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GUIDE FOR DEVELOPING AND EVALUATING REPAIR STATION AND
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Subject GUIDE FOR DEVELOPING AND Date 7 3 03 AC No 145 9. EVALUATING REPAIR STATION AND Initiated By AFS 340 Change. QUALITY CONTROL MANUALS, 1 PURPOSE This Advisory Circular AC provides information and guidance material for all. repair station certificate holders or applicants under Title 14 of the Code of Federal Regulations. 14 CFR part 145 to develop and evaluate a repair station manual RSM and quality control. manual QCM The material presented in this AC describes an acceptable means but not the. only means to develop a manual and comply with the referenced regulations. 2 CANCELLATION This AC cancels AC 145 3 Guide for Developing and Evaluating. Repair Station Inspection Procedures Manuals dated February 13 1981. 3 RELATED 14 CFR PARTS Title 14 CFR parts 1 21 43 65 91 121 125 129 135 and. 4 DEFINITION OF TERMS FOR THE PURPOSE OF THIS AC, a Acceptable Data is acceptable when it meets the requirements of the applicable. regulations, b Accountable Manager The person designated by the certificated repair station who is. responsible for and has the authority over all repair station operations that are conducted under. part 145 This person s duties include ensuring that repair station personnel follow the. regulations and serving as the primary contact with the Federal Aviation Administration FAA. c Approved Approved by the Administrator unless used with reference to another person. Approval is granted to a repair station when the information such as a process specification or. rating is listed on the operations specifications OpSpecs. d Article An aircraft airframe aircraft engine propeller appliance or component part. e Contracting Entering into an agreement between two or more persons for the. performance of maintenance functions on an article. AC 145 9 7 3 03, f Correction An action taken to eliminate a detected nonconformity For repair stations. electing to use an International Organization for Standardization ISO 9000 quality system a. correction may involve repair or rework and may be made in conjunction with a corrective. g Corrective Action An action taken to eliminate the cause of a detected nonconformity. or other undesirable condition to prevent its reoccurrence For repair stations electing to use an. ISO 9000 or similar system the undesirable condition may include potential regulatory. violations which differs from a nonconformity requiring correction. h Designated Engineering Representative DER A private person designated by the. FAA Administrator to act as its representative for examining inspecting and testing aircraft and. related data A DER may recommend approval or approve data within the limitations of his or. her certificate of authority, i Directly in Charge Responsible for the work of a certificated repair station that performs.
maintenance preventive maintenance alterations or other functions affecting aircraft. airworthiness A person directly in charge doesn t need to physically observe and direct each. worker constantly but must be available for consultation on matters requiring instruction or. decision from higher authority,j Line Maintenance, 1 Any unscheduled maintenance resulting from unforeseen events or. 2 Scheduled checks that contain servicing and or inspections that do not require. specialized training equipment or facilities, k Maintenance Inspection overhaul repair preservation and the replacement of parts. excluding preventive maintenance, l Maintenance Function A step or series of steps in the process of performing. maintenance preventative maintenance or alterations which result in approving an article for. return to service, m Major Alteration An alteration not listed in the aircraft aircraft engine or propeller. specifications that, 1 Might appreciably affect weight balance structural strength performance power.
plant operation flight characteristics or other qualities affecting airworthiness or. 2 Is not done according to accepted practices or cannot be done by elementary. operations,n Major Repair A repair that,Page ii Par 4. 7 3 03 AC 145 9, 1 If improperly done might appreciably affect weight balance structural strength. performance power plant operation flight characteristics or other qualities affecting. airworthiness or, 2 Is not done according to accepted practices or cannot be done by elementary. operations, o Operations Specifications OpSpecs The official document that describes the. authorizations ratings and limitations of the repair station. p Preventive Action An action taken to eliminate the cause of a potential nonconformity. or other potentially undesirable situation For repair stations electing to use an ISO 9000 system. preventative action is taken to prevent an occurrence whereas corrective action is taken to. prevent a reoccurrence For a repair station using an American Society for Quality ASQ. system preventative action is taken to remove or improve a process to prevent potential future. occurrences of a nonconformance, q Preventive Maintenance Simple or minor preservation operations and the replacement.
of small standard parts not involving complex assembly operations. r Procedure A specified way to perform an activity or a series of steps such as a. procedure that describes the methods steps or means to carry out policy. s Quality Control Manual QCM A manual that describes the inspection and quality. control procedures used by the repair station, t Rating A statement that as a part of the repair station s certificate describes the special. conditions privileges or limitations issued under part 145 sections 145 59 and or 145 61. u Repair Station Manual RSM A manual that describes the procedures and policies of. a repair station s operations, v Required Inspection Item RII An item of maintenance that if not performed properly. or if improper parts or materials are used could result in a failure malfunction or defect. endangering the safe operation of the aircraft An RII must be inspected by a trained qualified. and authorized inspector The inspector must be listed on the repair station s roster but can t be. the same individual who performed the work See parts 121 125 and 135 sections 121 371. 125 251 and 135 429 for details of this requirement. w Supervisor A person who directs the work performed under the repair station s. certificate and OpSpecs See part 145 section 145 153 for supervisory personnel requirements. Par 4 Page iii,AC 145 9 7 3 03, 5 BACKGROUND The FAA has revised part 145 the regulation for repair stations This. action is necessary because many of the former repair station regulations did not reflect. advancements in the repair station business and technologies Part 145 reorganizes the. requirements applicable to repair stations to reduce duplication of regulatory language and. eliminate obsolete information In addition it clarifies the minimum requirements for an RSM. introduces a QCM and describes the items that should be included in these manuals. s John M Allen for,James J Ballough,Director Flight Standards Service. Page iv Par 5,7 3 03 AC 145 9,Section Page,CHAPTER 1 GENERAL INFORMATION 1.
1 1 Purpose 1,1 2 The Manual s 1, 1 3 Combining Portions of the Repair Station Manual with the Quality Control Manual 3. 1 4 Identification and Control of Sections 4,1 5 Sample Procedure Formats 5. CHAPTER 2 MANUAL REVISION AND CONTROL 11,2 1 Procedures for Revision 11. 2 2 Provisions for Control 12,2 3 Electronic Format 12. CHAPTER 3 REPAIR STATION ORGANIZATION CHART 15,3 1 Organization Chart 15.
3 2 Duties and Responsibilities 16, CHAPTER 4 REPAIR STATION AND QUALITY CONTROL MANUAL ELEMENTS 19. 4 1 Repair Station Personnel Roster 19, 4 2 Operations Housing Facilities Equipment and Materials 21. 4 3 Capability List 24,4 4 Training Program Revision 26. 4 5 Work Performed at Another Location 27, 4 6 Maintenance Preventive Maintenance and Alterations Performed for Air Carriers. Under Parts 121 125 129 and 135 29,4 7 Contract Maintenance Information 32.
4 8 Proficiency of Inspection Personnel 36,4 9 Current Technical Data 38. 4 10 Inspection and Quality Control System 40,4 11 Required Records and Recordkeeping 49. 4 12 Calibration of Measuring and Test Equipment 52. 4 13 Taking Corrective Action on Deficiencies 55,APPENDIX 1 FORMS 2 pages 1. APPENDIX 2 CHECKLIST 13 pages 1,Page v and vi,7 3 03 AC 145 9. CHAPTER 1 GENERAL INFORMATION, 1 1 PURPOSE This document is a guide for development and evaluation of the RSM and.
QCM required by part 145 sections 145 207 through 145 211 This guide DOES NOT provide a. complete sample RSM and QCM for all repair stations The examples included illustrate one of. many possible ways to comply with the regulations,1 2 THE MANUAL S. a The repair station may have several manuals or documents that are part of its quality. control repair station and training manual system The applicant certificate holder may. combine portions required by section 145 209 with portions required by section 145 211 into one. section or chapter of the manual system For example the procedures required in. section 145 209 for RSM revision and the procedures required in section 145 211 for QCM. revision could be combined into one chapter section titled Manual Revision Additionally the. repair station may use applicable portions of its ISO manual or other quality system such as. ASQ to show compliance with part 145, b The repair station s manual s must remain current and be accessible for use by repair. station personnel as required by part 145 subpart D The manual s may contain more. procedures than required by the regulations for the certificate holder to describe the repair. station s overall functions responsibilities and quality control procedures Procedures described. in the manual s should ensure that the repair station could satisfactorily perform maintenance in. accordance with its rating s In that regard a repair station with a Limited Specialized Service. Rating would have different procedures in its manual system criteria than a repair station with a. Class 3 Airframe Rating Each manual system should be developed based upon the ratings. authorized and the size and complexity of the repair station. c The checklist in Appendix 2 may be used to assist the applicant certificate holder in. reviewing the content of its manual s Not all items listed on the checklist may be applicable to. each repair station due to differences in rating size and type of maintenance performed. d The applicant certificate holder may submit the manual s to the FAA certificate holding. district office CHDO on paper or by an electronic medium If the repair station submits the. manual as part of an initial certification the manual may be submitted together with related. documents such as the application form and repairmen applications to the CHDO If the repair. station submits the manual electronically the repair station should discuss the format software. and revision procedures with the CHDO before submittal All submissions will require a cover. letter The repair station should follow the procedures described in its manual when submitting. revisions to an existing manual see Chapter 2 Manual Revision and Control. e The basic regulatory requirements for manual content are listed below Each requirement. will be discussed in detail in the following sections of this AC. Par 1 1 Page 1,AC 145 9 7 3 03,1 RSM Elements,Manual Revision and Notifying the CHDO. Identification and Control of Sections of the Manual. Organization Chart,Identify each management position. The area of responsibility assigned to each management position. Duties and responsibilities,Rosters Procedures for Maintaining and Revising.
Description of Operations Including the Housing Facilities Equipment and. Capabilities List Procedures for if applicable,CHDO Notification. Self Evaluation Before Revision,Reporting Results,Training Program Procedures for. Submitting to CHDO, Procedures Governing Work Performed at Another Location. Procedures for Maintenance Preventive Maintenance or Alterations for Air. Contracting Procedures for, Maintaining and revising the list of approved maintenance functions. including submitting revisions to the CHDO, Maintaining and revising the list of contract maintenance providers.
including submitting revisions to CHDO,Required Records and Recordkeeping System. 2 QCM Elements,Revision Procedures and Notifying the CHDO. Page 2 Par 1 2,7 3 03 AC 145 9, Qualifying and Surveilling Non Certificated Persons Performing Maintenance. Preventative Maintenance or Alteration for the Repair Station. Establishing and Maintaining Proficiency of Inspection Personnel. Establishing and Maintaining Current Technical Data. Inspection System,Incoming raw material inspection. Preliminary inspection,Hidden damage inspection,Final inspection and return to service.
Calibration of Measuring and Test Equipment Including Intervals of Calibration. Corrective Action, Samples of Inspection Forms and Instructions for Completion may be a separate. 3 Portions Recommended for Most Manuals,Table of Contents. List of Effective Pages,Record of Revisions, 1 3 COMBINING PORTIONS OF THE REPAIR STATION MANUAL WITH THE. QUALITY CONTROL MANUAL, a The following chart illustrates one of several possible combinations that. This AC cancels AC 145 3 Guide for Developing and Evaluating Repair Station Inspection Procedures Manuals dated February 13 1981 3 RELATED 14 CFR PARTS Title 14 CFR parts 1 21 43 65 91 121 125 129 135 and 145 4 DEFINITION OF TERMS FOR THE PURPOSE OF THIS AC a Acceptable Data is acceptable when it meets the requirements of

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