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Approved Maintenance Organisation (AMO) - Technical Assessor Handbook PDF

209 Pages·2017·1.45 MB·English
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Part 145 - Approved Maintenance Organisation (AMO) Technical Assessor Handbook Version 5.2 November 2018 Approval Tier Three Approver Manager, Airworthiness and Engineering Sponsor Manager, Engineering Services Review Date June 2020 Part 145 Technical Assessor Handbook © Civil Aviation Safety Authority All material presented in this Guidance document is provided under a Creative Commons Attribution 4.0 International licence, with the exception of the Commonwealth Coat of Arms (the terms of use for the Coat of Arms are available from the It's an Honour website). The details of the relevant licence conditions are available on the Creative Commons website, as is the full legal code for the CC BY 4.0 license. Attribution Material obtained from this document is to be attributed to CASA as: © Civil Aviation Safety Authority 2018. This document becomes an uncontrolled document when printed. Refer to <www.casa.gov.au/scripts/nc.dll?WCMS:STANDARD::pc=PC_91264 > for current version. This document contains guidance material intended to assist CASA officers, delegates and the aviation industry in understanding the operation of the aviation legislation. However, you should not rely on this document as a legal reference. Refer to the civil aviation legislation including the Civil Aviation Act 1988 (Cth), its related regulations and any other legislative instruments—to ascertain the requirements of, and the obligations imposed by or under, the law. Uncontrolled when printed Part 145 Technical Assessor Handbook Preface As a Commonwealth government authority, CASA must ensure that the decisions we make, and the processes by which we make them, are effective, efficient, fair, timely, transparent, properly documented and otherwise comply with the requirements of the law. At the same time, we are committed to ensuring that all of our actions are consistent with the principles reflected in our Regulatory Philosophy. Most of the regulatory decisions CASA makes are such that conformity with authoritative policy and established procedures will lead to the achievement of these outcomes. Frequently, however, CASA decision-makers will encounter situations in which the strict application of policy may not be appropriate. In such cases, striking a proper balance between the need for consistency and a corresponding need for flexibility, the responsible exercise of discretion is required. In conjunction with a clear understanding of the considerations mentioned above, and a thorough knowledge of the relevant provisions of the civil aviation legislation, adherence to the procedures described in this manual will help to guide and inform the decisions you make, with a view to better ensuring the achievement of optimal outcomes in the interest of safety and fairness alike. Shane Carmody Chief Executive Officer and Director of Aviation Safety Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 3 of 216 Part 145 Technical Assessor Handbook Table of Contents Preface 3 Table of Contents 4 Glossary 8 References 10 Revision History 12 Part A Introduction to this Handbook 15 Purpose of this handbook 15 Who is this handbook for? 15 How to use this handbook 15 What this handbook covers 15 What this handbook does not cover 16 Where to go for further assistance 16 Part 145 overview 17 Background 17 Who is affected by these regulations 17 Requirement of Part 145 18 Approval certificates 18 Maintenance procedures 19 Subcontracting 19 Parts fabricated in the course of maintenance 19 Support functions 20 Authorising employees 20 Issuing certificates of release to service (CRS) 20 Quality management system 20 Safety management systems 20 Human factors 22 Policy statements 23 Assessment of a CASR Part 145 application 23 Part B Assessment Process 24 Assessment overview 24 Objective of the assessment 24 Preliminary and application requirements 24 Assessment scope 24 Assessment elements 25 Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 4 of 216 Part 145 Technical Assessor Handbook Assessment remarks 26 Review and subsequent assessments 27 Significant changes 27 Non-significant changes 27 Renewal 27 Part C Assessment Considerations 28 Part 1 - General 28 Accountable manager's statement 28 Safety and quality policy 28 Management personnel 31 Accountable manager 32 Responsible manager 34 Quality manager 36 Safety manager 37 Management organisational chart 39 Certifying employees 39 Manpower plan 41 Facilities 43 Scope of maintenance services to be provided 46 Significant changes 51 Changes that are not significant changes 52 Exposition 53 Providing employees with exposition 54 Keeping the exposition up-to-date and complaint 55 Changes to AMO exposition 55 Direction by CASA to change exposition 58 Part 2 - Maintenance Procedures 59 Supplier evaluation and subcontract control procedure 59 Receipt/inspection/acceptance of aeronautical products 62 Storage, tagging and release of aeronautical products 64 Tools and equipment 67 Calibration of tools and equipment 69 Use of tooling and equipment by employees 71 Cleanliness standards of maintenance facilities 73 Instructions for continuing airworthiness (ICA) 75 Repair procedure 77 Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 5 of 216 Part 145 Technical Assessor Handbook Airworthiness directives procedure 78 Optional modification procedure 80 Maintenance documentation in use and its completion 82 Technical records control 87 Rectification of defects arising during base maintenance 89 Maintenance certification and certificate of release to service 92 Records for the operator 94 Reporting of defects to CASA/operator/manufacturer 96 Return of defective aeronautical products to store 99 Defective aeronautical products to outside contractors 102 Control of computer maintenance records system 104 Man-hours planning versus scheduled maintenance 109 Control procedures for critical tasks 111 Specific maintenance procedures 115 Procedures to detect and rectify maintenance errors 118 Shift/task handover procedures 122 Procedures for maintenance data 125 Production planning procedures 128 CL2 Part L2 Additional Line Maintenance Procedures 133 L2.1 Control of aeronautical products, tolls, equipment etc. 135 L2.2 Procedures related to Servicing/fuelling/De-Icing etc 137 L2.3 Control of defects and repetitive defects 140 L2.4 Procedure for completion of the operator technical log 142 L2.5 Procedure for pooled parts and loan parts 146 L2.6 Return of defective parts removed from aircraft 147 L2.7 Procedure for control of critical tasks 148 Part 3 Quality and Safety Management 151 Quality management systems 151 Quality audit of organisation procedures 153 Quality audit of aircraft (and/or aeronautical products) 154 Quality audit remedial action procedure 156 Certifying employees - qualifications and training 158 Certifying employees' records 159 Quality audit employees 161 Manufacturer's and other maintenance working teams 162 Human factors training procedures 163 Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 6 of 216 Part 145 Technical Assessor Handbook Competence assessment of employees 165 Safety management systems 168 Safety policy and procedures 168 Safety risk management 177 Safety assurance system 178 Safety promotion 182 Other requirements specific to a Part 145 SMS 185 Part 4 Operations 188 Contracted operators 189 Operator procedures and documentation 189 Operators records completion 191 Part 5 Training and Assessment 192 Facilities 193 Personnel 193 Training and assessment procedures 194 Training sourcing and quality control 195 Authorisation and reporting 195 Records 196 Part 6 Appendices 197 List of documents 197 List of contractors 198 List of line maintenance locations 199 List of contracted Part 145 organisations 199 Provision of maintenance services for aircraft under the CAR 1988 requirements 200 Compliance matrix 200 Appendix 1 Technical Assessor Worksheet 202 Appendix 2 Voluntary Application of Part 145 (CAR 1988 activities) 213 Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 7 of 216 Part 145 Technical Assessor Handbook Glossary Acronyms and Abbreviations Acronym / Abbreviation Description AD Airworthiness Directive (issued under CASR Part 39) ALARP As Low As Reasonably Practicable AMC Acceptable Means of Compliance AME Aircraft Maintenance Engineer AMO Approved Maintenance Organisation AMP Approved Maintenance Program ATSB Australian Transport Safety Bureau AWI Airworthiness Inspector CAAP Civil Aviation Advisory Publication CAAS Civil Aviation Authority of Singapore CAMO Continuing Airworthiness Management Organisation CAO Civil Aviation Order CDCCL Critical Design Configuration Control Limitation CRS Certificate of Release to Service EASA European Aviation Safety Agency EDTO Extended Diversion Time Operating ERP Emergency Response Plan GM Guidance Material HF Human Factors ICA Instructions for Continuing Airworthiness ICAO International Civil Aviation Organisation MEL Minimum Equipment List MMEL Master Minimum Equipment List MOS Manual of Standards QM Quality Manager QMS Quality Management System RPT Regular Public Transport SAG Safety Action Group SFR Standard Form Recommendation – an internal CASA process SM Safety Manager SRB Safety Review Board Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 8 of 216 Part 145 Technical Assessor Handbook Acronym / Abbreviation Description STC Supplemental Type Certificate TC Type Certificate TMI Temporary Management Instruction Definitions Term Definition Applicant A legal entity (a person or organisation) who applies to engage in an activity for which a Part 145 approval certificate is required. For the purposes of this handbook, the applicant may be referred to as an AMO. CASA Intranet CASA internal website previously known as 'CASAConnect', now known as 'HORACE' EDRMS CASA Electronic document records management system previously known as 'TRIM' and currently 'RM8' Entry Control Regulatory consideration of an applicant's suitability to be granted a civil aviation authorisation by CASA. Handbook This CASR Part 145 AMO Technical Assessor Handbook Technical Assessor A CASA Inspector or CASA authorised person who is suitably qualified, trained and experienced (competent) in undertaking a technical assessment of an application for the grant of a civil aviation authorisation by CASA. Technical Assessment An assessment against regulatory requirements to determine compliance. Worksheet The CASR Part 145 AMO Technical Assessor Worksheet referenced in Appendix 1 to this handbook. Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 9 of 216 Part 145 Technical Assessor Handbook Key words Term Definition Must Defines an obligation. The term is used to convey regulatory requirements. 'Must' is used sparingly in the things for consideration sections of this handbook (Part C) to reiterate legislative requirements. Should Signifies a recommendation. The term is typically used in the things for consideration sections of this handbook (Part C) to denote those items that CASA recommends the technical assessor considers in making a decision regard the quality and suitability of an application. May Signifies something that is permitted by not required. The term is frequently used in the things for consideration sections of this handbook (Part C) to provide options and examples of how an applicant may demonstrate compliance with the regulatory requirements References Legislation and Guidance Material In developing this handbook, a number of legislative and technical documents were referenced. This section provides information regarding those referenced documents, as well as information on other material which may be useful in undertaking the technical assessment. CASA Regulatory and Technical Documentation Title Civil Aviation Act 1988 (the Act) Civil Aviation Safety Regulations 1998 (CASR) Civil Aviation Regulations 1988 (CAR) Part 145 Manual of Standards (MOS) Civil Aviation Orders (CAOs) Part 145 Acceptable Means of Compliance (AMC) and Guidance Material (GM) CASA Advisory Circulars Civil Aviation Advisory Publications Australian Standards AS 3669 International Civil Aviation Organization (ICAO) documents: • Annex 6 to the Chicago Convention: Operation of Aircraft • Annex 8 to the Chicago Convention: Continuing Airworthiness of Aircraft • Annex 19 to the Chicago Convention: Safety Management • Doc 9760: Airworthiness Manual • Doc 9859: Safety Management Manual Version 5.2 November 2018 Civil Aviation Safety Authority D18/201261 Uncontrolled when printed Page 10 of 216

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B1.1. Preliminary and application requirements. 21. B1.2. Assessment scope 66. C2.6. Cleanliness standards of maintenance facilities. 68. C2.7 .. Regulations 1998 (CASR) and the Part 145 Manual of Standards (MOS). policy information, Part B includes a high level overview of the assessment
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