluation 5-1 10 9/14/12 SECTION 6: TRAINING 6-1 10 9/14/12 SECTION 7: OFF PREMISES MAINTENANCE 7-1 10 9/14/12 7.1 Performance of Maintenance at a Location 7-1 10 9/14/12 Other than the Repair Station 7.2 Performance of Maintenance at A Location 7-1 10 9/14/12 Outside The United States 7.3 Performance of Maintenance at A One Time of 7-2 10 9/14/12 Special Circumstance Location SECTION 8: AIR CARRIER MAINTENANCE 8.1 Airworthiness Release For Air Carrier Work 8-1 10 9/14/12 8.2 Required Inspection Item RII 8-1 10 9/14/12 8.3 Mechanical Reliability Reports 8-2 10 9/14/12 SECTION 9: CONTRACT SERVICES 9-1 10 9/14/12 SECTION 10: QUALITY CONTROL SYSTEM 10-1 10 9/14/12 10.1 Introduction 10-1 10 9/14/12 10.2 Revisions to the Quality Control System 10-1 10 9/14/12 10.3 Initiating Work Orders 10-2 10 9/14/12 10.4 Continuity of Inspection Responsibility 10-3 10 9/14/12 10.5 Receiving Inspection 10-4 10 9/14/12 10.5.1 Materials, Equipment, and Tools 10-5 10 9/14/12 10.6 Preliminary Inspection 10-5 10 9/14/12 10.7 Hidden Damage Inspection 10-6 10 9/14/12 10.8 Part Identification and Tracking 10-7 10 9/14/12 10.9 In-Process Inspection 10-7 10 9/14/12 10.10 Final Inspection and Return to Service 10-8 10 9/14/12 10.10.1 Major Repairs and Alterations 10-8 10 9/14/12 10-9 10 9/14/12 10.11 Record keeping System and Procedures 10-10 10 9/14/12 Aeroweld RSM Rev 10 iv
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm 10.12 Reports of Failures, Malfunctions, or Defects 10-11 10 9/14/12 10.13 Scrap Parts Program 10-11 10 9/14/12 10.14 Correcting Repair Station Deficiencies 10-12 10 9/14/12 10.15 Technical Data 10-12 10 9/14/12 10.16 Tools and Equipment 10-13 10 9/14/12 10.17 Equivalent and Fabricated Special Tools 10-14 10 9/14/12 10.18 Calibration Policy and Procedures 10-14 10 9/14/12 10.19 Calibration Reference Standards 10-15 10 9/14/12 10-16 10 9/14/12 APPENDIX A: DESCRIPTION OF HOUSING AND FACILITIES A-1 10 9/14/12 A-2 10 9/14/12 APPENDIX B: APPROVED CONTRACT MAINTENANCE LIST B-1 10 9/14/12 APPENDIX C: CAPABILITIES LIST C-1 10 9/14/12 C-2 10 9/14/12 Aeroweld RSM Rev 10 v
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm PREFACE This manual was developed by Aeroweld, Inc., Inc. to meet current requirements of 14 CFR Part 145. It is intended to satisfy the requirements for a Repair Station Manual and Quality Control Manual. It describes the facilities, equipment, personnel, policy and procedures used in the operation of this repair station. Forms are contained in Forms Manual FM-01. Housing and facility changes that require FAA acceptance are described in Appendix A of this manual. Maintenance functions contracted to an outside source must be approved by the FAA are listed in Appendix B of this manual. NOTE All forms mentioned in this manual are contained in the forms manual FM-01. Aeroweld RSM Rev 10 vi
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm SECTION 1: GENERAL POLICY AND PROCEDURE 1.1 Introduction To operate as a certificated repair station, the person or organization must have a valid Repair Station Certificate issued in accordance with 14 CFR Part 145. Aeroweld, Inc., Inc. has met these certification requirements and been issued ratings by the FAA under certificate number W2XR853X. All work will be performed in accordance with 14 CFR Part 43 and the limitations prescribed in our Operations Specification and Capabilities List found in Appendix C to this manual. This repair station will not perform any service for which it is not rated, and will not perform any service for which it is rated if it requires technical data, equipment, materials, facilities or trained personnel that are not available. Policy and procedures pertaining to specific requirements are described in this manual will be followed. A copy will be accessible for use by repair station personnel at all times. 1.2 Definitions and Acronyms The following definitions for terms and acronyms shall apply when referenced in this manual. Accountable Manager - the person designated by the certificated repair station who is responsible for and has the authority over all repair station operations conducted under Part 145, including ensuring that repair station personnel follow the regulations and serving as the primary contact with the Federal Aviation Administration (FAA). article - an aircraft, airframe, aircraft engine, propeller, appliance, or component part. contract maintenance maintenance functions performed by person(s) or organizations under an agreement with the repair station. This contract may be written, verbal, or implied. CHDO - the certificate holding district office of the FAA with oversight responsibility of the repair station. EPA Environmental Protection Agency FAA - Federal Aviation Administration FSDO Flight Standards District Office RII - Required Item Inspection 1-1
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm RSM Repair Station Manual. For the purposes of this manual, the RSM is includes the repair station manual, quality control manual, and training program combined. 1-2
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm 1.3 Changes to the Repair Station If Aeroweld, Inc., Inc. intends to change the location of its facilities or makes changes to existing housing or facilities that could have a significant effect on the repair station s ability to perform work, those changes will be submitted as a revision to Appendix A of this manual. The revised Appendix A must be accepted by the FAA prior to these changes becoming effective. The Accountable Manager is responsible for ensuring this is accomplished. In the event that Aeroweld, Inc., Inc. sells or transfers its assets, an amended repair station certificate is required. The Accountable Manager is responsible for reporting these changes to the FAA. The new owner is responsible for preparing and transmitting to the FAA, the application for such an amendment, and may not operate the Repair Station until these changes have been accepted by the FAA. This repair station certificate does not have any fixed duration. It is effective until it is surrendered, suspended, or revoked. If our certificate is suspended or revoked, or if we elect to surrender it, the Accountable Manager will be responsible for returning it to the FAA. 1.4 Capabilities List Aeroweld, Inc., Inc. uses a Capabilities List to identify articles maintained by the repair station under the limited ratings. 1-3
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm SECTION 2: MANUAL REVISION AND CONTROL Aeroweld will use both an electronic version of the RSM and a hard copy version as required. Aeroweld provides enough computer work stations so all personnel required to use the RSM have access to the manual while performing work for the repair station. Aeroweld personnel working off-site will be issued an internet link to the electronic manual, as necessary. Revisions to this RSM may be initiated by the Chief Inspector and must be approved by the Accountable Manager. Each revision will be identified using sequential numbering and a date representing when the revision was initiated. A vertical bar (change bar) is placed in the margin adjacent to revised text to make changes easier to recognize by users. Existing change bars will be removed at the next revision to the page. The Table of Contents and List of Effective Pages are combined into one set of pages that help locate subject text and provide a means of verifying the current revision status of each page. Changes made to the RSM are approved by the Accountable Manager and documented by his/her signature on at the bottom of the last page of the Table of Contents and List of Effective Pages. Aeroweld electronic manuals will be constructed and maintained consistent with the recommendations of FAA Advisory Circular AC 120-78 (as revised). Only the Quality Assurance Manager or his/her designee shall have write capabilities to the Aeroweld manual system. Electronic versions will be published in Adobe Acrobat PDF format, and will be password protected to prevent changes. Receipt of instruction and familiarization on electronic manuals or revisions thereof shall be reflected by completion and return of Aeroweld Revision Notice/Acknowledgment (AW-33). The Chief Inspector also will notify the CHDO when the RSM has been revised by letter or email. Aeroweld will provide the CHDO a paper or electronic copy or Compact Disc (CD) of the revised RSM as requested. The FAA CHDO will notify Aeroweld in writing whether it accepts or rejects the revised RSM. The Chief Inspector will retain a copy of the CHDO s acceptance/rejection document for at least 2 years. Aeroweld will begin using the revised RSM as soon as it is issued. However, in the event the Federal Aviation Administration (FAA) subsequently notifies Aeroweld that a revision is not acceptable, the Director of Quality and the Manager of Quality Control will determine whether any repair station work is or was affected by the unacceptable revised procedure(s). The Chief Inspector will coordinate any rework required with the customer. If an article has already been approved for return to service, the Chief Inspector will notify the Accountable Manager and the customer, and work with the customer to develop an effective strategy to correct the deficiency. The Chief Inspector is responsible to ensure that revisions are issued for each copy of the RSM. The Revision Log and Transmittal Page are designed to provide a record of each revision and include instructions for entering the changes into the manual. When a revision 2-1
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm Manual Revision and Control (cont.) has been issued, a Revision Log/Transmittal Page is created for the revision. Instructions published on this page are followed by the manual holder when inserting the revision into their RSM. When this process is complete, the page is signed and dated at the bottom by person assigned to the manual. A copy of this page will be made and inserted into the manual to provide a record of revision. As subsequent revisions to the manual occur, each Revision Log/Transmittal Page is copied and added to the manual in front of the previous record, creating a revision history. The original signed Revision Log/Transmittal Page is returned to the Chief Inspector. The original signed Revision Log/Transmittal Page is returned to the Chief Inspector to provide a record for monitoring and controlling the revision status of each RSM. A distribution log of manuals will be maintained by the Chief Inspector listing all assigned copies of the manual by number and assignment. The original Revision Log/Transmittal Pages will be kept on file with the distribution log and made available to the FAA upon request. NOTE: Electronic versions of this manual are completely reissued at each revision, the last date inserted and initials may remain blank on electronic copies of this document. Each supervisor and inspector listed on the repair station roster and the FAA CHDO shall be assigned a copy of this RSM. A current copy of this manual will also be accessible for use by all repair station personnel. To prevent access to information that is not maintained current, no employee may make a copy of the manual or pages from the manual, without clearly identifying them as uncontrolled copies. The RSM will be maintained current at all times. The individual to whom the manual copy is assigned is responsible for updating their manual, even if the task is delegated. If the Chief Inspector does not receive the signed Revision Log/Transmittal Page within 2 weeks of the revision distribution, he/she will contact the individual responsible for that manual. If the manual has been completely revised, old manuals shall be destroyed. 2-2
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 SECTION 3: ORGANIZATION AND PERSONNEL 3.1 General This section contains policy and procedures that relate to personnel issues of the repair station. It includes a description of key positions in the repair station but may not describe other positions that do not directly affect the quality control system. Employees will be hired based on their skills, knowledge, and experience. Initial qualifications will be evaluated through a review of employment history, training records, and certifications. Job assignments will be made based on the employee s qualifications. Qualifications for specific positions are defined later in this section. 3.2 Organizational Structure This organization chart identifies (by title only) each position with authority to act on behalf of the repair station. Only positions that relate to the operation of the repair station are included. CEO Accountable Manager President Administration Director of Quality Director of Training Responsible Level III Maintenance Manager Quality Assurance Manager Chief Inspector NDT Manager Welder Machinist Technician Level III Technician Level II Technician Level I Technician 3-1
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 3.3 Personnel Duties and Responsibilities 3.3.1 Accountable Manager The Accountable Manager is the person designated by the repair station with responsibility and authority over all repair station operations. All duties of the Accountable Manager may be delegated to any qualified assistant, as they deem necessary. However, such delegation does not relieve the Accountable Manager of the overall responsibilities. The Accountable Manager is responsible for: Providing adequate equipment, materials and competent, qualified personnel, as necessary, pertinent to the operation of the repair station, in order that it may comply with all applicable Federal Aviation Regulation and manufacturer s recommendations. Ensuring that all repair station housing, facilities, and equipment are properly maintained. Directing, planning, and laying out details of inspection standards, methods, and procedures used by the repair station in complying with all applicable Federal Aviation Regulations and manufacturers' recommendations. Ensuring that repair station personnel are trained in accordance with the Personnel Training Program listed in Section 6. Maintaining a current roster of all management, supervisory, and inspection personnel. Coordinating revisions to the Repair Station Manual to insure that changes initiated by the Chief Inspector are properly reviewed and incorporated into the manual. In the absence of the Accountable Manager, the Director Quality acts on his or her behalf. 3.3.2 President The President reports to the Accountable Manager and is responsible for operations. He is the executive responsible for all operations and management of Aeroweld additionally; he has approval authority for all job quotes. The President is responsible for and has the authority over all repair station operations that are conducted under part 145. His duties include ensuring that repair station personnel follow the regulations. In the absence of the President, the Director Quality acts on his or her behalf. 3-2
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm 3.3.3 Director Quality AEROWELD, INC. Issue: 10 The Director Quality is responsible to the Accountable Manager or the President for the overall state of the company s Quality and Inspection system and also serves as the primary contact with the Federal Aviation Administration (FAA). He shall be the final authority in returning to service airframes, engines, propellers, appliances and the component parts thereof. He is also responsible for utilizing organizational resources in order to meet company goals and tasks. The individual provides job quotes and schedules technicians accordingly. He has return to service authority. Additional duties include but are not limited to the following: Ascertain that all inspections are properly performed and that the proper inspection records, reports and forms used by the Repair Station are properly executed prior to releasing the product for return to service. Accomplish the final acceptance of all incoming material, including new parts, supplies and the airworthiness of articles on which work has been performed outside the Repair Station by contract. Ensures that preliminary, hidden damage, in-progress, and final inspections of all articles processed by the repair station are recorded as outlined in this manual. Oversee the proper tagging and identification of all parts and components as outlined in this manual. Provide for continuity of inspection responsibility, assuring completion of required inspection when personnel shift or assignment changes occur. Ensure rejected and unserviceable parts are handled in such a way as to prevent their reuse as serviceable parts. Ensure that all inspections are properly performed on all completed work before it is approved for return to service, and that the proper inspection and maintenance records, reports, and forms required for such release are properly executed. Maintain files of completed work orders and inspection forms in such a manner that the file pertaining to a specific repaired item can be located for review. In the absence of the Director of Quality, the NDT Manager acts on his or her behalf. 3-3
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 3.3.4 Quality Assurance Manager This individual reports to the Director Quality and has unimpeded access to the CEO. In addition, he is responsible for directing, planning, and laying out the details of inspection standards, methods, and procedures used by the repair station in complying with all applicable Code of Federal Regulations (CFR) and manufacturer s specifications and recommendations. The Quality Assurance Manager is authorized by the Accountable Manager to make applications for Repair Station Certification and/or rating, FAA Form 8310-3, as it pertains to the original application for certification and rating, change in rating, and changes in location or housing facilities and other forms and initiate correspondence with the FAA in regard to the certification or operation of the Repair Station. It is the duty of the Quality Assurance Manager to: Assist the Director Quality and provide direction to all personnel assigned as nondestructive testing technicians. Maintain and keep a current file of pertinent CFR s, Specifications, and Airworthiness Directives Determine that all technical data on all articles inspected by the Repair Station are secured and kept current with the latest revisions. In addition, assure that all military technical orders used in the overhaul and repair of components have been evaluated and approved by the FAA. Assure that periodic checks are made on all inspection tools and the calibration of precision test equipment used by the repair station is current. Further, assure that a current record of those inspections and test is maintained. Determine that no defective, unserviceable, or unairworthy parts are installed in any component or articles released by the Repair Station. Submit reports to the FAA within 96 hours of discovering any failure, malfunction or defects of unairworthy condition in accordance with CFR 145.221. The proper execution of Malfunction and Defects Report, Form 8010-4 or Service Difficulty Report, Form 8070-1, when required. Assure the proper execution of FAA form 337, and / or a maintenance release when it is required. Report to the FAA Flight Standards District Office (FSDO) any known violations of CFR s that the Repair Station is responsible for. Reporting shall be in a manner consistent with AC 120-56, Voluntary Disclosure Report. Responsible for the drug and alcohol program. Providing adequate training, equipment, materials, and competent personnel pertinent to the operations of the repair station in order that it may comply with all applicable 3-4
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 CFR, manufacturer s recommendations, company and quality standards and requirements. Assuring that all personnel who perform aircraft maintenance or preventive maintenance functions on Part 121 programs are relieved from duty for at least 24 consecutive hours during any seven day period or the equivalent thereof within any one calendar month. In the absence of the Quality Assurance Manager, the NDT Manager acts on his or her behalf. 3.3.5 Chief Inspector The Chief Inspector is responsible to the Director Quality for the overall operation of the inspection department and, as such will have authority in the returning to service. In addition, the inspector is responsible for directing, planning and laying out the details of inspection standards, methods and procedures used by the repair station complying with all applicable CFR s, manufacturer s specifications and recommendations. It is the Chief Inspector s duty to: Ascertain that all inspections are properly performed on all completed work and that the proper inspection records, reports and forms used by the repair station, are properly executed prior to releasing the product for return to service. Maintain and keep current a file of pertinent CFR s, specifications, type certification data sheets, and airworthiness directives. Shall be responsible to keep a record of test and calibration equipment. Shall see that test equipment is maintained and calibrated according to the standards specified in this manual. Determine that no defective, unserviceable, or unairworthy parts are installed in any component or articles released by the repair station. Submit reports of unairworthy condition in accordance with CFR 145.221 Assure the proper execution of FAA Form 8130-3 when required, and/or a maintenance release. Accomplish the final acceptance of all incoming material, including new parts, supplies and the airworthiness of articles on which work has been performed outside the repair station by contract. Conduct the receiving, preliminary, hidden damage, in progress, and final inspection of all articles processed by the repair station and record results as outlined in this manual. Oversee the proper tagging and identification of all parts and components as outlined in this manual. Provide for continuity of inspection responsibility, assuring completion of required inspection when personnel shift or assignment change. 3-5
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 See that rejected and unserviceable parts are handled in such a way as to prevent their reuse as serviceable parts. Ascertain that all inspections are properly performed on all completed work before it is approved for return to service, and that the proper inspection and maintenance records, reports, and forms required for such release are properly executed. Maintain files of completed work orders and inspection forms in such a manner that the file pertaining to a specific item repaired can be readily located for review. Responsible for the roster of certificated inspection personal authorized to sign a maintenance release for return to service. Audit the work order package to ensure all sign offs are correctly executed and all items accounted for prior to releasing the aircraft. Assigns trips outside the United States and notifies the CHDO. Maintains and distributes the Electronic Manual in accordance with Section IX of this manual. Issue badges to new employees. NOTE: The Chief Inspector may delegate all duties assigned to any qualified assistant as necessary, however, such delegation does not relieve the Chief Inspector of the overall responsibilities. In the absence of the Chief Inspector, the NDT Manager acts on his or her behalf. 3.3.6 Maintenance Manager The welding department manager is responsible for directing and maintaining all welding and other operations of Aeroweld as instructed by the Accountable Manager or President. Additional duties include but are not limited to the following: Directing all personnel assigned to the production department. Provide adequate training, equipment, materials and competent personnel pertinent to the operations of the repair station in an order that it will comply with all applicable CFR and manufacturer s recommendations. Ensure that all welding operations are properly performed and that the proper records, reports, and forms used by the repair station are properly executed. Ensure that preliminary, hidden damage, in-progress and final inspections of all articled processed by the repair station are recorded as outlined in this manual Responsible for reviewing welding documents submitted to Aeroweld and to provide support to parties involved. This individual is also responsible for the procurement and proper housing of materials and supply for the maintenance shop. 3-6
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 Ensure that all maintenance and if necessary, calibration of equipment contained in the welding shop are maintained in accordance with manufacturer s recommendations. In the absence of the Maintenance Manager, the Director Quality acts on his or her behalf. 3.3.7 NDT Manager The NDT Manager is responsible to the Director Quality for the overall operations of the NDT Department. The Manager of NDT shall have the final authority in the NDT acceptance of airframe, engines, propellers, appliances and the component parts thereof. Additional duties include but are not limited to the following: Assist, supervise and direct all personnel assigned to the NDT Department. Ascertain that NDT inspections are properly performed on all completed work and that inspections records, reports and forms used by the Repair Station are properly executed prior to releasing the product for return to service. Ensure that periodic checks and calibration of all department equipment is performed. Perform additional duties as required by the Director Quality. In the absence of the NDT Manager, the Director Quality acts on his or her behalf. 3.3.8 NDT Level III An NDT Level III is responsible for the training, qualification and certification of NDT Level I and Level II Technicians. This position has return to service authority. Perform additional duties as required by the NDT Manager. 3.3.9 NDT Level II Technician An NDT Level II is a certificated repairman and as such has return to service authority. Perform additional duties as required by the NDT Manager. 3.3.10 NDT Level I Technician 3-7
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 An NDT Level I Technician may receive guidance or supervision from a certified Level 2 or 3 when necessary. When authorized by the Responsible Level 3 may perform interpretations and evaluations of specific products(s) or product form(s) for acceptance or rejection in accordance with approved work instructions and have return to service only for those specific items authorized by the Level 3. Perform additional duties as required by the NDT Manager 3.3.11 Welder A welder performs welding under the direction of the Maintenance Manager. A welder does not have return to service authority. Perform additional duties as required by the Maintenance Manager. 3.3.12 Technician A technician performs any function that he is qualified for. The technician may hold an FAA Airframe, Power Plant, or Repairman certification. The Technician does not have return to service authority. Perform additional duties as required by the Maintenance Manager. 3.3.13 Machinist A Machinist performs machining operations under the direction of the Maintenance Manager. A Machinist does not have return to service authority. Perform additional duties as required by the Maintenance Manager. 3-8
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 3.4 Personnel Qualifications 3.4.1 Supervisors Supervisors will be technically qualified and have a working knowledge of the overall job functions of the repair station. He/She will be certificated under 14 CFR Part 65 appropriate to the work assigned. The Accountable Manager is responsible for verifying this before assignment of a supervisor and must also meet these qualification requirements. 3.4.2 Repairmen Repairman certificated under 14 CFR Part 65 for this repair station may perform, supervise and approve aircraft for return to service work for the repair station under the ratings and limitations of their certificate. He/she may not supervise or return to service any work functions that are not specified on the certificate. To be qualified for any ratings under a repairman certificate, a candidate must have a minimum of 18 months of practical experience in the procedures, practices, inspection methods, materials, tools, and equipment generally used in the duties of the specific job. He/She must be familiar with and understand the policy and procedures of this manual and meet all other requirements of 14 CFR Part 65.101. The Accountable Manager and the Director of Quality will determine when AEROWELD requires a repairman. The Accountable Manager and the Director of Quality will review the qualifications of all individuals AEROWELD recommends for repairmen to ensure they meet the requirement of 14 CFR Part 65.101 for the job function they are occupying. The Accountable Manager will recommend individuals as repairmen. The Director of Quality will ensure all individuals who receive repairman certificates have their training record updated to reflect the certificate. If an employee leaves AEROWELD or no longer performs the job requiring the repairman certificate, the Director of Quality will ensure the individual s repairman certificate is surrendered to the FAA in accordance with 14 CFR Part 65 and the individual s training record annotated as such. 3.4.3 Inspection Personnel The Director of Quality selects inspection personnel based on an individual s qualifications and training. To be an inspector, an individual must be an employee of the repair station and have: 3-9
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 Completed company training covering the applicable Federal Aviation Regulations and current RSM procedures in accordance with Training Program Manual TP-01. The ability to read, write, speak, and understand the English language. A thorough understanding of the inspection methods, techniques, and equipment used to determine the airworthiness of the article, including visual inspection aids. Before assignment as an inspector with the authority to approve an article for return to service, the Accountable Manager will determine that all of the above requirements have been met. This will be documented and maintained in the inspector s personnel records. Recurrent training will be conducted in accordance with the Training Program to ensure that proficiency is maintained (reference Training Program Manual TP-01). 3.5 Personnel Records and Roster The repair station will maintain a roster of all management, supervisory and inspection personnel, including identification of individuals responsible for approving articles for return to service and RII authorizations. The Accountable Manager is responsible for ensuring that this roster is kept current and will revise the roster within five days after any change in personnel or work assignments that could affect the accuracy of the roster, and will notify the CHDO in the same timeframe. This roster may be maintained either on paper or electronic format, as long as it contains all of the information listed above. The roster will be kept in the Accountable Manager s office and available for review by the FAA and repair station employees at any time. The repair station will also maintain employment summaries for each person whose name appears on the roster. The summary will include the employee s position, certificates held, experience, address, and at least the last three places of employment and description of responsibilities at those locations. Employment summaries will be maintained by the Accountable Manager in his/her office. 3.5.1 Inspection Personnel Roster The Inspection personnel roster will contain the following information: Legal name, present title, and scope of current position; total years of experience and the type of work performed; employment history, including name of previous employer and length of employment by month and year; a sample of the signature and initials used on work documents scope of present employment and 3-10
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 Type and certificate number of any certificate held, along with any ratings or limitations. 3.5.2 Supervisor Personnel Records The Supervisor personnel roster will contain the following information: Legal name, present title, and scope of current position; total years of experience and the type of work performed; employment history, including name of previous employer and length of employment by month and year; a sample of the signature and initials used on work documents scope of present employment and Type and certificate number of any certificate held, along with any ratings or limitations. 3-11
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 SECTION 4: HOUSING AND FACILITIES Aeroweld, Inc. (Aeroweld), FAA Certified Repair Station No. W2XR853X is located at 433 Breesport San Antonio, Texas 78216. Our offices and nondestructive testing instruments, welding and related equipment are stored and maintained at this location. The Accountable Manager is responsible for the efficient layout of the repair station and for ensuring the facilities and equipment are adequate to perform all work under the repair station certificate. The Chief Inspector shall be responsible for all tools / equipment that is rented, leased, or borrowed. He shall ensure that the tools / equipment meet the customer s requirements and if calibration is required he shall verify that the instrument has a proper calibration label and verify the label with the calibration certificate. In general, Aeroweld uses only company owned equipment. In some instances, an expensive and infrequently used piece of equipment may be rented. When special tools or equipment is required, the Quality Department will obtain the necessary tools or equipment. All tools and equipment, even if not owned or controlled by Aeroweld, will be received and processed through Aeroweld s receiving inspection process. This includes proper labeling and identification and, if required, verification of calibration. The calibration records must indicate that the equipment is calibrated to the standards established by the article manufacturer, the equipment manufacturer, or standards traceable to the National Institute for Standards and Technology (NIST) or equivalent. The building is of steel frame with concrete block walls construction on a concrete slab and is approximately 5000 square feet. The building has a 120/240 volt electrical supply system with central heat and air conditioning. The shop area has a 150 psig compressed air system. Equipment consists of welding machines, mill, shear, break, lathe, drill press, Heat Treat Oven and non destructive test sets. Whenever a significant change is anticipated to the location, housing, or facilities that might have a significant impact on the ability of the repair station to accomplish its work, the Chief Inspector will develop a revision to Appendix A. The Accountable Manager must approve this revision before a copy is sent to the FAA CHDO for acceptance. The FAA must approve these changes prior to their implementation. After FAA approval, standard manual revision procedures will be followed. 4-1
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 SECTION 5: CAPABILITIES LIST The capability list shall those items Aeroweld may inspect using X-Ray under Aeroweld, Inc. Limited Ratings. It is controlled by revision number and date. The Accountable Manager of this repair station maintains a current Capability List. The Capability List is available for review to all personnel of this repair station. During receiving/inspection, the receiving inspector shall refer to the capabilities list to verify that the services requested are listed. If the services requested are not on the list, the Accountable Manager is notified immediately. The customer will be contacted and the services requested revised to be in compliance with the Capability List, or the work will be declined. 5.1 Capabilities List Self Evaluation The regulations permit Aeroweld to revise its capability list after conducting a self-evaluation of the repair station s capability. The Director of Quality is responsible for determining if an article is within the scope of Aeroweld s authority before adding an article to the capability list. Aeroweld will conduct a self-evaluation to determine if it has adequate housing, facilities, equipment, tools, material, technical data, processes, and trained personnel to perform work on an article under CFR Part 145. This review will be conducted by the Director of Quality when new capabilities are sought, but not less than once a year. The purpose of the yearly review will be to insure that all of the equipment, documentation, training, and personnel necessary to support the existing listed capabilities are still in place. The Director of Quality will use the Capability List Self Evaluation Form (AW-20) to determine that Aeroweld has the facilities, equipment, data, and trained personnel necessary to perform the work. The Director of Quality will review the results of the evaluation with the Accountable Manager. If deficiencies are found, they must be corrected and the correction validated before the capability list may be revised. If approved, the Director of Quality or designee will revise the capability list. He will also review the capabilities list at that time and delete any items that no longer meet the minimum requirements of the self evaluation. The Chief Inspector will submit the revised capability list with a cover letter to the CHDO within five (5) working days of the addition. Upon receipt of the revision, the CHDO is requested to indicate review and acceptance by completion of the FAA CHDO Acceptance Section of the List of Effective Pages and returning to Aeroweld. Changes made per that revision will be indicated by change bars located in the left hand margin. 5-1
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm AEROWELD, INC. Issue: 10 Records/documentation in support of revisions to the Aeroweld capability listing including but not limited to Aeroweld form AW-20 and any correspondence with the CHDO will be maintained by the Chief Inspector for two (2) years. Records may be purged after the two (2) year required period. 5-2
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm Date: 9/19/12 SECTION 6: TRAINING Training of Repair Station personnel will be accomplished in accordance with the Repair Station Approved Training Program. This program is set forth in a stand-alone document titled, Training Program Manual, TP-01. The Quality Assurance Manager has the overall responsibility for seeing this program is fully implemented. He will also review the effectiveness of the program every 120 days, and initiate changes if found necessary. 6 1
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm SECTION 7: OFF PREMISES MAINTENANCE 7.1 Performance of Maintenance at a Location Other Than the Repair Station The NDT / Maintenance Manager will be responsible for assigning the personnel required to complete the job, and the supervision necessary to perform the work in a satisfactory manner. The Chief Inspector will insure that all required forms and work is completed as required by this manual. He will also assign a qualified Inspector who will be responsible for approving/returning the aircraft to service. In addition, the responsible Manager will ensure that the article undergoing maintenance will be protected from damage and from the elements, and that all Repair Station personnel will work in a safe environment. He will also be responsible for providing work forms, tools, technical data, and any other necessary equipment to accomplish the required work, as well as insuring that a copy of the RSM is available for use.. He will establish an effective communication system between the field site and the Repair Station. All personnel assigned to the field site will accomplish the specific function of work in the same manner as if it were performed at the Repair Station, unless deviations are approved by the Chief Inspector, and in accordance with all applicable Federal Aviation Regulations. 7.2 Performance of Maintenance at a Location Outside The United States Aeroweld Inspections may provide specialized service for its customers at a location outside the United States on a temporary basis. An occasion may arise in which an Aeroweld customer has an aircraft located in a foreign country that requires specialized services; Aeroweld will provide services for which it is rated, provided the following occurs: The Aeroweld customer inquires about the possibility of work being performed A Contract or Work Order is executed between Aeroweld and the customer describing the work to be performed. 7 1
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm The CHDO will be notified of operations to be performed in a foreign country by the Chief Inspector by phone conversation and followed by a formal letter of request e-mailed or faxed for approval. Work is performed in accordance with procedures in this section. Services provided in a foreign country will be conducted on a temporary basis, and will terminate upon completion of the services as defined in the contract. Regardless of where maintenance services are to be performed, an evaluation will be made of the work to be performed by the Chief Inspector, or his designee, in determining the scope of work to be performed, required personnel, and material required to accomplish the job. The Chief Inspector may delegate his duties to the technician outside of the United States, if physical tasks normally performed by the Chief Inspector are required. 7.3 Performance of Maintenance At A One Time or Special Circumstance Location Should Aeroweld need to perform services at a location not previously approved under this RSM, the Chief Inspector will contact the CHDO to obtain permission. This contact will be either in writing or via e-mail. The response of the CHDO will be retained for a minimum of two years after the work is performed. 7 2
UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm SECTION 8: AIR CARRIER MAINTENANCE Aeroweld may perform maintenance, preventive maintenance, alterations, and inspections for air carriers conducting operations under CFR Parts 121, 125, 129, and 135, and for other customers. Before work is accepted, the Chief Inspector will verify that Aeroweld is authorized and has the proper manuals, tools, test equipment, and qualified personnel to accomplish the work. If there is any special training required, including training by the customer (as would be the case for an RII), the Chief Inspector will notify the Accountable Manager. For training provided by the customer, the Manager of Training will work with the customer to ensure any Aeroweld personnel requiring training receive the training before beginning work. The Chief Inspector will be the principal contact for the Air Carrier. He will review all purchase orders and purchase order amendments for complete and correct instructions. The Chief Inspector will keep a file of the Air Carrier s procedures, including all necessary technical data. 8.1 Airworthiness Release For Air Carrier Work All work performed under the continues airworthiness requirement of CFR 121, 125, 129, and 135 will have an airworthiness release or appropriate entry in the aircraft log prepared in accordance with the certificate holders manual for the work performed. Aeroweld will maintain adequate personnel for the performance of work which it contracts. Prior to starting any work, Aeroweld will have in its possession, a current copy of the applicable section of the maintenance manual for the work that is to be performed. Each person performing maintenance or preventative maintenance, working a Part 121 aircraft under the provisions of continuous airworthiness requirement will be relieved from duty for 24 consecutive hours during any seven day period or its equivalent, in any one calendar month. A list of supervisory and inspection personnel is maintained at Aeroweld listing the authorized personnel in responsible for the maintenance and inspections and who hold an appropriate FAA Mechanic s or Repairman s Certificate. 8 1