Repair Station Manual (Vol. I)

Repair Station Manual (Vol. I) Quality Control Manual

DATE: 14 July 10 Rev 20 Page i

Quality Control Manual

Texas Air Composites, Inc. T42R821Y

15050 Trinity Blvd Fort Worth, TX 76155

Telephone: 972-709-2866 Facsimile: 972-709-2979

Manual Serial Number

021

Copy Assigned To

Tech Library


DATE: 27 August 2013 Rev 30 Page ii

Record of Revisions

Rev: 30 Rev Date:08/27/13 Revised by: Jeremy Ward Date Inserted:08/27/13 Inserted by (Initials): JW

Revision Summary Pages Affected: Multiple (see below) Revised: Section 3.2 Removing Sample Vendor List and the requirement to print other NAA certifications held. Revised: Section 3.13 combining both Section 3.13 and Section 3.14 together. Removed: Section 3.14

Rev: 29 Rev Date:05/05/13 Revised by: Jeremy Ward Date Inserted:05/13/13 Inserted by (Initials): JW

Revision Summary Pages Affected: Multiple (see below) Revised: Section 2.5.1.1 to state Please see the FAA’s Code of Federal Regulations for a review of the definitions for accepted/approved data.

Revised: Appendix A to show new floor plan.

Rev: 28 Rev Date:08/13/2012 Revised by: Jeremy Ward Date Inserted: Inserted by (Initials): JW

Revision Summary Pages Affected: Multiple (see below)

Revised: Section 3.1 to state The company does not allow use of personal Calibrated Tools (i.e. gauges, calipers, etc.) and test equipment (i.e. ohmmeters, thickness gauges, etc.) for Inspection or return to service. Revised: Section 2.13.3 updating the reference to current active AC 21-26 Which has material handling and storage requirements in Section 12. Revised: Section 3.11 to show Maintenance Program compliance requirements.


DATE: 04 June 2012 Rev 27 Page iii

Rev: 27 Rev Date:06/04/2012 Revised by: Mike Campbell Date Inserted:06/19/2012 Inserted by (Initials): JW

Revision Summary Pages Affected: Multiple (see below) Revised: Section 3.12, Requirement to retain Boeing / Aviall records for seven years per Boeing’s PO Quality Notes from 7 Years to 10

Years. Revised: Chart 2.0 Name to state Repairable Part Receiving Inspection. Added: Chart 2.1 Material Receiving Inspection. Revised: Section 2.13.3 to state that Form TAC-043 must me completed and attached to all receivers for freezer materials. Revised: Section 1.6 Company Organization chart to include Manager of Quality Control. Revised: Section 1.9.6 duties and responsibilities for Director of Quality Control Added: Section 1.9.7 duties and responsibilities for Manager of Quality Control Revised: Section 1.9.8 duties and responsibilities to Final Inspector and changed who they are directly responsible to from Director of Quality Control to the Manager of Quality Control. Revised: Section 1.9.9 duties and responsibilities to In process Inspector and changed who they are directly responsible to from Director of Quality Control to the Manager of Quality Control. Revised: Section 1.9.10 duties and responsibilities to Preliminary Inspector and changed who they are directly responsible to from Director of Quality Control to the Manager of Quality Control. Revised: Section 1.9.11 duties and responsibilities to Receiving Inspector and changed who they are directly responsible to from Director of Quality Control to the Manager of Quality Control. Revised: Section 1.9.12 duties and responsibilities to Engineering/Planners. Revised: Section 1.9.13 duties and responsibilities to Purchasing Manager. Revised: Section 1.9.14 duties and responsibilities to Shop Managers. Added: Section 1.9.15 duties and responsibilities For Mechanics

Revised: Appendix B Calibration Intervals to state all NDT calibration intervals reference Texas Air Composites NDTM.


Revision Summary Pages Affected: Multiple (see below)

Revised: Section 1.5 Housing and Facility to include 2321 Solona Ave, as a fixed location. And added transportation of tools, equipment, materials, and repaired parts. Added: Page A-2 in Appendix A, 2321 Solona Ave Layout. Revised: Section 2.7 to read (Inspection will be notified). Revised: Section 2.6 revised the notes that it is permissible to perform work for individual discrepancies out of order as long as it does not prevent the inspection of work not yet performed.


DATE: 16 August 2011 Rev 24 Page iv


Revision Summary Pages Affected: Multiple (see below) Revised: Section 1.1.1 to include electronic submission of manuals to the FAA for Approval/Acceptance Added: Section 1.9.5 duties and responsibilities for Quality Assurance Representative. Revised: Section 1.9.6 duties and responsibilities to Director of Quality Control Added: Section 1.9.7 duties and responsibilities Preliminary Inspector Revised: Section 1.9.8 duties and responsibilities to In Process Inspector Added: Section 1.9.9 duties and responsibilities for Receiving Inspector. Added: Section 1.9.10 duties and responsibilities for Engineering/Planners Revised: Section 1.9.11 duties and responsibilities to Final Inspector Revised: Section 1.9.12 duties and responsibilities to Purchasing Manager Revised: Section 1.9.13 duties and responsibilities to Shop managers Added: Section 1.9.14 duties and responsibilities Mechanics Revised: Section 2.4 adding components which require maintenance prior to completion of the disposition of discrepancies are required to complete TAC Form TAC-019B in detail and provide a printed copy to operations. Revised: Section 2.5 to state what will be checked for on all articles that are maintained or altered. Revised: Section 2.13.1 paragraph 3 adding FAA approval of new articles to the materials the inspector will check. Revised: 2.13.1 paragraph 4 adding and free from contamination. Revised: Section 2.5.2.3 to have the Shop Manager review the work order requirements and print work order paperwork. Revised: Section 3.1 (paragraph 7) (F) adding or initial and date on the bottom of the calibration certificate. Revised: Section 3.1 adding paragraph 10 stating how TAC will maintain, store, and check each tool prior to use.

Rev: 24 Rev Date: 07-6-11 Revised by: Mike Campbell Date Inserted: 8-29-11 Inserted by (Initials): CB

Revision Summary Pages Affected: Multiple (see below) Revised: In multiple sections QC Manager to Director of Quality Control Revised: Section 1.1 to change the format and media requirement for the Master List of Technical Data Removed: the requirement for sectioning of company manuals by chapter from Section 1.1 Revised: Section 1.1.2 for the authority to complete a company MIL to the QA Manager Added: In multiple sections the word “Management” to the Master List for personnel. Revised: Section 1.3.1 changing the responsibility for AD verification from GM to Director of QC Revised: Section 1.6 Company Org Chart to include the addition of Dir. Of QC & removing Shop Leads or PG Leads Removed: The temporary delegation of supervisor from Section 1.7.2 Revised: Section 1.9 in multiple places to move responsibilities from GM to other delegated areas Revised: All areas of the manual previously referencing the Manager of QC to Director of QC Revised: Section 2.5.2.3 to have the Shop Manager print work order paperwork. Revised: Section 2.6 In-Process documentation requirements to make more clear inspection points for shop and inspection personnel Added: Requirements for the stock room to check inventory when restocking freezer materials, and for a monthly check of freezers. Added: A quarterly check requirement for quarantine areas. Revised: Charts 4, 5, and work order documentation chart as needed to reflect minor changes only.


DATE: 24 August 2011 Rev 24 Page v

Rev: 23 Rev Date: 03-8-11 Revised by: Chris Booth Date Inserted: Inserted by (Initials):

Revision Summary Pages Affected: ii, vii, 1-1, 1-2, 1-15, 1-22, 2-6, 3-10, 3-13, and A-1 Revised: Record of revisions page, and LEP to indicate changes incorporated Revised: Section 1.1, removing the requirement to issue a copy of this manual to inspection and supervisory personnel. Instead, the manual will be made available to all repair station personnel and Inspection, Management, and Supervisory personnel will receive a notice of changes by distribution of a Revision Instruction Page. Revised: Section 1.1 of this manual to clarify the use of prints and drawings as reference only and make clear the requirement for checking of currency of said prints and drawings when using them as reference data. Added: In Section 1.8, specific method by which inspection proficiency will be established. Added: In Section 2.6, added instructions for the accomplishment of in-process inspections. Added: In Section 3.1.2, and 1.9.5 responsibility to the MQC for repair tooling. Revised: In Section 3.6.1, scrap on-site procedure to include digital images of mutilated parts taken by TAC and forwarded to the customer. Added: In Section 3.12, a requirement to retain Boeing / Aviall records for seven years per Boeing’s PO Quality Notes. Removed: In Section 1.9.5 removed duplicate responsibility for the MQC to be familiar with 14 CFR. Revised: The shop floor plan to indicate the area segregated for parts in the process of being scrapped on site.

Rev: 22 Rev Date: 12-13-10 Revised by: Mike Campbell Date Inserted: 01-24-11 Inserted by (Initials): CB

Revision Summary

Pages Affected: ii, v, vii, 1-12, 1-13, 1-17 thru 1-27, 3-1, 3-8, 3-13, A-1 Added: Revised Section 1.7.1 to reflect changes to Master List of Supervisory & Inspection Personnel (differentiation between Management and Supervisory Personnel). Added: In Section 1.9.3, updated duties and responsibilities of the Quality Assurance Managers to include the Daily Walk Around. Added: In Section 1.9.4, updated duties and responsibilities of the Quality Control Manager to include ensuring proficiency of inspection personnel; also removal of the Daily Walk Around responsibility. Changed: In Section 3.0, changed name of Malfunction and Defect Report to Service Difficulty Report. Clarified entire process. Added: In Section 3.2.1, TAC now requires non-certificated vendors to maintain their own FAA/DOT compliant Drug and Alcohol Program to be considered for subcontracted maintenance. Added: In Section 3.12, specified GE Aviation Materials Records Retention Requirements to be 7 years from Return to Service. Changed: In Section 3.12, updated address where open W/O will be stored to reflect TAC’s new address. Changed: Org Chart and Management positions to include Director of Operations and remove stockroom supervisor Changed: Revised Floor Plan

Rev: 21 Rev Date: 07-27-10 Revised by: Michael Fornal Date Inserted: 08-06-10 Inserted by (Initials): M.F.

Revision Summary Pages Affected: ii, vii, 1-13 Added: In Section 1.7.1, a reference to form TAC-039 (Record of Revisions for the Master List of Supervisory/Inspection Personnel). Changed: In Section 1.7.2, to describe what is listed on the newest revision of form TAC-016 (Employee Summary).


DATE: 04 June 2012 Rev 27 Page vi

Table of Contents

Section Title Page Cover Page i Record of Revisions ii Table of Contents vi List of Effective Pages ix CHAPTER 1 Section Title Page 1.0 Introduction 1-1 1.1 Manual Control 1-2 1.1.1 Revision Acceptance (Company Manuals) 1-4 1.1.2 Maintenance Information Letters (MIL’s) 1-4 1.1.3 Operations Specifications 1-5 1.2 Forms 1-5 1.3 Capabilities List 1-5 1.3.1 Self Evaluations 1-6 1.4 Operation 1-7 1.5 Housing and Facilities 1-12 1.6 Company Organization 1-13 1.7 Records of Supervisory and Inspection Personnel 1-14 1.7.1 Master List of Supervisory and Inspection Personnel 1-14 1.7.1.1 Inspection Authorities 1-14 1.7.2 Employment Summary 1-15 1.7.3 Repairmen Certificates 1-15 1.8 Training 1-16 1.9 Duties and Responsibilities 1-17 1.9.1 President 1-17 1.9.2 Vice President/General Manager (Acct Manager) 1-18 1.9.3 Director of Operations 1-19 1.9.4 Quality Assurance Manager 1-20 1.9.5 Quality Assurance Representative 1-22 1.9.6 Director of Quality Control 1-23 1.9.7 Manager of Quality Control 1-24 1.9.8 Final Inspector 1-25 1.9.9 In-Process Inspector 1-26 1.9.10 Preliminary Inspector 1-27 1.9.11 Receiving Inspector 1-28 1.9.12 Engineering/Planners 1-29 1.9.13 Purchasing Manager 1-30 1.9.14 Shop Managers 1-31 1.9.15 Mechanics 1-32


DATE: 13 December 2010 Rev 22 Page vii

Chapter 2 Section Title Page 2.0 Inspection System (General) 2-1 2.1 Inspection Personnel 2-1 2.2 Customer’s Work Order 2-2 2.3 Receiving 2-2 2.4 Evaluation & Teardown Inspection 2-3 2.5 Disposition of Discrepancies 2-3 2.5.1 Determination of Major/Minor Repairs & Alterations 2-4 2.5.1.1 Differences between Major / Minor Repairs & Alt. 2-4 2.5.2 Work Order Documentation 2-5 2.5.2.1 Engineering Orders 2-5 2.5.2.2 Operations Sheets 2-6 2.5.2.3 Documentation Flow 2-6 2.6 In-Process Inspection 2-7 2.7 Hidden Damage (Add-ons) 2-7 2.8 Final Inspection and Release to Service 2-7 2.9 Rejection at Final Inspection 2-8 2.10 Tagging of removed piece parts 2-8 2.11 Shipping 2-9 2.12 Identification Stamps 2-9 2.12.1 Stamp Use 2-10 2.12.2 Loss and Recall of Inspection Stamps 2-10 2.13 Supplies and Raw Materials 2-10 2.13.1 Receiving 2-10 2.13.2 Non-Conforming Material 2-11 2.13.3 Freezer Material Receiving Requirements 2-11 2.13.3.1 Freezer Material Storage 2-12 2.13.3.2 Freezer Material Control & Issue 2-13 2.13.4 Customer property received for use on

customer components 2-13 2.13.5 Shelf Life 2-14 2.13.6 Stockroom 2-14 2.13.7 Conformance Sampling 2-15 2.13.8 Materials with Temperature Requirements 2-15 2.14 Quarantine 2-15 2.15 Paperwork Corrections 2-15 2.16 Repair Details 2-16 Chapter 3 Section Title Page 3.0 Service Difficulty Report (FAA from 8010-4) 3-1 3.1 Measuring and Test Equipment 3-1 3.1.1 Leasing of Required Tools 3-3


DATE: 27 August 2013 Rev 30 Page viii

Chapter 3 Section Title Page 3.1.2 Special Tools other than those recommended by the Manufacturer 3-3 3.1.3 Lost & Missing Tools 3-4 3.1.4 No Calibration Required/Self Calibrating 3-4 3.2 Subcontracted Maintenance 3-4 3.2.1 Vendor Approval 3-7 3.3 Suspected Unapproved Parts (SUPS) 3-83.4 Internal Evaluation 3-8 3.5 Retention of Customer Audits 3-8 3.6 Disposition of Non-Repairable / Unserviceable

Customer Parts 3-9 3.6.1 Scrap on site procedures 3-9 3.7 Maintenance away from the Repair Station 3-9 3.8 Duty Time Limitations 3-10 3.9 Separation of Certificated from Non-Certificated Components 3-10 3.10 Continuity of Maintenance 3-11 3.11 Maintenance for Air Carriers Operating Under 135 or 121 3-11 3.12 Required Records and Record Keeping 3-12 3.12.1 Work Order Folder/Sleeve Paperwork Flow 3-13 3.13 Electronic Signatures/ Electronically Stored Company Manuals 3-14 3.13.1 Electronic Signature Security 3-14 3.13.2 Correction of Documents Signed Electronically 3-15 3.13.3 Electronic Signature Traceability/Non-Repudiation 3-15 Appendix A 15050 Trinity Blvd Layout A-1 2321 Solona Ave Layout A-2 Appendix B Calibration Intervals B-1


DATE: 27 August 2013 Rev 30 Page ix

List of Effective Pages

Page # Rev. # Date i REV 20 07/14/10 ii REV 30 08/27/13 iii REV 27 06/04/12 iv REV 24 08/16/11 v REV 24 08/16/11 vi REV 27 06/04/12 vii REV 22 12/13/10 viii REV 30 08/27/13 ix REV 30 08/27/13 1-1 REV 24 08/16/11 1-2 REV 24 08/16/11 1-3 REV 24 08/16/11 1-4 REV 25 01/11/12 1-5 REV 25 01/11/12 1-6 REV 24 08/16/11 1-7 REV 17 04/29/09 1-8 REV 27 06/04/12 1-9 REV 27 06/04/12 1-10 REV 17 04/29/09 1-11 REV 24 08/16/11 1-12 REV 26 01/31/12 1-13 REV 27 06/04/12 1-14 REV 22 12/13/10 1-15 REV 24 08/16/11 1-16 REV 23 03/08/11 1-17 REV 19 06/10/10 1-18 REV 24 08/16/11 1-19 REV 24 08/16/11 1-20 REV 20 07/14/10 1-21 REV 24 08/16/11 1-22 REV 25 01/11/12 1-23 REV 27 06/04/12 1-24 REV 27 06/04/12 1-25 REV 27 06/04/12 1-26 REV 27 06/04/12 1-27 REV 27 06/04/12 1-28 REV 27 06/04/12 1-29 REV 27 06/04/12 1-30 REV 27 06/04/12 1-31 REV 27 06/04/12 1-32 REV 27 06/04/12

Page # Rev. # Date 2-1 REV 24 08/16/11 2-2 REV 24 08/16/11 2-3 REV 25 01/11/12 2-4 REV 29 05/05/13 2-5 REV 29 12/04/12 2-6 REV 25 01/11/12 2-7 REV 26 01/31/12 2-8 REV 17 04/29/09 2-9 REV 17 04/29/09 2-10 REV 25 01/11/12 2-11 REV 28 08/13/12 2-12 REV 27 06/04/12 2-13 REV 24 08/16/11 2-14 REV 24 07/06/11 2-15 REV 24 08/16/11 2-16 REV 17 04/29/09 3-1 REV 28 08/13/12 3-2 REV 25 01/11/12 3-3 REV 25 01/11/12 3-4 REV 24 08/16/11 3-5 REV 24 08/16/11 3-6 REV 24 08/16/11 3-7 REV 22 12/13/10 3-8 REV 17 04/29/09 3-9 REV 24 08/16/11 3-10 REV 24 08/16/11 3-11 REV 28 08/13/12 3-12 REV 27 06/04/12 3-13 REV 24 08/16/11 3-14 REV 30 08/27/13 3-15 REV 30 08/27/13 A-1 REV 29 05/05/13 A-2 REV 26 01/31/12 B-1 REV 27 06/04/12 Quality Assurance Manager Approval__________________


Chapter 1

DATE: 16 August 2011 Rev 24 Page 1-1

1.0 Introduction Texas Air Composites, Inc’s (TAC) Repair Station Manual consists of 5 Volumes. This Quality Control Manual (QCM) is Volume I of the Repair Station Manual. It has been prepared in accordance with the current Federal Aviation Regulations and the internal policies of Texas Air Composites, Inc. Other volumes that make up TAC’s Repair Station Manual are:

Vol II Forms Manual Vol III Training Manual Vol IV Internal Evaluation Program Vol V Repair Detail Procedures Manual

This manual explains the internal inspection systems in detail, including the continuity of inspection responsibility. It gives samples or makes reference to inspection forms currently in use. The manual gives detailed explanation of the following portions of the inspection system: incoming materials, preliminary inspection, in-process and final inspection of articles being processed through this facility. The general repair or alteration of products will be performed in accordance with current Federal Aviation Regulations, process specifications, manufactures’ data, engineering data, customer data, drawings, specifications and /or bulletins or other technical data acceptable to the Administrator. When performing work for aircraft governed under parts 121, 125, 135, or 129, the work shall be performed in accordance with the operator’s approved inspection program / FAA-approved maintenance program respectively. The Director of Quality Control will be responsible for coordinating with the carrier to obtain any manuals or portions of manuals required to perform the maintenance requested by the carrier. This repair station will not alter or maintain any item for which it is not rated, and will not maintain or alter any article for which it is rated if it requires technical data, equipment, materials, facilities, or trained personnel that are not available. The technical library and this manual, required for operation by this repair station, will be maintained in a current status at all times. The Quality Assurance Manager, or his/her designee, will be responsible for ensuring the current status of all technical data maintained by the repair station either by purchase or by the customer supplying the data. Monthly, a representative of the quality assurance department will perform a full audit of all technical data not on revision service to ensure that currency is properly maintained. Said audit shall be documented and maintained on record for review by internal and external auditors for a period of not less than two years. This manual will be made available to all repair station personnel and changes to the manual shall be communicated to all inspection, management, and supervisory personnel by


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distribution and receipt of a manual revision control page to ensure their understanding of incorporated changes. 1.1 Manual Control The Quality Assurance Manager will be responsible for control of technical data; the Director of Quality Control shall serve as the back up. Any copy of controlled manuals (or portion of) used by maintenance personnel as a reference to repair aircraft components, will be marked with the date copied and will be disposed of or revision re-verified no later than 30 days from the date copied. This may be accomplished by dating the front page, adding a revision verification page, or other equivalent method. Other copies of controlled manuals (or portions of) used for purposes other than the repair of aircraft components, will be marked “FOR REFERENCE ONLY”. This may be accomplished by marking the document itself or by marking where it is stored (i.e. filing cabinet). NOTE: The marking of “FOR REFERENCE ONLY” is not to be used for technical data used by inspection, engineering/planning, or maintenance personnel during the course of evaluating or repairing components. A Master List of all manuals will be maintained in an acceptable electronic format. Regardless of the format chosen for maintaining this list of all technical data it is to contain at a minimum the manufacturer name, manual description, revision level, revision date, and aircraft model. The Quality Assurance Manager or his designee will perform audits of technical data IAW the Internal Evaluation Program. A) Company Manuals New or changed information on each page is identified by a vertical line in the left margin; however, changes such as spelling, grammar corrections, etc. which do not change the substance of the manual need not be denoted by the vertical line. The header of each page in a manual will contain the volume number and title of the manual and the chapter number. All manuals will be drafted with a cover page, record of revision page, table of contents, and a list of effective pages, (LEP). All pages will be numbered in the right corner of the footer for proper use of the LEP. The revision number and revision date will be located in the left corner of the page footer. The LEP of all company manuals are to be signed by the QA Manager indicating company acceptance of the manual. Each controlled manual will have an assigned serial number on the cover page (TAC Form TAC-021), other methods such as colored dots with a number and initials or stamp may be used for tapes, CD ROMS etc.


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Any personnel may suggest changes to Company Manuals through the Quality Assurance Manager. The QA Manager will review proposed changes and, if approved, produce the revision. Upon acceptance by the QA Manager, the revision will be routed to the appropriate regulatory authority as required. B) OEM Manuals The preferred method for revision of OEM manuals will be by a contracted revision service. When a revision service is not available, the revision status of the manual shall be checked monthly, as noted in section 1.0. The Quality Assurance Manager, or his/her designee, shall insert all revisions in accordance with the OEM's instructions. Each controlled copy of OEM manuals will have an assigned serial number. The serial number will be written on a colored sticker (or other acceptable method) and initialed by the person labeling the media. Manuals that do not have a revision service will have the last date checked stored and tracked in the TAC database. All personnel must be aware that OEM Manuals may have temporary revisions not located with it. This is especially true for media such as tapes, internet, and CD ROM's, but may also be true for hard copy documents as well. When temporary revisions exist, they must be reviewed prior to using the manual. If personnel are unsure whether or not there are temporary revisions, they shall coordinate with the QA Department for review. C) Prints and drawings A list of all prints and drawings held by the repair station will be maintained by the QA department. Because prints and drawings are not considered FAA Approved Data for the purpose of repairs said prints and drawings are to be used as reference only and will be treated as such IAW with this manual. Prints and drawings are to be checked for currency when incorporated into the referenced technical data for repairs or repair detail fabrication if the date since last check for current revision is greater than 30 days past the date issued. D) Customer data Customer data is revised by the customer and revisions will be inserted per their instructions. Each controlled copy of customer manuals will have an assigned serial number. The serial number will be written on a colored sticker (or other acceptable method) and initialed by the person labeling the media. All personnel must be aware that customer manuals may have temporary revisions, EO's, ETN's, etc. not located with it. This is especially true for media such as tapes, internet, and CD ROM's, but may also be true for hard copy documents as well. When temporary revisions exist they must be reviewed prior to using the manual. If personnel are unsure of whether or not there are temporary revisions, they shall coordinate with the QA Department for review.


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DATE: 11 January 2012 Rev 25 Page 1-4

1.1.1 Revision Acceptance (Company Manuals) Revisions will be submitted to the FAA via electronic format, i.e. CD-ROM, Flash Disk, E-Mail, etc. Approval and or Acceptance (as applicable) of revisions by TAC will be noted on the List of Effective pages (LEP). The Quality Assurance Manager will denote his acceptance by signing the appropriate space on the LEP, and the FAA will denote acceptance by letter. Upon approval and/or acceptance (as applicable) by the FAA, the signed copy will be maintained by the QA Manager. Revisions will be distributed to all controlled manual locations once said approval/acceptance is provided by the FAA. Upon updating of the revision, each person required will be responsible for reviewing all changes, then signing and returning the revision instruction page (TAC Form TAC-014) to the QA Manager. When the QA Manager receives a revision instruction page, he will keep it on file, reflecting that the manual has been reviewed for changes. A Maintenance Information Letter, (MIL), may be issued at the discretion of the QA Manager for each revision to make personnel aware of the change. In lieu of issuing a MIL, the QA Manager may communicate said changes at a company wide meeting(s). The QA Manager may incorporate revisions prior to acceptance at their discretion; however, as a general practice, TAC will wait for manual revisions to be accepted by the CHDO prior to incorporation. Should a revision that has been incorporated prior to acceptance not be accepted by the CHDO, TAC will coordinate with the CHDO to make any necessary changes to the manual. 1.1.2 Maintenance Information Letters (MIL’s) MIL’s are for informational purposes only. Information in MIL’s cannot override the contents of this manual or other approved or accepted data. From time to time it is necessary to disseminate information to all maintenance personnel. In order to ensure that all maintenance personnel receive this information in a timely manner, MIL’s will be issued and communicated ASAP. MIL’s will be numbered as follows: Year (two digit)-Sequential number starting at 1 for each new year i.e. 99-01. A MIL binder will be kept by the QA Manager. The binder will be kept in a location which makes them available to all personnel at all times. The QA Manager will sign the bottom of each MIL denoting he has instructed all personnel in its contents. MIL’s will remain active for a period of six months from the date of issue and will then be discarded. All newly hired personnel will read active MIL’s as part of their new hire training.


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1.1.3 Operations Specifications TAC’s Air Agency Certificate and Operations Specifications will be kept in a binder by the QA Manager, and will be made available to the public upon request. When changes to the Operations Specifications, (Ops Spec’s) are required, a person designated by Section A007 of the current Ops Spec’s will submit for the change in a form or manner acceptable to the administrator. Upon receipt of the changes, the QA Manager will replace the appropriate pages and return the old originals to the CHDO. 1.2 Forms Due to the fact that this and several other manuals may require the use of the same form, while the manuals are on different revision letters, all of the forms required by this manual are located in the TAC Forms Manual. 1.3 Capabilities List TAC will not perform maintenance on any article under its repair station certificate unless it is listed on TAC’s capabilities list. The capabilities list will be maintained and articles will be added and removed in accordance with the procedures outlined in this section. The Director of Quality Control will be responsible for maintaining the capabilities list IAW this section. The capabilities list is maintained in the TAC database and can only be updated by personnel authorized on the Master List of Supervisory, Management, and Inspection Personnel. At this time, the CHDO is not requiring that each individual article be accepted by them at the time it is added. The capabilities list will be forwarded to the CHDO in electronic format, as an Excel file, on a semi-annual basis. The reports submitted to the CHDO shall include a full listing of all parts on the Capabilities List, a list of all part numbers added and/or removed between reporting periods. The CHDO will provide written response indicating acceptance of the items submitted. No article will be added to the capabilities list until a self evaluation (See section 1.3.1) has been performed by a person authorized on the Master List of Supervisory and Inspection Personnel. After completion of the self evaluation, the person who performed the evaluation will denote the completion of the self evaluation in the TAC database by checking the appropriate blocks (the database will automatically record the identity of the person who added the article/performed the self evaluation and the date). In order to maintain data integrity, articles will not be physically deleted from the capabilities list maintained by the database, but will be removed by checking the removed block in the database (the date removed will automatically be recorded) and entering the reasons why the article was removed in the notes section of the database. This will prevent a work order from being issued for that article. For an article to be reinstated after removal, the self evaluation must be performed again, the removed block unchecked, and date reinstated will be recorded in


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the notes section. If an article is then removed again, the removed date will be entered in the notes section. If an article is received by TAC that is not on its capabilities list, a work order will be generated in the TAC database for tracking purposes. The customer’s Repair Order will be routed to a person with the Inspection Authority to add or make changes to the Capabilities List, and the part will be held in receiving until a proper self evaluation, “New Part Evaluation”, is performed. If it is deemed that TAC does not have the capability and rating to perform maintenance on the article, the part number will be added and removed from the Capabilities List as noted in the paragraph above. 1.3.1 Self Evaluations The self evaluation consists of the following items:

A) A review of TAC’s current Ops Spec’s to ensure it has the appropriate rating for the article to be added.

B) Ensure TAC’s facilities are adequate to perform the necessary maintenance. C) Ensure that appropriate technical data required to perform maintenance on the article

is available and current. D) Review the technical data and any other appropriate data to determine any necessary

tools, equipment, and materials required to perform maintenance on the article and ensure they are available.

E) Ensure TAC has sufficient qualified personnel to perform the required maintenance. F) Review for Airworthiness Directives using the FAA website to identify whether there are

any applicable Airworthiness Directives. Note: The Director of Quality Control will be responsible for identifying AD’s issued for parts that are already listed in TAC’s Capabilities List. This will be performed by auditing daily AD’s that are issued by the FAA.

If any of the above requirements are not met, the article will not be added to the capabilities list.


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DATE: 29 April 09 Rev 17 Page 1-7

1.4 Operation The following flow charts depict the general process flow of a component sent for repair to TAC. Chart 1: Dock to Dock:


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DATE: 04 June 2012 Rev 27 Page 1-8

Chart 2: Repairable Part Receiving Inspection


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Chart 2.1 Material Receiving

Material Received at TAC

Does Material have Proper

Trace?

(QCM 2.13.1)

Segregate Material

(QCM 2.13.2)

Issue Supplier Non-Conformance(QCM 2.13.2)

Issue Supplier Non-

Conformance(QCM 2.13.2)

Receive Material In Database

(QCM 2.13.1)Upon

Notification from Purchasing

Material is Returned to

Vendor

Segregate Material

(QCM 2.13.2)

Segregate Material

(QCM 2.13.2)

Issue Supplier Non-

Conformance(QCM 2.13.2)

NOTE: When receiving purchase orders for testing of chemicals for the etch line or penetrant line require verification of approval from the Director of Quality Control. This will be noted in the notes section of the purchase order.

Is this Freezer /Shelf Life

Material?

Did Material Include Temp Recorder?

(QCM 2.13.3)

Is Material Packaged With Dry Ice?(QCM 2.13.3)

Was Vendor Able To Provide Trace?

(QCM 2.13.1)

Does Material Have Proper Trace?(QCM 2.13.1)

Is Out Time Properly Documented?(QCM 2.13.3)

Was Vendor Able To Provide Proper Out Time

Document?(QCM 2.13.3)

If Freezer Material

Generate Time Out Log

(Form TAC-006)

Print Receiver and Labels

(QCM 2.13.1)

Upon Notification from Purchasing

Material is Returned to Vendor

Deliver Material To Stockroom

No

Yes No

NoYes

No

YesYes

No

Yes

Yes

Yes

Yes

No


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Chart 3: Shop Floor


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Chart 4: Shipping

Final Inspection

(See Note 1)

Shipping

(See Note 2)

Customer Service

Final Inspection

Packaging

Database Entries

(See Note 3)

Note 1: Notify Customer Service and hold the part in Final Inspection until advised to ship for work orders

without proper quote approval.

Note 2: Notify Final Inspection of any paperwork discrepancies.

Note 3: Generate all required shipping documents, enter the weigh bill information in the TAC Database,

and print all required Packing Slips and Shipment Notifications.


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1.5 Housing and Facility TAC operates at two locations. The certificate location is located at 15050 Trinity Blvd, Fort Worth, TX 76155, and at another fixed location, (2321 Solona Ave. Unit D Haltom City, TX), both are noted in the repair station Operations Specifications. The location in Fort Worth totals approximately 137,000 square feet, consisting of approximately 112,000 square feet of shop space and approximately 25,000 square feet of office. The building is constructed of reinforced concrete floors and the exterior building consists of pre-cast concrete tilt-wall panels. Shop space area is illuminated with high intensity discharge light fixtures and is fully climate controlled. The Building in Solona totals approximately 3,300 square feet, consisting of approximately 2,200 square feet of shop space and approximately 1,000 square feet of office space. The building is constructed of concrete floors and the exterior building consists of pre-cast concrete tilt-wall panels. Shop space area is illuminated with florescent and flood light fixtures and is climate controlled. A floor plan for each building is located in Appendix A. Any changes to the location or housing of the company must be approved in writing by the local FSDO in advance. In the event that there is an equipment/building failure which affects the ability of the repair station to properly perform maintenance, work will be discontinued until the problem is resolved and the equipment and/or buildings are returned to its proper operating condition. Company vehicles shall be utilized for the transportation of tools, equipment, materials, and repaired parts. All such components shall be properly packaged with regards to ensuring no damage or defect is incurred during transport. Certificated maintenance will be performed in designated areas only. Said designated areas may be identified by using green or other distinguishing color striping on the shop floor which differentiates the area from areas used for non-certificated maintenance only. Note: Eating, drinking, smoking shall be done in designated areas only.


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1.6 Company Organization This chart defines the reporting responsibilities of the supervisory and inspection personnel at TAC. It is the intended to demonstrate the separation between the production and inspection departments.

President / CEO

Vice President / COO

General Manager

Accountable Manager

Director of

Operations

Director of Quality

Control

Purchasing

Manager

Engineering /

Planners

Quality Assurance

Manager

Manager of Quality

Control

Inspectors

Receiving,

Preliminary,

In-Process, & Final

Shop Managers /

Supervisors

Mechanics

Company Quality

Assurance

Representative


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DATE: 13 December 2010 Rev 22 Page 1-14

1.7 Records of Supervisory and Inspection Personnel 1.7.1 Master List of Supervisory and Inspection Personnel

A master list of inspection, management, and supervisory personnel will be maintained by the QA Manager with each inspector, manager, and supervisor’s full name, initials, and stamp number (if applicable). The Master List is maintained and generated from the TAC database.

The master list of supervisory and inspection personnel shall be updated within 5 days to reflect any changes that may occur due to reassignment, termination of employment or any other reasons that effect the duties and assignments of supervisory or inspection personnel. The QA Manager will update and maintain Form TAC-039 (Master List, Records of Revision) each time the Master List is changed. Personnel shown on this list as supervisors, or return to service personnel must meet the certification requirements of 14 CFR Part 145.153 & Part 65. 1.7.1.1 Inspection Authorities

Example: Legend to Authority:

1 Evaluation and Teardown (Repairable Components) 2 In-Process inspection 3 Final inspection / Return to Service* 4 Receiving inspection, raw material 5 Add/Delete articles from capabilities list 6 Generate Repair Orders

The legend of authority will be located at the bottom of the master list. *Persons with final inspection / return to service authority will be approved IAW TAC’s Training Manual and be authorized to complete FAA Form’s 337.

If required by an air carrier to perform RII inspections IAW their manual, TAC will add to the legend of authority RII for the specific carrier. Inspectors will be trained, qualified, and authorized by the carrier IAW their manual. The QA Manager will coordinate with the carrier for training and authorization of inspectors.


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1.7.2 Employment Summary (TAC Form TAC-016) The QA Manager will maintain an employment summary of individuals on the Master List of Supervisory, Management and Inspection Personnel. Active and inactive summaries will be maintained as required. Inactive summaries will be maintained for the time required by section 3.12. The summary will provide the name and title of the individual, the scope of present employment, type certificate(s), rating(s), and total years of experience, from/to dates of employment, and a description of the position(s) held. 1.7.3 Repairmen Certificates The Quality Assurance Manager will determine the need for repairmen certificated IAW FAR Part 65 Subpart E. The QA Manager will apply for a certificate and appropriate class rating for said persons, or for an additional rating, in a form manner prescribed by the Administrator. The following is required to be eligible for a repairman certificate:

A) Be 18 years of age B) Be specially qualified to perform maintenance on aircraft or components thereof,

appropriate to the job for which he is employed C) Be employed for a specific job requiring those special qualifications by a certificated

repair station, or by a certificated commercial operator or certificated air carrier, that is required by its operating certificate or approved operations specifications to provide a continuous airworthiness maintenance program according to its maintenance manuals

D) Be recommended for certification by his employer, to the satisfaction of the Administrator, as able to satisfactorily maintain aircraft or components, appropriate to the job for which he is employed

E) Have either—

(i) At least 18 months of practical experience in the procedures, practices, inspection methods, materials, tools, machine tools, and equipment generally used in the maintenance duties of the specific job for which the person is to be employed and certificated; or

(ii) Completed formal training that is acceptable to the Administrator and is specifically designed to qualify the applicant for the job on which the applicant is to be employed; and


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DATE: 08 March 2011 Rev 23 Page 1-16

F) Be able to read, write, speak, and understand the English language, or, in the case of an applicant who does not meet this requirement and who is employed outside the United States by a certificated repair station, a certificated U.S. commercial operator, or a certificated U.S. air carrier, described in paragraph (c) of this section, have his certificate endorsed “Valid only outside the United States.”

Privileges and limitations of certificate:

(a) A certificated repairman may perform or supervise the maintenance, preventive maintenance, or alteration of aircraft or aircraft components appropriate to the job for which the repairman was employed and certificated, but only in connection with duties for the certificate holder by whom the repairman was employed and recommended.

(b) A certificated repairman may not perform or supervise duties under the repairman certificate unless the repairman understands the current instructions of the certificate holder by whom the repairman is employed and the manufacturer's instructions for continued airworthiness relating to the specific operations concerned.

(c) This section does not apply to the holder of a repairman certificate (light-sport aircraft) while that repairman is performing work under that certificate.

Display of certificate:

Each person who holds a repairman certificate shall keep it within the immediate area where he normally exercises the privileges of the certificate and shall present it for inspection upon the request of the Administrator or an authorized representative of the National Transportation Safety Board, or of any Federal, State, or local law enforcement officer.

Whenever personnel holding a repairman’s certificate cease employment with TAC, the QA Manager will notify the Local FSDO in writing and return the repairman certificate. 1.8 Training All training will be conducted in accordance with TAC’s FAA Approved Training Manual. Inspection proficiency will be established by meeting the initial training requirements found in Texas Air’s Training Program Manual, and will be maintained by meeting the recurrent training requirements found in Texas Air’s Training Program Manual.


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1.9 Duties and Responsibilities 1.9.1 President The President is responsible for the overall operation of the repair station, which includes providing adequate housing and continued maintenance thereof. The President:

Shall be responsible for providing adequate training, equipment, materials, and competent personnel pertinent to the operations of the company in order to comply with all applicable Federal Aviation Regulations (FAR) and manufacturer’s recommendations.

Shall oversee the implementation and effectiveness of the Internal Evaluation Program. The President may delegate his responsibilities or duties to any qualified individual as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve him of the overall responsibility.


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1.9.2 Vice President/General Manager (Accountable Manager) The General Manager is responsible to the President for the overall management and operation of the repair station. The General Manager shall serve as the Repair Station Accountable Manager. The General Manager:

Shall settle any disputes between personnel reporting to him/her.

Shall be responsible for maintaining the premises of the repair station clean and in an orderly manner.

Shall be responsible for assuring that the personnel in the affected departments do quality work.

Shall appoint properly qualified personnel to oversee Purchasing, Operations, Quality, and Engineering functions.

Shall be familiar with and have ready access to all appropriate FAA publications and documents.

Shall have a thorough working knowledge of 14 CFR parts as they relate to the proper repair/overhaul parts maintained by the repair station.

Is responsible for providing direction to the Engineering Department personnel, as needed.

The General Manager may delegate to any qualified assistant as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve the General Manager of his overall responsibilities.


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1.9.3 Director of Operations The Director of Operations, (DO), is directly responsible to the General Manager for the overall operation of the operations department. The Director of Operations must be certificated IAW FAR Part 65 Subparts D or E and must understand, read and write English.

Shall be responsible for ensuring the repair station maintains an adequate number of certificated personnel.

Shall be responsible for assuring the proper handling of all parts while in repair process and when work is completed.

Shall be responsible for maintaining the preservation of parts during work process, installation, and storage.


Shall be oversee and provide overall supervision of all maintenance performed by the repair station.

Shall ensure all maintenance personnel are properly qualified and trained for the maintenance which they are assigned.

The Director of Operations may delegate his responsibilities or duties to any qualified individual as necessary. However, such delegation does not relieve him of the overall responsibility.


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DATE: 14 July 2010 Rev 20 Page 1-20

1.9.4 Quality Assurance Manager The QA Manager is responsible to the General Manager for the production of all assigned duties. The Quality Assurance Manager shall serve as the FAA liaison and is located at 15050 Trinity Blvd, Fort Worth, TX 76155. Phone: 972-709-2866 Fax: 972-709-2979.

Shall be responsible for maintaining and keeping current pertinent Federal Aviation Regulations.

Shall maintain and revise company manuals, including this QCM, and coordinate with the FAA Flight Standards District Office/Certificate Holding District Office, as required, to obtain approval/acceptance of all manual changes, as required.

Shall be responsible for the calibration and record keeping of tools owned by the company and employees used for Return to Service of airworthy parts and components.

Shall be responsible for ensuring the repair station maintains an adequate number of certificated personnel.

Shall issue MIL’s on an as needed basis to properly disseminate information to personnel performing safety-sensitive duties.

Shall be responsible for maintaining the master list of supervisory/inspection personnel (repair station roster) and employment summaries.

Shall be responsible for the Training Program, and Training Records.

Shall be responsible for ensuring all required initial, and recurrent training is performed as needed.

Shall be responsible for the vendor approval program, ensuring that all sub-contracted maintenance is performed by properly certified personnel.

Shall be responsible for the Internal Evaluation Program.

Shall perform sampling of parts, materials and supplies on a monthly basis.

Shall be responsible for all Quarantine Areas.



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Will be responsible for accomplishing all Daily Walk Around inspections, documenting, and maintaining records of TAC Form TAC-025 (Daily Walk Around).

Shall be responsible for maintaining and keeping current FAA approved technical data used by the repair station, manufactures data, and customer required technical data.

Shall be responsible for the development and liaison with the FAA or FAA Delegates for the approval of company repair data such as Process Specifications, Repair Specifications, and individual DER approvals, etc.

The QA Manager may delegate to any qualified assistant (Quality Assurance Representative-QAR) as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve the QA Manager of his overall responsibilities.


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1.9.5 Quality Assurance Representative The Quality Assurance Representative is responsible to the Quality Assurance Manager for the production of all assigned duties. The Quality Assurance Representative:

Shall be responsible for regularly researching and interpreting all applicable Federal Aviation Regulations, Advisory Circulars, as well as Orders & Notices

Shall be responsible for creating and maintaining employee training records in the training database, and processing required documentation and records for issuing job licenses.

Shall be responsible for assisting in developing corrective actions for audit findings, both internal and external, as well as other customer discrepancies.

Shall be responsible for assisting with record and documentation retrieval, and reviews during customer and regulatory audits.

Shall be responsible for assisting with the calibration program which includes but is not limited to: receiving new equipment, sending equipment out for calibration, etc.

Shall assist the Quality Manager for making and/or maintaining revisions to the company’s quality manual(s) as directed by the Quality Assurance Manager.

Shall be responsible for working with various departments to develop and/or improve quality processes and procedures.

Shall be responsible for performing audits in accordance with the Internal Evaluation Program schedule as assigned by the Quality Manager.

Shall be responsible for performing monthly conformance sampling of parts, materials, and supplies on a monthly basis

Shall be responsible for performing as a back-up for material receiving inspection personnel.

Shall be responsible for completing customer quality surveys.

Shall be responsible for assisting in keeping vendor records and approvals current.

Shall be responsible for entering records for items added to and removed from quarantine locations IAW Section 2.14 of this manual.


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1.9.6 Director of Quality Control The Director of Quality Control is directly responsible to the General Manager. The Director of Quality Control must be certificated IAW FAR Part 65 Subparts D or E and must understand, read and write English.

Shall be responsible for the directing, planning and layout of details for the inspection department, as pertaining to inspection standards, methods, procedures and policies used by the repair station.

Shall be responsible for maintaining records of work and inspection forms in such a manner that the file can be readily located for review.

Shall be responsible for maintaining all required material traceability documentation.


Shall be responsible for providing adequate tools, equipment, training, and supervision to all inspection personnel for the performance of receiving, evaluation and teardown inspection, in-process inspection, and final inspection. This shall also include providing for continuity of inspection responsibility and recurrent training. Per 14 CFR 145.211.c.iv, the Quality Control Manager will ensure said training ensures proficiency of all inspection personnel.

Shall be responsible for the training of all personnel utilizing electronically signed company forms.

Shall be responsible for the development of all Repair Detail Packages to meet the requirements of the Repair Station Manual Volume V, (RDPM).

The Director of Quality Control will be responsible for coordinating with the carrier to obtain any manuals or portions of manuals required to perform the maintenance requested by the carrier.

Shall accomplish other duties as may be assigned by the General Manager. The Director of Quality Control may delegate his responsibilities or duties to any qualified individual as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve him of the overall responsibility.


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1.9.7 Manager of Quality Control The Manager of Quality Control is directly responsible to the Director of Quality Control. The Manager of Quality Control must be certificated IAW FAR Part 65 Subparts D or E and must understand, read and write English.

Shall be responsible for ensuring that all raw materials received by the repair station for use in the repair of airworthy items is inspected prior to issuance to production or stores.


Shall segregate all non-conforming material to preclude its use in accordance with applicable procedures.

Shall be responsible for performing preliminary, in-process, hidden damage, and final inspections on repaired components.

Shall be responsible for ensuring that all airworthiness directives have been accomplished and that record of the embodiment has been properly recorded in the work order package.

Shall be responsible for dispositioning discrepancies found during all phases of inspection.

Shall accomplish other duties as may be assigned by the Director of Quality Control The Manager of Quality Control may delegate his responsibilities or duties to any qualified individual as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve him of the overall responsibility.


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1.9.8 Final Inspector Final Inspectors are directly responsible to the Manager of Quality Control. Final Inspectors must be certificated IAW FAR Part 65 Subparts D or E and must understand, read and write English. Final Inspectors

Shall be responsible for ensuring that all raw materials received by him for use in the repair of airworthy items is inspected prior to issuance to production or stores.

Shall verify all pertinent shipping information and purchase order requirements and document this inspection in accordance with applicable procedures.


Shall be responsible for performing preliminary, in-process, hidden damage and final inspections on repaired components.

Shall accomplish other duties as may be assigned by the Director of Quality Control.


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1.9.9 In Process Inspector In Process Inspectors are directly responsible to the Manager of Quality Control and must understand, read and write English. In Process Inspectors:

Shall be responsible for ensuring that all raw materials received by him for use in the repair of airworthy items is inspected prior to issuance to production or stores.

Shall verify all pertinent shipping information and purchase order requirements and document this inspection in accordance with applicable procedures.


Shall be responsible for performing preliminary, in-process, and hidden damage inspections on repaired components.



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1.9.10 Preliminary Inspector The Preliminary Inspector is responsible to the Manager Quality Control for the production of all assigned duties. The Preliminary Inspector:

Shall be responsible for performing the required preliminary inspection of the component documented on TAC Form TAC‐019A & TAC‐019B.

Shall be responsible for inspecting all components received that have been (or have been suspected of having been) involved in an accident or incident in accordance with Federal Aviation Regulation 145.211(iii) (Hidden damage).

Shall be responsible for notifying the General Manager immediately if he believes a part may have been involved in an accident/incident.

Shall be responsible for remaining thoroughly familiar with the applicable sections of Federal Aviation Regulations parts 45,21,23,25,43,65,121,129, and 135 that pertain to their job functions, and be proficient in using the various types of inspection equipment and visual inspection aides appropriate for any article they inspect.

Shall be responsible for remaining thoroughly familiar with all inspection methods, techniques, and equipment used in their area of responsibility to determine the quality of workmanship and airworthiness of any article undergoing maintenance, repair, or alterations.

Shall be responsible for confirming all components have the correct serial and part number as applicable, and making appropriate entries in the database.

Shall be responsible for completing the Part Number/Serial Number Change Form (Form TAC-037) printed from the database, and delivered to customer Service as required.



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1.9.11 Receiving Inspector The Receiving Inspector is responsible to the Manager Quality Control for the production of all assigned duties. The Receiving Inspector:

Shall be responsible for performing inspections of purchased parts and subassemblies according to standard physical, mechanical and electrical measurements. In accordance with section 2.3 of this manual.

Shall be responsible for assuring proper certification, physical and chemical test data, special process certification or source inspection certifications are with the items to be inspected as required.

Shall be responsible for verifying the unit part number and serial number against the physical unit when possible, and against the customers provided paperwork.

Shall be responsible for recording the return shipping location and contact information listed on the customer’s paperwork when available.

Shall be responsible for recording any special customer requirements listed on the customers provided paperwork including but not limited to: service bulletins, engineering orders, ect.

Shall be responsible for noting that the customer states the unit is accident/incident related, or is suspected of the same.

Shall be responsible for performing a visual inspection of the part for shipping damage or other obvious damage not noted on the customer provided paperwork.

Shall be responsible for completing and attaching a Repairable Tag to the component (TAC Form TAC‐018).

Shall be responsible for taking a picture of each component and downloading it into the proper location.

Shall be responsible for initiating the computer record by entering the appropriate information from above into the TAC database.

Shall be responsible for creating a Work Order Folder.



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1.9.12 Engineering/Planners

Engineering/Planners are directly responsible to the General Manager for the production of all assigned duties. Engineering/Planners must be certificated IAW FAR Part 65 Subparts D or E and must understand, read and write English.

The Engineering/Planner:

Shall be responsible for proper disposition of discrepancies found during all phases of inspection, using appropriately approved/accepted technical data.

Shall be responsible for the development and liaison with the FAA or FAA Delegates for the approval of company repair data such as Process Specifications, Repair Specifications, and individual DER approvals etc.

Shall be responsible for the development of all Repair Detail Packages to meet the requirements of the Repair Station Manual Volume V, (RDPM).


Shall have a thorough working knowledge of 14 CFR parts as they relate to the proper Repair/overhaul parts maintained by the repair station.

Shall be responsible for assisting mechanic and inspection personnel with all repair related technical questions.

Shall be responsible for presenting engineering related data to various groups of people. The Engineering/Planner may delegate to any qualified assistant as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve the Engineering/Planner of his overall responsibilities


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1.9.13 Purchasing Manager The Purchasing Manager is responsible to the General Manager for the production of Purchasing and Production Control functions. The Purchasing Manager:

Shall be responsible for purchasing only parts approved for installation on aircraft IAW all current and applicable regulations.

Shall be responsible for obtaining and uploading all Material Safety Data Sheets (MSDS) to the MSDS Online website.

Shall be responsible for the preservation of all articles or parts, while carried in inventory, including parts that are subject to deterioration and shelf life specifications.

Shall be responsible for the freezer material program.

Shall be responsible for the Shelf Life Program.

Shall be responsible for assuring that all parts are marked IAW this manual while in the stockroom.

Shall be responsible for performing monthly flammable locker inventories. The Purchasing Manager may delegate to any qualified assistant as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve the Purchasing Manager of his overall responsibilities.


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1.9.14 Shop Managers Shop Managers are responsible to the Director of Operations for the production of their shop. Shop Managers must be certificated IAW FAR Part 65 Subparts D or E, understand, read and write English. Shop Managers:

Shall be responsible for indoctrinating the personnel in observing the safety precautions relevant to the functions for which they may be utilized.

Shall be responsible for the scheduling of all work orders routed through their shop.

Shall be responsible for the verification of accuracy for materials requisitioned to work orders.

Shall be responsible for quoting the estimated hours of completion for work orders routed through their shop.

Shall accomplish other duties as may be assigned by the Director of Operations. Shop Managers may delegate to any qualified assistant as necessary, unless doing so conflicts with other requirements in the RSM. However, such delegation does not relieve the Shop Managers of his overall responsibilities.


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1.9.15 Mechanics All Mechanics are responsible to assigned Shop Managers for the production of all assigned duties.

Mechanics:

Shall be responsible for ensuring all shelf life items have receiving labels attached and are current and viable prior to each use.

Shall be responsible for ensuring all test equipment has a current and legible calibration label prior to each use.

Shall be responsible for ensuring all maintenance related work is performed in accordance with current manuals.

Shall be responsible for performing other work-related duties as assigned by the Operations Manager.

Shall accomplish other duties as may be assigned by Shop Managers and/or the Director of Operations.


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2.0 Inspection System (General) The Director of Quality Control is responsible for the accomplishment of all work in accordance with this manual, current Federal Aviation Regulations, process specifications, manufactures data, engineering drawings, specifications and /or bulletins, customer data, or other technical data acceptable to the Administrator. Any entry made on inspection forms, FAA forms, internal inspection aids, or any other documents used to record Approval for Return to Service must be signed in ink using the full name of the inspector completing the inspection or the appropriate electronic signatures, as directed in section of 3.13 of this manual. The inspector’s inspection stamp must also be affixed. Current specifications involving inspection tolerances, limits, and procedures as set forth by manufacture of the item undergoing inspection and other forms of inspection information, such as FAA Airworthiness Directives, Manufactures Bulletins, etc., are available to all inspection personnel. A library of applicable Maintenance Manuals, Engineering Letters, Service Letters, FAA regulations, etc. are maintained by the General Manager. The basic inspection system flows through a normal progression of inspection and repair. The types of inspections are:

A. Receiving B. Evaluation and Teardown Inspection C. Hidden Damage Inspection D. In-Process Inspection E. Final Inspection

Specific instructions for performing the above inspections are contained in the body of this chapter. 2.1 Inspection Personnel All inspectors shall comply with the procedures in this manual, and other internal company procedures, as written and / or as supplemented by written or oral directives or revisions, to meet or exceed those requirements of the FAA and / or individual customers. Inspection personnel shall be thoroughly familiar with the applicable section of FAR Part 145,21,23,25,43,65,121,129,135 that pertain to their job functions and be proficient in using the various types of inspection equipment and visual inspection aides appropriate for article they inspect. Inspection personnel are required to be thoroughly familiar with all inspection methods, techniques and equipment used in their area of responsibility to determine the quality of workmanship and airworthiness of an article undergoing maintenance, repair or alterations.


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2.2 Customer’s Work Order The documents provided to the customer are the customer’s Work Order. The customer’s Work Order includes the 8130-3 and the Disposition Report. When a customer sends TAC a revision for a repair order / purchase order, customer service will immediately give the Director of Quality Control the revision. The part will be placed on hold while the revised RO/PO is reviewed by QC/Engineering and any required changes will be made to the work order. If TAC cannot comply with the revised RO/PO, it will contact the customer to discuss possible options. TAC will not comply with any revised RO/PO for a part that has already been returned to service and shipped. 2.3 Receiving The receiving clerk will:

A) Verify the P/N and S/N against the part and customers RO. (Enter discrepancies in the TAC database)

B) Record the ship to location and contact on the customers RO. C) Record any special customer requirements and verify the customer has specified

the data that may be used to repair the part. D) Note if the part is accident related or if he suspects the same. E) Verify the customer reported discrepancies. F) Perform a visual inspection of the part for shipping damage or other obvious

damage not noted by the customer. G) Attach a Repairable Tag to the component (TAC Form TAC-018). H) Take a picture of component.

The repairable tag shall remain attached to the component throughout the repair process, except when it is not practical. When not practical for the repairable tag to remain attached, the component shall be identified by some other suitable means, such as tape with the work order number, tagging the table the component is on, etc. The receiving clerk will initiate the computer record by entering the appropriate information from above into the TAC database. The receiving clerk will create a Work Order Folder. Items to be placed in the W/O Folder at this time include: Customer RO and any other necessary customer documents received with the component. The folder will be forwarded to customer service. All items or components undergoing repair shall be handled in a manner to preclude damage. Suitable trays, racks, and protective covering shall be utilized to afford maximum protection.


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2.4 Evaluation and Teardown Inspection (Preliminary Inspection): A qualified inspector/planner will perform the required preliminary inspection of the component. Said preliminary inspection will be annotated on TAC Form TAC-019A & TAC-019B. Some components undergoing repair will need to be disassembled and existing coating removed in order to inspect the component for damage not easily noticed otherwise. The extent of disassembly and coating removal will be determined by the type of component, previous history, and the extent of the visible damage to the unit. At a minimum, the areas surrounding the visible damage will be inspected. For components which have maintenance requirements necessary prior to completion of the disposition of discrepancies per section 2.5 of this manual, the required actions are to be entered on TAC Form TAC-019B, with detailed instruction and the reference to appropriate technical data, as the first discrepancy. TAC Form TAC-019B is to then be printed and provided to operations. This is to be retained with the work order as part of the maintenance record. Upon full completion of the disposition the work order is to be printed as noted in chart 2 and included in the work order package as detailed in section 2.5.2.3 of this manual. Any component received that has been involved in an accident or incident must also be inspected IAW FAR 145.211(c)(iii) (Hidden Damage) and documented on form TAC-019B. The inspection should include a search for any secondary damage that could result from an accident, such as fire or heat damage. Inspection personnel should be aware that the customer may not notify TAC that the part was involved in an accident or incident and should therefore be alert to any suspicious damage that may indicate the part was involved in an accident. If an inspector feels a part may have been involved in an accident, he should notify the GM immediately, who can then make the proper contacts with the customer. For components that have serial number or part number discrepancies, the error will be confirmed, entries made in the database, Part Number/ Serial Number Change Form (Form TAC-037) printed from the database, and delivered to customer Service. Other forms used by TAC to record maintenance are listed in sections 2.5.2, 3.2, and customer supplied documents. 2.5 Disposition of Discrepancies All discrepancies will be assessed to determine if it is a major or minor repair/alteration. Because of the subjective nature for determining major/minor repairs, the person who makes this determination must be knowledgeable of the regulations and the intent for having a major and minor classification. TAC will only allow a person who has the duty authorization for Disposition of Discrepancies on the Master List of Supervisory and Inspection Personnel to make the determination of major or minor and add the means of correction (disposition), once determined, on Form TAC-019B.


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DATE: 05 May 2013 Rev 29 Page 2-4

TAC will perform inspections of all articles that are maintained or altered to check for the following:

A) Proper documentation, identification, and traceability B) Shipping damage and contamination C) State of preservation D) Life Limits E) Airworthiness Directives and Service Bulletins F) Determination of necessary repairs

NOTE: For details regarding the qualifications of those authorized to make major/minor determinations, please see TAC’s FAA approved Training Program. 2.5.1 Determination of Major / Minor Repairs and Alterations As mentioned above, the determination for major / minor repairs can be subjective. At this time, the best guidance available for making the determination is:

a) FAR Part 1.1 Definitions

Major repair means a repair: (1) That, if improperly done, might appreciably affect weight, balance, structural

strength, performance, powerplant operation, flight characteristics, or other qualities affecting airworthiness; or

(2) That is not done according to accepted practices or cannot be done by elementary operations.

b) FAR Part 43 Appendix A(1)(i-xiii) Note: For an in-depth review regarding the meaning of the above definitions, please see TAC’s FAA approved Training Program.

2.5.1.1 Differences between Major and Minor Repairs and Alterations The following are the main differences between major and minor. Technical Data 1) Minor repairs/alterations require data that is acceptable to the Administrator. 2) Major repairs/alterations require data that is approved by the Administrator. Please see the FAA’s Code of Federal Regulations for a review of the definitions for accepted/approved data. Due to the interpretive nature of data acceptable to the


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DATE: 05 May 2013 Rev 29 Page 2-5

Administrator, and TAC’s Ratings and Limitations restricting TAC only to the use of “APPROVED DATA” for repairs, TAC will ONLY use approved data on repairs or alterations, even when they are determined to be minor. Additional documentation for Major repairs and alterations

Documents in addition to the customer’s work order that TAC must provide to the customer are: a. FAA Form 337 (See note 1), or b. Any 8110-3, and c. The Disposition Report must state contain a full description of the work/inspections

performed. Note 1: The 8130-3 and Disposition Report (Work Order) may be substituted for the 337 for major repairs only unless otherwise requested by the customer. The DR must also contain the following statement: “Pertinent details of the repair are on file at this repair station under W/O XXXXX.” DER’s ARE NOT allowed to make this determination! If TAC is unsure of the classification, TAC’s FSDO should be consulted. DER’s that are used will have their credentials kept on file by the engineering department. When a new DER is utilized, it will be the responsibility of the engineer/planner to receive their credentials. Annually, the General Manager will perform a review of DER credentials and update them, as necessary. 2.5.2 Work Order Documentation 2.5.2.1 Engineering Orders (EO’s) EO’s are used to track and organize repair data developed by TAC for specific work orders. The EO cover page (Form TAC-26) will denote if the EO is a minor repair or alteration, major repair or alteration (as determined IAW Section 2.5), if the data is approved or accepted, the person/agency approving/accepting the data, the applicable aircraft type/model, applicable P/N’s, the affectivity, and an overview of the EO. Documentation supporting the approval/acceptance of the EO will be attached to the EO. EO numbers will be in the following format: Aircraft type/model-ATA-ATA-ATA/#


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2.5.2.2 Operations Sheets (TAC Form TAC-028) Certain components may be of the type that generic procedures can be developed and then used each time that particular component is repaired. Other components may need very detailed instructions developed to alleviate the need for excessive repair documents to be present at mechanic work stations. In these incidents, OPS sheets can be developed to be used in conjunction with TAC Forms 019B. OPS Sheets will be developed from existing approved/accepted data. The first page of all OPS Sheets will contain the Approved / Accepted data used to develop the OPS Sheet, the revision number of the data and the media form of the data. There is also a block for an inspector to sign/stamp and date, verifying that the data listed was current at the time the OPS sheet was issued. This is extremely important in the cases where generic OPS Sheets are used on a recurring basis since technical data is revised at regular intervals. Prior to issuing a generic OPS Sheet if the reviewing inspector finds that some of the technical data has been revised after the OPS Sheet was developed, the QC department will be notified in order to make any necessary changes prior to issuing the OPS Sheet. 2.5.2.3 Documentation Flow Upon completion of the disposition the inspector / planner will route the customer’s repair order to operations for review. A Shop Manager, delegated by the Director of Operations, will review the work order requirements, print forms 019A, 019B, 019C, and any other appropriate documents such as EO’s, OPS Sheets, etc., and attach a copy of the customers repair order along with any teardown documented on TAC form TAC-019B (reference section 2.2 of this manual), and place them in a Work Order Sleeve. This becomes the work order package as detailed in section 3.12 of this manual.


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2.6 In-Process Inspection TAC will inspect all steps in the repair process (100% buy off). For this reason, it is necessary, at a minimum, to perform in-process inspection before any portion of the repair process is “covered up.” As an example: If a delamination was noted in a composite sandwich structure, the damaged skin could be removed, the skin set back to prepare for lay-up, and the core stabilized before performing an in-process inspection; however, the repair plies could not be laid up without an in-process inspection since they would prevent the inspector from verifying proper set backs, etc. The inspector who performed the in-process inspection will affix his stamp or initials/employee number in the appropriate portions of form TAC-019B. Any discrepancies noted during the in-process inspection will be documented on form TAC-019B. This required inspection is to be indicated by entering "Inspection Required" and a horizontal line drawn adjacent to this entry for the inspector to affix his/her stamp, (reference TAC Forms Manual for instructions in the proper completion of in-process points). The person performing and stamping for in-process inspections is to ensure that the work, as noted, has been performed in its entirety IAW the referenced technical data and all inspection and maintenance tasks have been properly completed as noted in the TAC work order traveler. NOTE: INSPECTION PERSONNEL PERFORMING THIS TASK, ARE TO BE THOROUGH AND INSPECT FOR THE PROPER COMPLETION OF MAINTENANCE AND MAINTENANCE DOCUMENTATION. IT IS PERMISSABLE TO PERFORM WORK FOR INDIVIDUAL DISCREPANCIES OUT OF ORDER AS LONG AS THE WORK PERFORMED DOES NOT PREVENT THE INSPECTION OF WORK NOT YET COMPLETED ON OTHER DISCERPANCIES NOT YET COMPLETED. 2.7 Hidden Damage Inspection (add on discrepancies) Discrepancies noted during the repair process will be considered hidden damage. When hidden damage is discovered, Inspection will be notified, who will evaluate and disposition the damage. Hidden damage discrepancies will be documented on the hidden damage section of form TAC-019B. 2.8 Final Inspection and Release to Service A Final Inspector will signify by signing or stamping the block at the bottom of each form TAC-019B that all corrective actions on that page have been completed. The final inspection will be denoted by a final inspector completing form TAC-019C. The final inspection checklist (Form TAC-019C), will consist of a visual inspection of the component for any discrepancies that may not have been found during the preliminary, hidden damage, and in-process inspections, a review of the paperwork to ensure proper completion and that all required paperwork is present, that he has inspected the noted discrepancies to the extent possible, that serial numbers and part numbers match between TAC paperwork and the part, that all requirements on the customers RO have been met, and that all requested maintenance has been performed


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and any other part specific or customer specific inspections have been performed. When approval has been given by the above review, an individual authorized on the official roster of inspectors and properly certificated under FAR Part 65 Subparts D or E, will approve the item for return to service. The inspector will complete a disposition report (TAC Form TAC-001) containing a maintenance release statement and the actions taken to repair the component, and an FAA form 8130-3 (see note 1). The original Disposition Report and 8130-3 will be attached to the part and accompany the part during shipment. A copy of the Disposition Report and 8130-3 will be placed in the work order folder along with all documents in the work order sleeve (The W/O folder then becomes the W/O package). A TAC identification sticker Form TAC 023 or 023A shall be attached to the component. If it is not practical to affix the label to the component, the label shall be affixed to a manila tag and the tag attached to the component, or the part may be part marked with an indelible ink stamp containing the Work Order Number, Part Number, and Serial Number. Note 1: FAA form 337 may be required in place of FAA form 8130-3 for major alteration and repairs see section 2.5.1.1 for details. Components with Life and or overhaul limits will have the current life/overhaul limits listed on the 8130-3 in block 13. 2.9 Rejections at Final Inspection Rejections at final inspection will be documented in the same manner as discrepancies noted during in-process inspection, except the final inspector will also generate an entry in the Rejection Log (TAC Form TAC-020). The Rejection Log will be maintained by the inspection department. The log will contain the date of the rejection, the inspector’s name and a brief description of the reason for rejection. The QA Manager will review the Rejection Log periodically for possible trends that may require corrective action. 2.10 Tagging of removed piece parts Piece parts removed from components shall be marked with the work order number they were removed from. Suitable means of marking are, but are not limited to, placing in parts bins or bags and labeling the bin or bag, placing a tag on the piece part with the work order number, etc. Un-serviceable piece parts should be discarded or given to QC for proper handling. If un-serviceable piece parts need to be kept temporarily, they may be marked by the same means as serviceable parts but must also contain the word un-serviceable on the markings. All efforts should be made to store the un-serviceable piece parts away from serviceable parts.


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2.11 Shipping Prior to packaging, the shipper shall verify that the P/N and S/N on the paperwork, part marking, and part coincide. Any discrepancies shall be brought to an inspector’s attention. On repaired items, when possible, the original shipping container shall be utilized for return shipment. Packaging may consist of cardboard, wood, or any other suitable material. Determining factors include, but are not limited to or by, size, weight, customer requirements, destination, and/or shipping method. General shipping requirements include, but are not limited to or by, the following:

1) Cardboard containers may be utilized for components weighing 70 pounds or less, wood containers for components over 70 pounds.

2) Components shall be individually wrapped with a cushioning material of not less than 1/16 inch thick. Wrapping material shall be secured with masking tape on surfaces not covered by final topcoats.

3) There shall be at least 1 inch of packing material between the component and the edge of the container.

4) Suitable packing material may include, but is not limited to or by, bubble wrap, styrofoam products, paper wadding, pressurized foam, foam blocks, and/or material requested by the customer.

2.12 Identification Stamps This procedure establishes the requirements for issuing, using, auditing, and controlling identification stamps.

Identification stamps will be made of acid resistant rubber for use with permanent marking inks. Stamps used by inspectors will have a unique number and the letters INSP and TAC enclosed in a circle. Inspectors will use red ink. Stamps used by maintenance personnel will have a unique number and the letters TAC enclosed in a triangle. Maintenance personnel will use a color other than red; the preferred color will be blue. The identification stamps in use by the company are shown and issued on TAC Form TAC-002 (Inspection and Identification Stamp Record), maintained by the Quality Assurance Manager. Control of all identification stamps is vested with the QA Manager, who shall retain sole authority for their issuance, use, and recall.


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2.12.1 Stamp Use

Inspectors will use their stamps whenever this manual requires it. They may also use it in situations requiring signatures, initials, or employee number that have not been covered in this or another manual. Maintenance personnel who have been issued stamps may use them in lieu of this manual’s requirement for initials and employee number or signature (unless specifically noted otherwise). Not all maintenance personnel will be issued stamps; individuals will be evaluated on a case-by-case basis. The stamp recipient is the only person permitted to use the assigned stamp and is responsible for its safeguarding, cleanliness, and legibility. Worn stamps are to be returned to the QA Manager for replacement. 2.12.2 Loss and Recall of Inspection Stamps

The loss of any identification stamp is to be immediately reported to the Quality Assurance Manager. The QA Manager is responsible for the immediate issuance of a Maintenance Information Letter announcing the loss of the stamp, and establishing a beginning and ending date when its use will not be accepted. If not found, all stamps that are lost shall remain inactive for a period of 24 months before they can be re-issued. All stamps recalled shall remain inactive for a period of six months prior to re-issue. These stamps shall be stored under the control of the QA Manager in a safe manner, which will prevent them from being used until the six month period has passed. 2.13 Supplies and Raw Materials 2.13.1 Receiving The receiving area will be separated from areas where certificated maintenance is performed and materials not yet sent through the receiving process will be controlled through limited-access to the receiving area. All material received by the company for use in the repair of aircraft components will be routed through receiving inspection prior to release to stock. Only inspectors with raw material receiving authorization on the Master List of Supervisory, Management, and Inspection Personnel shall be able to receive items in the TAC database. The inspector will check the material’s documentation against TAC’s purchase order to confirm that all purchase order requirements are met, with regards to traceability, part number, quantity, MSDS reports, Federal Aviation Administration approval of new articles, and test reports, as required.


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All incoming material will be visually checked to ensure that there are no apparent defects or malfunctions, the material is in a good state of preservation, and free from contamination. The material will also be visually checked to ensure it has the correct part number, serial/batch number, quantity, and expiration date, as applicable. Conforming material will be received into the TAC database by the inspector and a receiver will be generated. All traceability documents received with the material shall be attached to the receiver and retained in a cabinet maintained at the location which the material is received, or long-term storage. See section 3.12 for retention requirements. The TAC database will generate receiving labels (TAC Form TAC-005) with the receiver. The inspector will place the receiving label on the material before releasing it to the stockroom. For items with shelf life expirations, the receiving label shall be placed on the item in a manner that will keep the label with the item after initial use, whenever possible. For example, the label should not be placed on boxes that may be discarded, but placed on the actual tube or can. 2.13.2 Non-Conforming Material Material lacking proper traceability will not be accepted into the TAC database. Upon finding a non-conforming item, the inspector will immediately place the material in a segregated temporary holding area within the controlled receiving area. The inspector will then enter a Supplier Non-Conformance in the database, which will automatically notify purchasing of the non-conformance. The Purchasing Manager is responsible for contacting the supplier and correcting the non-conformance or returning the product to the supplier. When the inspector receives the correct traceability documentation from the Purchasing Manager, he will receive it in IAW receiving procedures in section 2.13.1. Please see section 3.3 for procedures related to Suspected Unapproved Parts. 2.13.3 Freezer Material Receiving Requirements (Prepregs, Adhesives etc.) The following procedures have been developed IAW the guidelines set forth in AC 21-6

paragraph Section 12. The procedures in AC 21-26 (and therefore the following procedures) have been found to be an acceptable alternative means of compliance with the OEM purchaser receiving inspection requirements. When certification to specifications is required, if the material is purchased from an approved supplier (directly or indirectly), IAW the OEM or other FAA-approved material specification, Normal traceability paperwork will be considered adequate documentation of the material conformity to the material specification. When material is purchased from non-approved sources, copies of the original material manufacturer test reports (Not simply traceability),


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showing actual results, must accompany each batch of material received, and verification testing will be accomplished IAW the requirements of the material specification. All materials received, must also have documentation showing the amount of “out time” used and documentation of storage and shipping temperatures from the time it left the approved suppliers freezer to the time it arrived on TAC’s dock. The required documentation could be in the form of chart recorders, tapes or other empirical data. If shipment is done with dry ice alone, check the following:

1) The shipment must have been packaged in a container with appropriate insulating material (usually Styrofoam 1 to 1.5 inches thick) with an original quantity of dry ice equal to approximately .0035 pounds per cubic inch.

2) There must be dry ice remaining in the packaging. 3) Shipping time cannot have exceeded 72 Hrs. * Material may be packaged with different quantities of dry ice and shipped over longer periods of time if the shipper has a documented and proven shipping method. Documentation of shipper’s method must be obtained and kept on file by the QC Manager.

Forms equivalent to TAC’s time out log may be accepted for material purchased from other 145 repair stations or 121 air carriers in place of the documentation showing compliance up to leaving the 145 repair station or 121 carriers freezer, provided they have a system containing all the elements contained in the previous paragraphs. Documentation of their system must be obtained and kept on file in order to show their system is equivalent. TAC Form TAC-043 (Freezer Receiving Checklist) will be completed and attached to Texas Air Composites Receiver for all freezer material. TAC Form TAC-006 (Time out Log) is used in lieu of the receiving label form TAC-005. Proper use of the time out log can be found in the instructions for that form in the forms manual. See section 3.12 for retention requirements When transporting freezer materials, the time out is to be logged on the Time out Log when removed, and sent with the material. The location receiving the material is to inspect the material for adverse exposure, and ensure that the Time out Log is completed properly. The location receiving the material will maintain the Time Out Log properly as required by this manual. 2.13.3.1 Freezer Material Storage Pre-impregnated cloth should be stored in moisture proof containers and placed in the freezer in a manner that does not promote resin migration (i.e roll should not be stood on end, but laid flat and suspended in the air). When removed from the freezer the material should be allowed


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to thaw in the moisture proof container until condensation on the exterior of the container has dissipated in order to prevent atmospheric moisture condensation on the material. The time out log may be placed inside the protective bag/container for organizational purposes: if the log can not be easily read, the P/N, receiver number and expiration date will be written on the bag/container. 2.13.3.2 Freezer Material Control and Issue Due to its susceptibility to the environment and its special shelf life requirements, freezer material is of special concern. For this reason, the freezers will be locked and controlled by the stockroom. Stockroom and inspection personnel are the only persons authorized to open and remove items from the freezer. Whenever maintenance requires freezer material, authorized personnel will remove the required material for them, identify the material by marking the bag or other appropriate means, generate and issue a Material Usage Log (TAC Form TAC-035), and make the appropriate entries on the timeout log. The material, under no circumstances, shall be released to the floor without a completed Material Usage Log. The timeout log will then be kept by the stockroom until the material is ready to be placed back in the freezer. The authorized person returning the material to the freezer will then make the appropriate entries on the timeout log and place it with the material IAW section 2.12.3.1. Stockroom personnel returning material to the freezer will use the completed Material Usage Log to record the amount of material consumed into the TAC Database. This database entry will be made prior to restocking the material and stockroom personnel shall initial/stamp (IAW procedures outlined in this manual) the line item of the material usage log to verify that the physical quantity of material remaining correctly reflects the quantity as displayed by the TAC Database. When all of the material is used, all of the remaining quantity shown in the database will be issued and the timeout log completed and forwarded to the Stockroom Supervisor for retention IAW section 3.12. Stockroom personnel shall conduct a 100% freezer check the last week of every month and attach a log of items due to expire the following month to the outside of the freezer. 2.13.4 Customer property received for use on customer components. Customers that are certificated under FAR part 121, 145 or 135, must supply traceability documents for all parts they supply for use on their components.

Customer supplied property will be clearly marked as to the ownership of the property to ensure use only on the customers components and, whenever possible, stored separate from TAC owned stock.


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2.13.5 Shelf Life

This section sets forth the procedures for controlling parts and materials that have a limited useful life due to constraints placed upon it by the product manufacturer or other regulatory authority. The primary responsibility for ensuring compliance with this section lies with the Purchasing Manager; the QA Manager will serve as a backup. The part number, batch/lot number, receiver number, purchase order number and expiration date will be recorded in a computerized file to track the shelf life limit while in the stock room. Special handling items such as prepregs will also have its history recorded on a time out log (TAC Form TAC-006), which will be generated upon receipt and maintained with the material. All shop lockers will have a 100% check performed during the last week of each month. Any items that will expire prior to the end of the following month will either be removed or recorded on a log that will be placed on the locker. Each day during the daily walk around the database shelf life log will be checked and all locker logs will be checked. Any material expiring before the next work day will be removed and quarantined awaiting disposition. All personnel are required to verify the expiration date on any controlled material before use. This verification shall include ensuring the material is properly labeled, the container was properly resealed since last use and the material is within shelf life limitations. Any non-conforming material found by any personnel shall be brought to the immediate attention of the QC department. Pot Life requirements will be noted on the container used for all required items. The container used to mix multiple part kits will be marked with the name of the contents, the time and date mixed, and the time and date which the pot life will expire. All personnel are required to verify the Pot Life requirements on any controlled material before use. 2.13.6 Stockroom All stock materials shall be properly stored, segregated, and protected to maintain serviceable condition. Any unserviceable items discovered in stock will be removed and discarded. Only acceptable supplies and materials shall be issued for any job. Acceptable industry practices shall be followed for the proper protection and storage of materials. Refer to section 3.9 for proper identification of Non-Certificated materials.


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2.13.7 Conformance Sampling The QA Manager will perform sampling of parts, materials, and supplies on a monthly basis for conformance to specifications and record the results on the Conformance Sampling Log (TAC Form TAC-003). 2.13.8 Materials with Temperature Requirements Areas that have material which possess specific temperature requirements, whether stored in the stockroom or on the shop floor, shall have a temperature recording device to ensure the material remains within its requirements’ limits. During the Daily Walk Around (Form TAC-025), the person performing the walk around will check the temperature recording devices to ensure they are within their limits. Once a week, the data for the temperature recording devices will be recorded. If the temperature recorder records using a chart, the date the chart was placed on the recorder and the date it was removed will be noted on the back of the chart. The inspector will then stamp the back of the chart signifying he has reviewed the chart to ensure it was within acceptable limits. If it is an electronic device, the data will be downloaded and saved in accordance with the software’s instructions. When an individual retrieves material from any location, it is their responsibility to view the temperature recording device to ensure the material being used has been stored within limits. If it is not, the individual should immediately contact the QA Manager, who will place the item in quarantine to preclude its use. 2.14 Quarantine Quarantine areas, directly under the control of the QA Manager, shall be maintained for the segregation of discrepant materials. Any part or material found deficient for reasons such as incomplete certifications, damage during shipment, not on capabilities list or any other reason shall be placed in a controlled area to preclude its use. A Quarantine Log (TAC Form TAC-007) will be maintained to control these areas. The quarantine log, kept by the TAC database, will be checked against the items actually in the areas weekly during the daily walk around. Additionally, a quarterly review will be performed to determine whether or not there are any items quarantined that can be dispositioned. 2.15 Paperwork Correction White-out is not permitted on documents used for the repair of parts and components. When an error is made, a single line will be drawn through the portion to be corrected. The person


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correcting the error will also initial the line and write EIE (entered in error) on the line. If the portion to be corrected is very large, an X may be drawn across the portion to be corrected and the X initialed in the same manner as a single line. In lieu of writing the employee’s initials after EIE, an employee’s inspection or operation stamp may be used. 2.16 Repair Details TAC may produce repair details for use in the repair of components they maintain IAW current FAA regulations. TAC will NOT sell or use these details for any other purpose other than the repair of a component they have in house. Details are to be classified into 3 categories, (definitions are located in section 3.5 of the RDPM). Each detail produced requires the data listed below for its appropriate category. Note: TAC is not to produce details classified as Category 1 as noted in the section 3.2 of the RDPM without revising this manual first). Category 2 data required

A) The detail being produced is to have drawings with dimensions sufficient for inspecting a completed detail for proper size requirements, FAA Approved Data containing specifications necessary to show the configuration of the detail, information on materials used to produce the detail, and processes required for the production of the detail necessary to define the structural strength of the detail.

B) Inspection and test procedures. C) Substantiating data to support the FAA Approved Data as required by FAA Order

8110.37 (611)(a). D) Airworthiness Limitations if applicable. E) Instructions for Continued Airworthiness if the current OEM instructions would not

apply. Category 3 data required

A) Data adequate to substantiate that the detail, as consumed in the repair, returns the product to its original or properly altered condition (e.g. AC 43.13, Service Bulletins, Component Maintenance Manuals , service history, prior service experience, etc.) in accordance with section FAR 43.13(b).

B) Production of all details must be accomplished in accordance with methods,

techniques, and practices acceptable to the Administrator in accordance with FAR 43.13(a).

Repair details will be identified with a Repair Detail Identification Number (RDIN) See Vol 5 (Repair Detail Procedures Manual) for complete instructions and details.


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3.0 Service Difficulty Report (FAA from 8010-4)

Reports on serious failures, malfunctions or defects will be made within ninety-six (96) hours after their discovery, on an FAA Form 8010-4 in the manner set forth in the Forms Manual. The report must be made without withholding any pertinent information.

When work is being accomplished for an air carrier or operator, (Parts 121, 125 or 135), the air carrier will be notified in order that the air carrier may issue a mechanical reliability report or service difficulty report. In this case, TAC will not file its own 8010-4. The President or the General Manager is responsible for preparing and submitting the Malfunction or Defect Report to the FAA office in Oklahoma City, OK in accordance with the directions supplied on the form. 3.1 Measuring and test equipment The QA Manager shall be responsible for the calibration system; the Director of Quality Control shall serve as his backup. All measuring (i.e. gauges, calipers, etc.) and test equipment (i.e. ohmmeters, thickness gauges, etc.) used in the repair station operations are subject to periodic inspection and calibration. All repair station personnel, before using test equipment, are responsible to check that the testing unit has a current calibration label attached. Any piece of test equipment found in the repair station without a current legible calibration label attached shall be given to QA for disposition. The company does not allow use of personal Calibrated Tools (i.e. gauges, calipers, etc.) and test equipment (i.e. ohmmeters, thickness gauges, etc.) for Inspection or return to service. The QA Manager maintains a record of all tooling, test equipment, etc. which requires calibration. The records will contain all calibration certificates required by section 3.12. The TAC database will track all calibrated equipment and will contain the next due date, location of the equipment. Each day, the calibration due report will be checked during the daily walk around. Any tools that will expire before the next working day will be removed and placed in quarantine or sent out for calibration prior to the end of the day. A company calibration sticker (TAC Form TAC-022) is required on all items that require calibration (the vendor calibration sticker may be used in place of the company sticker). Any tool with a calibration sticker that is torn or unreadable is considered unserviceable and must be turned in to the QA Manager for disposition. At this time, all calibration is conducted by outside vendors and no tool is calibrated in house. Calibration of all measuring instruments is the responsibility of the QA Manager and will be done in accordance with standards traceable to the National Institute of Standards and Technology, manufacturers’ recommendation, or other standard acceptable to the administrator.


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When removing an item from service to be calibrated, the database record for that item shall have its history tab updated to show its removal from service and current status. Upon receipt of calibrated equipment, new or re-calibrated, a qualified inspector will check the following items:

A. Verify that the calibration was done IAW NIST, manufacturers’ recommendations, or other standard acceptable to the administrator. And that a certificate of calibration has been provided.

B. Verify that the calibration due dates on the calibration sticker and the calibration certificate match. If there is no vendor calibration sticker, the inspector will fill out and place a TAC calibration sticker on the equipment using the information from the calibration certificate.

C. Update or create the computer entries for the tracking of the calibrated item, including updating the history tab section of that record.

D. Inspect the item for any obvious defects or damage that may have been caused during shipment.

E. Ensure the calibration certificate contains the name of the person performing the calibration, date of calibration, date next calibration is due, the standard used to perform the calibration, the method used to perform the calibration, and the result of the calibration.

F. Place his/her stamp or initial and date the bottom of the calibration certificate to denote the performance of this inspection.

G. If new, and no calibration certificate is available, the tool will be sent out for calibration.

H. The calibration certificate is to indicate the measured values of the tool as it was received, the measured values of the tool as it is returned, and the proper tolerance per the approved specification.

NOTE: If the certification indicates that the tool was received in an out of tolerance

condition, a risk assessment is to be performed/documented and maintained in the required tool calibration records.


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The Quality Assurance Manager is to perform/document a Risk Assessment of any tool which is noted to be out of tolerance at the time of calibration, and/or suspected of being dropped, mishandled, or damaged during transportation. At a minimum, the Risk Assessment is to include the following information, and once completed shall be maintained in the required tool calibration records.

A. Tool Serial Number B. Tool Description C. Reason for the Risk Assessment D. Noted Out of Tolerance Readings (If Applicable) E. Documented findings of the assessment, to include any recall of product due to a significant out of tolerance condition which could result in safety of flight issues.

When transporting tools/test equipment from one location to another, the person receiving the transported item(s) is to perform a thorough visual inspection of the item(s) to ensure no damage from transportation has occurred. TAC will maintain work space and storage areas in an appropriate manner as required to ensure the proper maintenance and protection of tooling and equipment. All equipment and tooling used to perform maintenance or preventive maintenance will be subject to a visual and/or physical check prior to each use. Appendix B contains types of calibrated equipment and their calibration intervals. 3.1.1 Leasing of required tools Certain tools, due to their frequency of use or cost, may be leased as needed. No component will undergo any maintenance without the required tools. When a tool is leased, the QA Manager will be responsible for ensuring that the equipment is calibrated (if necessary) and in good condition. If the equipment is not the equipment recommended by the manufacturer, the QA Manager will obtain the documentation determining equivalency and the acceptance of the equivalency by the FAA. When leased equipment is used, the supplier of the tool and the appropriate identification numbers will be listed in the corrective action block for the discrepancy requiring the use of the tool. 3.1.2 Special Tools other than those recommended by the manufacturer Whenever TAC decides to make or have made tools other than those recommended by the manufacturer, TAC must determine equivalency and have them accepted by the FAA. Reverse engineering alone without, data, drawings, testing, or reports is not considered an equivalent method of manufacturing special tools or test equipment. When determining equivalency, TAC will obtain/design any data/documents needed to ensure that the equipment is capable of performing all normal tests and checking all required parameters of the article.


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The level of accuracy will be equal to or better than that of the equipment recommended by the manufacturer. Equivalent tools used by TAC will be tracked in the TAC database. The TAC database will include a notation that it is an equivalent tool. Documentation used to determine equivalency will be recorded on TAC Form 030 (See Forms Manual for detailed completion instructions) and will be maintained on file with the tooling records. In short, the requirements of TAC Form 030 are: Documentation of the data used to manufacture the tool and show equivalency, documentation of the inspection determining compliance of the tool to the data, and a qualified engineer’s acceptance. TAC also fabricates many assembly and bond fixtures used in repairs, (Repair Tooling), for which the use of these tools is not called for in the OEM Maintenance Manuals and/or Service Documents. Repair Tooling does not require FAA Equivalency; however, TAC will track these tools and inspect the condition of the tools periodically, as needed. TAC Repair Tooling is to be categorized two ways, “Shop Tools,” and “Warehouse Tools.” Shop and Warehouse Tools will be tracked in the TAC database. Shop Tools are to be inspected at least annually for damage and basic functionality of the tool by QC department personnel as assigned by the Director of Quality Control. Warehouse Tools will be inspected prior to transporting the tool to the requested location and upon return by QC department personnel. Due to the inspections performed above on Warehouse Tools, no annual inspection is required. 3.1.3 Lost and Missing Tools When it is discovered that a tool has been lost or missing, every effort will be made to locate the tool. If the tool cannot be located, the tool will be marked as missing in the TAC database. When internal evaluations are conducted on the calibration program, the auditor will conduct a search for all tools shown to be missing. If the tools have not been recovered within 2 years after their last calibration due date, they may be removed from the system by showing them as scrapped. 3.1.4 No calibration Required and Calibration before each use Some equipment has the appearance of requiring calibration but, in fact, does not. The QA Manager will make his best effort to tag all such equipment with a label stating that no calibration is required. Other tooling requires calibration before each use or is self-calibrating. Equipment of this type will be labeled “Self Calibrating” or “Calibrate before each use.” 3.2 Subcontracted Maintenance The QA Manager is responsible for the vendor (subcontracted maintenance provider) approval program, as outlined in section 3.2.1. The Purchasing Manager shall be responsible for the issuance of Repair Orders IAW this section, and the Director of Quality Control shall be responsible for the receipt of repair orders IAW this section. An approved list of maintenance functions which TAC may subcontract to vendors will be maintained by the QA Manager.


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Changes to the list will not be made without prior approval from the CHDO. Changes to the list will be made by submitting the revised list to the CHDO for approval. FAA approval will be denoted by signing the list in the appropriate section. The Vendor List will be available through the TAC database (The CHDO is not requiring notification of revisions to the vendor list at this time, except that they are to be submitted with the bi-annual reports as noted below). The informational list will contain the following information:

1) Name of Subcontractor (Vendor) 2) Approved Maintenance Functions 3) FAA Certificate Number & Ratings (Certificated Vendors) 4) Next Audit due

Maintenance functions performed by vendors will be listed using numeric characters. Functions denoted by numerals will correspond to the function on the FAA Approved Maintenance Functions List and may be performed by appropriately approved vendors. Certificated vendors will have their FAA Approved Ratings denoted on the Approved Vendors List, and may only perform maintenance for which they are appropriately rated to perform. Vendors approved to perform subcontracted maintenance will be authorized IAW section 3.2.1. TAC may not provide only approval for return to service of a complete type-certificated product following contract maintenance. When work by an approved vendor is necessary, an RO will be generated, (by persons with the appropriate Duty Authorization on the Master List of Supervisory, Management, and Inspection Personnel), in the TAC database detailing the work to be performed. The instructions provided on the RO should provide enough technical detail for the work to be accomplished in accordance with the applicable approved / accepted data, and to provide an inspector enough technical detail to inspect the part upon return. When the work is to be performed by a non-certificated vendor, the receiving inspection will be completed by personnel authorized to perform in-process inspections. Work performed by certificated vendors will be subject to the same receiving process as raw materials, but must have return to service paperwork. All pertinent vendor paperwork shall be attached to the repair order receiver generated by the TAC database and maintained on file. See section 3.12 for retention requirements and chart 5 for repair order generation and flow.


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Chart 5: Repair Orders

Engineering/QC are to define the OSP

requirements in the corrective action of the

work order.

(To include processes and applicable data

to be followed by the Vendor)

Purchasing/OSP coordinates

with the QA Manager for

vendor approval if vendor is not

on the Approved Vendor List

Purchasing/OSP e-mails RO

to engineering and quality to

review for errors.

Purchasing/OSP initiates the

Repair Order, and determines

the vendor which will be used.

Is vendor on

Approved Vendor

List?

No

Yes

Are errors

found?

Part and all required

documents are routed to

vendor. Note 1

Note 1 – Purchasing/OSP tracks

the progress/status of all open

RO’s.

Errors on RO are corrected,

as required, and an

amended RO is generated.

Yes

No

Parts are returned through

receiving inspection.

Certificated or

Non-Certificated

Vendor?

Receiving/In-Process inspector

ensures all documents received from

vendor are correct and all work is

completed and referenced on the

8130-3. A visual inspection is

performed for any apparent defects.

Part is routed as

required for

completion.

In-Process inspector verifies by

inspection or test that all requested

work has been properly performed,

and that the documentation supplied

describes said work and references

to applicable technical data.

Certificated

Non-

Certificated


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DATE: 13 December 2010 Rev 22 Page 3-7

3.2.1 Vendor Approval FAA-certificated vendors who perform work on components are not required to have an onsite audit performed unless performance or other issues dictate an audit is required. When an on-site audit is required on FAA-certificated vendors, Form TAC-008 will be used. Before adding a certificated vendor to the Approved Vendor List, the QA Manager will ensure the vendor has completed the Certificated Vendor Survey (Form TAC-036). Copies of the facility’s OpSpecs and Air Agency Certificate will be maintained on file with the survey. Records will be updated on a 24 month cycle. Non-certificated vendors will be audited on-site using TAC form TAC-008 or checklists developed specifically for the work for which they are being contracted. The representative from Texas Air Composites Inc, performing the on-site audit will determine by performing a review of the vendors Quality System any requirements needed for the vendor to have a QUAILTY SYSTEM EQUIVELENT TO TAC’s, as required by 14 CFR Part 145.217 (b)(1). All non-certificated vendors will be required to sign and return a Vendor Contract, (TAC Form TAC-033), denoting acceptance to perform and certify maintenance as noted in the contract, and allow FAA inspections of their facility. Audits will be conducted by persons approved to perform audits IAW the TAC Internal Evaluation Program on a 24 month cycle. Non-Certificated vendors which do not provide their own FAA approved DOT Drug and Alcohol Program will not be eligible to perform maintenance for Texas Air Composites, Inc as an approved Vendor. The TAC database will track the 24 month cycle by entering the last date audited and entering the next audit due as the same day two years later. An audit will not be considered overdue as long as it is performed during the month prior to or month after the database shows it due (i.e. due 3/5/11 may be performed 2/1/11 through 4/30/11). If an audit is performed during the time frame noted above, the next audit due date will be as if the audit had been performed on the exact date due. If an audit is performed outside the time frame above, the next audit due date will be taken from the date performed. The QA Manager shall be responsible for contacting the vendors to arrange for an on-site audit if the need arises. In the event that an on-site audit is performed, it shall be made clear that the audit is for internal use of this repair station and shall in no way constitute any other type approvals. Vendor approval shall be granted if the vendor has, or will, demonstrated that the required audit objectives have been satisfied, and for non-certificated vendors, returned the required completed Vendor Contract. In the case where deficiencies have been found, approval shall not be granted until such time that all the corrective action have been complied with. A letter stating the deficiencies will be sent to the appropriate person at the vendor’s facility. Written responses to the deficiencies will be received prior to vendor approval. Copies of both the discrepancy letter and the vendor’s responses will be maintained in the vendor’s file. The QA Manager will determine the need for follow-up audits. Purchasing/OSP will not be authorized to use a vendor until the QA Manager has accepted all responses and appropriately approved the vendor.


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3.3 Suspected Unapproved Parts (SUPS) This repair station will make every effort to preclude the use of any unapproved parts in the repair of any airworthy components. This will be accomplished by strict adherence to policies and procedures as outlined within this manual, to include but not limited to: receiving inspection of raw material, in-process inspection to ensure that proper materials are utilized for the repair, reference to approved or accepted data such as Structural Repair Manual (SRM) or Component Maintenance Manual (CMM). Variations from existing data will be incorporated only after the data has been approved or accepted by the Administrator, customer engineering, or original equipment manufacturer. In any case, the work order shall contain a copy of all pertinent data related to the deviation. A copy of all approvals (or reference to) will be kept in the work order package. In the event that a suspected unapproved part exists, this repair station will immediately report its findings to the customer. If the customer cannot provide the necessary documentation to substantiate the discrepancy, this facility will notify its FSDO, completing current version of FAA Form 8120-11 IAW the current version of FAA AC 21-29. Any suspected unapproved parts will be quarantined in such a manner as to preclude its induction into the work area. The Quality Control Manager shall have complete control of the part and is responsible for the preservation of the part to maintain its originally received condition for future review. 3.4 Internal Evaluation The QA Manager is responsible for the Internal Evaluation Program. This program is designed to provide a path for open communication between employees and management. The program evaluates and verifies that all departments respond to company policy, development and changes. This program will evaluate the ongoing audits performed by all departments. The program is designed to have an open channel to the President to ensure all technical matters receive the attention and support required. All audits will be conducted in accordance with the TAC Internal Evaluation Program Manual. 3.5 Retention of Customer Audits The QA Manager is responsible for ensuring that all customers performing an audit or survey have available to them previously conducted audits.


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At the conclusion of a customer audit, the Quality Assurance Manager will initiate and verify the completion of all necessary corrective actions. He shall ensure the corrective actions are addressed in a timely manner and coordinated with the proper customer authority. The customer audit and corresponding corrective actions shall be retained by the QA Manager for the period specified in section 3.12. 3.6 Disposition of Non-Repairable / Unserviceable Customer Parts The Director of Quality Control is responsible for the disposition on non-repairable / unserviceable parts; the General Manager shall serve as his back up. When it has been determined that a customer part cannot be repaired it will either be returned to the customer or destroyed in accordance with FAA Order 8120.11. A Certificate of Destruction will be sent to the customer if the part is destroyed by TAC under these procedures. A copy of the Certificates of Destruction (TAC form TAC-011) will be kept in the work order package for the period specified in section 3.12. A log of all scrapped parts can be obtained from the TAC database. 3.6.1 Scrap on site procedures When it has been decided to scrap a part at TAC, the following procedures will be completed: A) Place the part in Quarantine IAW section 2.14, (or perform steps B – G

Immediately). B) Remove part from quarantine and destroy/mutilate to an extent that will prevent the part from being reconstructed to appear as if it were airworthy.

C) Destroyed parts are to be discarded only. Parts are never to be retained on hand or transferred to any persons at anytime for any reason.

D) Take a digital picture of the scrapped part and save the picture on the company Intranet, using the work order number as the file name.

E) Scrap the part in the TAC database using the scrap menu. F) Print and complete a Certificate of Destruction using the TAC database and send

it along with the digital image of the mutilated part to the customer. G) Place a copy of the Certificate of Destruction in the work order package.

3.7 Maintenance away from the Repair Station Repair services for which the repair station is rated will be provided for customers on an as needed basis at a place away from the repair station. Only the General Manager is authorized to initiate a work order for such services. The General Manager shall be responsible for assigning the necessary personnel to perform the work.


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A final inspector with approval for return to service will be present for all phases of the repair and will act as the supervisor (the final inspector will not perform any of the work). The Director of Quality Control will be responsible for assigning the inspector. All work will be performed exactly as if the work were being performed at TAC’s facility. The final inspector will be responsible for assuring that all technical data, equipment, tools, and materials needed for the completion of the work will be present at the repair site, including a copy of this manual. Customer tools and test equipment cannot be used unless the work is being performed for a part 121 air carrier and tools are under their tool and test equipment program. Customer supplied materials must go through the procedures outlined in section 2.13.4.

Documentation of the repair will be done the same as if the work had been performed at the repair facility (i.e. all paperwork such as work orders, 8130-3’s etc. shall be completed). The final inspector will be responsible for coordinating paperwork production with TAC’s home facility when required and for transporting all documentation back to TAC’s home facility. 3.8 Duty Time Limitations TAC shall relieve each person performing maintenance or preventative maintenance from duty for a period of at least 24 consecutive hours during any seven consecutive days, or the equivalent thereof within any one calendar month. 3.9 Separation of Certificated from Non-Certificated Components All production personnel shall ensure that all non-certificated components are removed from a work area before any work begins on a certificated component. All consumable materials (pre-preg, resin, epoxy, etc.) and tooling not covered by current established quality control procedures will also be removed from the work station before work on a certificated component begins. The Shop Manager, when feasible, will designate certain areas or workstations for certificated components only. At no time shall certificated and non-certificated work in-process be stored together unless the non-certificated components are clearly marked as such and the certificated parts are clearly marked with customer, part number, serial number and work order number. Whenever possible, separate areas will be used for storage of all molds, tooling, and non-controlled materials. All non-certificated component Work Orders/Op-Sheets must clearly state the fact that the component is “Non-Certificated.” Non-certificated work is all work that is not a repair which will require a return to service by the repair station (i.e. owner operator produced parts, non-aviation related work, work performed for a manufacturer, etc.).


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Raw materials which are purchased for use on non-certificated articles are to be identified with a colored receiving label. All raw materials purchased for certificated maintenance shall be printed on white labels. 3.10 Continuity of Maintenance Both the inspection department and the repair department will maintain a written passdown (TAC Forms TAC-012 & TAC-013) to ensure continuity of maintenance suspended by a change in shifts. While the passdown may be used to communicate any necessary information, its primary purpose is to relay the status of work in-process. The supervisor/inspector in charge of the off going shift will complete the passdown, using the appropriate form from TAC’s Forms Manual, at the end of each shift. Each passdown will be read and signed by both the off going and on coming supervisor/inspector. Whenever possible, the passdown will also be given verbally to aid in the comprehension of its contents. 3.11 Maintenance for Air Carriers operating under 135 or 121. When performing maintenance, preventative maintenance, alterations, or required inspections for an air carrier or operator having a continuous airworthiness maintenance program (CAMP) under part 121, 129 or 135, TAC will follow the air carrier or commercial operator’s CAMP and applicable sections of their manual. The General Manager will coordinate with the carrier to obtain any manuals or portions of manuals required to perform the maintenance requested by the carrier. In order to document compliance with the air carrier’s Maintenance Program, TAC will submit Form TAC-038 121/135/129 CAMP Letter to the air carrier for completion. All new air carriers must complete and return this form within 30 days of receipt. If Texas Air Composites does not receive Form TAC-038 back within 10 days TAC will submit a quote to the operators with Maintenance Program requirements noted, including, if applicable, additional requirements from the air carrier, such as training, etc. Whenever work is received from an air carrier, the receiving inspector will ensure that the repair order clearly specifies the technical data to use when performing the maintenance. If the repair order does not state the data to use, the receiving inspector will contact customer service or the General Manager who will coordinate with the carrier to obtain the required information.


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3.12 Required Records and record keeping The Director of Quality Control will be responsible for the maintenance of required records. All records will be made available to the FAA and the NTSB for inspection. The following is a list of required records and there retention requirements: Record Retention requirements

Work Order Package* 2 Years from approval for RTS Raw Material Traceability 3 Years from date of receipt Repair Order Paperwork 3 Years from date of receipt Employment Summaries 3 years from date of separation Customer Audits 3 Years from date of completion Calibration Records 2 Years from date of calibration

Time Out Logs 3 Years from stock depletion Temperature and Humidity Charts 3 Years Record of Technical Data Review 2 Years Boeing, Aviall, & GE Aviation Materials Work Order Packages 10 Years from approval for RTS Bombardier-Shorts Work Order Packages 10 Years from approval for RTS *Consists of all that are applicable: 8130-3, Disposition Report, Certificate of Destruction, Form 019A, Forms 019B, 019C, EO’s, FAA Form 337, FAA Forms 8110-3, Ops Sheets or any other form that work accomplished is recorded on. Some documents that are referenced and kept separately need not be in the package (i.e. Repair Orders, 8110-3 used to approve Process Specs. etc). All completed work order packages shall be stored at a designated location. Older packages may be stored off site in suitable storage areas and containers. A copy of the customers repair order will be routed with all work order packages. Open Work Order Folders will be maintained at 15050 Trinity Blvd, Ft. Worth TX 76155. Raw Material traceability, Calibration Records, and Temperature and Humidity Charts will be stored at the location which the materials are received and/or the equipment is used.


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3.12.1 Work Order Folder and W/O Sleeve Paperwork Flow

Part on Dock

Part in Receiving:

Work Order Folder is Generated

(See Section 2.3)

Customer Service Review:

The Work Order Folder

documents and database entries

are reviewed, and Customer

Service quotes the cost for

services to the customer.

The Work Order folder is filed in

the Open Work Order Cabinet

Supervisor Review:

The Supervisor received the Work

Order Sleeve, estimates hours,

and reviews requisitions

Part is scheduled and placed in

work as needed to meet said

schedule

Evaluation & Teardown:

Part is inspected, discrepancies

are entered in the database, and

the work order documents are

routed as required

(See Section 2.4)

Hidden Damage Discrepancy:

Discrepancy is noted in the

database, dispositioned, and

paperwork/part are re-routed to

supervisor for review

(See Section 2.5)

Final Inspection:

Return to Service Inspection is

performed and all required

documents are completed

(See Section 2.7)

Part is Shipped

(See Section 2.10)

All Work Order Documents are

consolidated in the Work Order

Package

(See Section 3.12)

Customer Service reviews the

Work Order Package

Director of Quality reviews the

Work Order Package and the

folders are filed as required


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3.13 Electronic Signatures / Electronically Stored Company Manuals The Director of Quality Control may permit the use of electronic signatures as an acceptable form of completing repair station forms which typically require a handwritten signature. It is the responsibility of the Director of Quality Control to ensure proper implementation, revision, and monitoring of the repair station software which is used to insert the electronic signature. FAA approval of the use of electronic signatures by TAC shall be noted in the Repair Station Operations Specifications, (Reference Paragraph A025). Forms which are selected by the Director of Quality Control for the use of electronic signatures may still be completed with a handwritten signature in lieu of the use of an electronic signature. For security purposes, the use of electronic signatures will only be used when the form being signed is generated using the TAC database. Refer to Section 3.13.1 for more information on the security of electronic signatures. The Director of Quality Control will be responsible for providing proper training to all personnel executing forms with an electronic signature inserted. Proper training is to include, at a minimum, a review of the database functions which establish the uniqueness, significance, scope of information being affirmed with the electronic signature, signature security, non-repudiation, and traceability of all forms signed electronically. The TAC database will notify an individual any time an entry is made that will generate and insert the user’s electronic signature. The user will be required to affirm/accept the entry of their signature on the form. Users will be allowed access to retrieve a report from the TAC database which indicates all records which have been completed with their signature, including the date and time said entries were completed. Company manuals which are controlled electronically will be stored on the company network. The QA Manager will create a PDF of the manual which will be used as the controlled copy available through the technical library. This will ensure no one may edit or change the manual’s content. Access to TAC’s technical library is available through its intranet at all computers in the company. All employees, upon being hired, will be given training on accessing TAC’s company manuals through the technical library. See TAC’s Training Program Manual for more information. 3.13.1 Electronic Signature Security TAC’s database requires a login name and password on entry. This login will be used to establish the initial level of security for the use of all electronic signatures. The TAC database will limit the entry of a person’s name on any form being completed electronically by only allowing the name of the person logged into the TAC database to be selected.


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The TAC database will confirm that the person logged in has the appropriate inspection authority, as required, before generating any forms with the electronic signature inserted. Employees authorized to insert an electronic signature will submit a handwritten signature which will be stored in a secure file location within TAC’s server farm. This electronic file may only be accessed by the General Manager and Information Systems personnel. The electronic file containing the signature will be deleted by the General Manager immediately upon notification of the change in employment status. As noted in Section 3.13 above, a record of all forms completed with an electronic signature will be maintained in the TAC database. The record of said electronic signature entries is to include a record of the form completed, reference to the appropriate work order or other record which the form was used, the name of the person which completed the form electronically, and the date and time the form was completed. Forms signed electronically will require that the person who inserted the electronic signature affix their identification stamp adjacent to the electronic signature indicating their acceptance of the electronic signature entry. 3.13.2 Correction of Documents Signed Electronically In the event an entry is made in error the signature inserted in the form is to become invalidated. However, record of the initial signature entry will remain on file in the TAC database. The individual completing the corrected document will be required complete the same processes as the initial entry in order to insert an electronic signature in the corrected form. 3.13.3 Electronic Signature Traceability/Non-Repudiation As noted in Section 3.13.1, all electronic signatures are to be affirmed by affixing the individual’s identification stamp adjacent to the electronic entry. The affixing of the identification stamp will indicate the non-repudiation and proper traceability of the individual which inserted the signature.


Appendix A

DATE: 05 May 2013 Rev 29 Page A-1

Appendix A 15050 Trinity Blvd

1) Areas in the shop may be used for both certificated and non-certificated maintenance; however, this does not relieve

the repair station from the requirement to separate said differences. Areas are to clearly separate non-certificated and

certificated items. Areas designated with green tape are designated repair station areas, and for certificated

maintenance. If working non-certificated products in said area all certificated materials and parts are to be removed

from the mechanics area which the non-certificated work is being performed.

2) Shop equipment, to include but not limited to, the autoclave, ovens, paint booths, sanding booths, etc., may be used

by both certificated and non-certificated maintenance. However, if processed together the parts/materials being

processed are to be clearly marked to prevent the inter-mixing of certificated and non-certificated items.


Appendix A

DATE: 31 January 2012 Rev 26 Page A-2

Appendix A 2321 Solona Ave

134'-0"

56'-0

"

Office Space

Office

1500 sq. ft.

12'-1 1

/16"

Shop Equipment

17'-8

3/4

"

134'-0"

56'-0

"

56'-0

"

134'-2"

Shop

Equipment

31'-2 9/16"

31'-3"

Storage Rack

The Only maintenance to be performed at this location is the testing of radomes.


Appendix B

DATE: 04 June 2012 Rev 27 Page B-1

Appendix B Type Equipment Cal. Interval Temperature and Humidity measuring equipment 1 Year Oven 1 Year Micrometer, Calipers and Depth Gauges 1 Year Hardness Testers 1 Year Multimeters 1 Year Hot bonders (Wichitech) 1 Year Vacuum and Pressure Gauges 1 Year Radius Gauges 1 Year 1-2-3 Blocks 1 Year Scales 1 Year Torque Wrenches 1 Year Precision Gage Blocks (Masters) 6 Months Note: For all NDT calibration intervals reference Texas Air Composites NDTM.

Repair Station Manual (Vol. I)

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Transcript of Repair Station Manual (Vol. I)