DASR 21 - Department of Defence · Major Changes to a Type Certificate • Applicant is MTC holder...

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Defence Aviation Safety Regulation

DASR 21

Introduction to Initial Airworthiness

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Course administration

Welcome:

• Emergency Brief – Fire Exits / First Aid

• Amenities – Toilet / Coffee / Food etc

• Mobile Phones

• Course:

– Style (guided discussion)

– Questions

– Feedback (formal/informal)

– Sign in (PMKeys reported)

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Background & Introduction to DASR 21

Subpart B – MTC & MRTC

Subpart D & E – changes to MTC & MSTC

Subpart M – Repairs

Subpart H – MCoA & MRCoA

Subpart P – MPTF

Subpart K – Parts & Appliances

Subpart O – AUSMTSO

Subpart J – MDOA

Safety Management System (SMS)

Subpart F & G – Production

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Learning Outcomes

To provide working level understanding of DASR 21 regulation and its application.


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Background


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Nimrod Accident (Haddon-Cave)

Findings:– Clear line of accountability and responsibility

– Issues with outsourcing

– Assignment of risk

– Status of continued/ing airworthiness


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Outline• Defence Aviation Safety Regulation (DASR)

– Structure

– Definitions

– Organisational responsibilities

• Definition of Airworthiness and scope of Initial Airworthiness

– Certification of products, changes to products and repairs

– Continued airworthiness

– Production

– Airworthiness of individual aircraft

– Organisation approvals


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Explosives

Aviation

Radiation

Falling objects

Confined spaces

Noise

Lifting

Demolition

Diving

Electrical

Chemicals

Lead

Asbestos

Fire

Contaminated air

Heights

Maintenance of plant

Excavating

Poor training

Poor labels

Poor health monitoring

Poor reporting

Risk decisions regarding capab

ility / safety

Command exploits air power in satisfaction of Australia’s Strategic Defence Initiatives (SDIs) while satisfying statutory safety obligations


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Explosives

Aviation

Radiation

Falling objects

Confined spaces

Noise

Lifting

Demolition

Diving

Electrical

Chemicals

Lead

Asbestos

Fire

Contaminated air

Heights

Maintenance of plant

Excavating

Poor training

Poor labels

Poor health monitoring

Poor reporting Defence Aviation Safety Framework

• Defence AA

• DASA

• DASP- Policy/Regulation- Promotion/Education- Initial Safety Case- Ongoing Assurance

• DASRRisk decisions regarding capab

ility / safety

Risk advice

regarding defensibility and credibility

DASF amplifies statutory safety obligations in line with international conventions for aviation safety.

Command exploits air power in satisfaction of Australia’s Strategic Defence Initiatives (SDIs) while satisfying statutory safety obligations


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DASF assures that safety of military aviation is both credible and defensible

Command must ensure that hazards are eliminated SFARP or if not, that risks are minimized SFARP

Obligation from S10/11 of Defence Act to amplify statutory safety obligations IAW

international conventions in safety aviation

Risk decisions regarding capab

ility / safety

Risk advice

regarding defensibility and credibility

WHS s14, s16 and s46

WHS s14

WHS s20‐s26

Upstream Duty Holders

CEO

COO

AM

RM

HASD

DGAir

OCSPO

CENGR

ACAUST

FEGCDR/DLC

OC Wing

CO SQN

DASA

DASP

DASR

DoSA

DefenceAACAF

WHS s22‐s26 WHS s20‐s21


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Defence Aviation Safety Framework

Defence Aviation Authority(Chief of Air Force)

Defence Aviation Safety Authority

ACPA DFSB

Command / Executive Authority Responsible for Aviation Safety

OperationalOrganisations

Continuing AirworthinessOrganisations

Continued AirworthinessOrganisations

Assure aviation safety.

Ensure aviation safety.

Assure aviation safety.

Ensure aviation safety.

Saf

ety

Inve

stig

atio

n

Program Level

System Level

Com

plia

nce

and

Rev

iew

DIA, DCA, DAVENG, DPEPS, DBSI

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Defence Aviation Safety Policy

CAF Charter LetterAppoints Defence AA and articulates accountabilities

Basic RegulationImplementing Regulation

AMC & GM Glossary

Joint Directive 24/2016Mandates compliance with aviation safety policy manuals

Defence Aviation Safety Assurance ManualEstablishes aviation safety framework and gives effect to subordinate manuals

Defence Aviation Safety Regulations

MDOA & MPOA Instructions & Publications

DOE & POE

TCAE QM & SMS Flight Manual / ICACPP


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Airworthiness Operations

DASR Framework


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Initial vs Continuing Airworthiness• Initial airworthiness:

– Type design– Certification of products– Continued airworthiness– Certification of design changes and repairs– Production – Certificates of Airworthiness– Military Permits to Fly

• Continuing airworthiness:– Control and conduct of maintenance– Processes ensuring that the aircraft:

• complies with airworthiness requirements• is in condition for safe operation• Supported within a ‘Controlled Environment’


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Basis of safe flight

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Military Type Certificate(MTC)

Certificate of Airworthiness

(CoA)

The design is safe

The aircraft matches the approved design

The aircraft is in a condition

for safe operation

Continued Airworthiness(MTC Holder)

Military Airworthiness Review Certificate

(CAMO)


Current Certificate of Release to Service (CRS)

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Introduction to DASR 21


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ICAO Annex 8 – Airworthiness of Aircraft• Certification, Production, Certificates of Airworthiness, Standards

– Flight - performance, flying qualities, stability and control

– Structure - mass and mass distribution, limit loads, strength and deformation, etc

– Design and construction - aeroelasticity, occupants accommodation features, etc

– Powerplant - engines, propellers, powerplant installation

– Systems and equipment - safety and survival equipment, lights, ice protection, etc

– Operating limitations and information - flight manual, continuing airworthiness, etc

– Crashworthiness and cabin safety - cabin fire protection, evacuation, etc

– Operating environment and human factors - flight crew, ergonomics, etc

– Security Least-risk - bomb location, protection of the flight crew compartment, etc


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Scope of DASR 21

• DASR 21 – Certification of Military Aircraft and Related Products, Parts and Appliances, and Design and Production Organisations

– Certification vs qualification

– Relevant products,parts and appliances

– Relevant organisations


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Overview: DASR 21 SubpartsA General Provisions J Military Design Organisation Approval

BMilitary Type-Certificates & Military Restricted Type-Certificates

K Parts & Appliances

C N/A L N/A

DChanges to Military Type-Certificates & Military Restricted Type-Certificates

M Repairs

E Military Supplemental Type-Certificates N N/A

FProduction without Military Production Organisation Approval

OAustralian Military Technical Standard Order Authorisations

GMilitary Production Organisation Approval

P Military Permit to Fly

HMilitary Certificates of Airworthiness & Military Restricted Certificates of Airworthiness

QIdentification of Products, Parts & Appliances

INoise Certificates (to be added later if required)


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DASR 21 OutputsDesign approvals

Military Type CertificateMajor Change Approval (change to MTC or MSTC)Minor Change ApprovalAUSMTSO Authorisation

Repair design approvalsMajor Repair Design ApprovalMinor Repair Design Approval

Aircraft operating instrumentsCertificate of AirworthinessMilitary Permit to Fly


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Declaration of safety (DO)

Holder obligations

continued airworthiness

Initial Airworthiness Output Process

Application requirements

(BE–DO–SHOW)

DASA assurance

Approve / issue to a holder

ENSURE (applicant/holder)

ASSURE (DASA)


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Questions/Discussion?Break


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Subpart B

Military Type Certificates and Military Restricted Type

Certificates

Subpart B MTC & MRTC

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Outline

– Military Type Certificate (MTC)

– Type Certification Basis (TCB)

– Certification Program (CP)

– Issue of MTCs & MRTCs

– Holder obligations

– ADF context


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Military Type Certificate

• Recognition that the Type Design of a product complies with the appropriate airworthiness standards (TCB)

• Fully accounts for intended role and usage

• Can include equivalent level of safety findings

• No feature or characteristic that makes the product unsafe for its intended use

• Accompanied by a Type Certificate Data Sheet (TCDS)


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Type Certification Basis

• An agreed set of airworthiness requirements a product must be compliant with in order to obtain a Type Certificate

• Consists of:

– Primary certification code

• Equivalent safety findings

– Special conditions

– Elect to comply

– Exceptions

• TCBs are first proposed by the applicant in the Certification Program


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Type Certification Basis

FAR 25 Amdt 87

25.1

↓

25.1801

Special Conditions

SC 1

SC 2

Elect to Comply

25.605 Amdt 88

Exceptions

25.815

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Certification Programme

• An agreement between the applicant and DASA on how to achieve Type Certification

• An approved CP gives confidence to both parties that the product will be Type Certified

• Documents:

– The TCB (including tailoring)

– Means of compliance

– Evidence to be submitted toDASA for inspection


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Type Certification Basis Means of Compliance

FAR 25 Amdt 87

25.1 Ground/flight test

↓ Simulation

25.1801 Safety assessment

Special Conditions

SC 1 Engineering analysis

SC 2 Inspection/demonstration

Elect to Comply

25.605 Amdt 88 Document review

Exceptions

25.815 MCRI

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Compliance with the TCB

• Applicant is responsible for showing compliance with the TCB has been achieved

• Relief (partial or full) may be grantedby DASA

• Applicant must provide DASA accessto all data demonstrating compliance

• Applicant must declare compliance


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Type Certification Basis Means of Compliance Compliance documents

FAR 25 Amdt 87

25.1 Ground/flight test Test Plan / Test Report ABC

↓ Simulation Simulation Report XYZ

25.1801 Safety assessment Safety Case 123

Special Conditions

SC 1 Engineering analysis Engineering Report DEF

SC 2 Inspection/demonstration Drawing No. 789

Elect to Comply

25.1529, 1581 Amdt 88 Document review ICA / AFM version 1.0

Exceptions

25.815 MCRI MCRI 001

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Issue of an MTC

• DASA must have sufficient confidence that:

– The applicant has demonstrated itsorganisational capability to applyfor an MTC

– The CP has been followed

– The Type Design complies with the TCB

– Arrangements are in place forcontinued airworthiness


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Military Type Certificate Holder

• Single accountability for continued airworthiness of the product

• Obligations are at DASR 21.A.44


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MTC Holder• Monitor in-service usage of the product to identify, investigate, analyse

and correct safety deficiencies in the design

• Report potential unsafe conditions to DASA, including corrective action to be taken

• Establish arrangement with the aircraft manufacturer to support continued airworthiness

• Keep all certification records

• Produce, maintain and distribute all manuals required by the TCB

• Produce, maintain and distribute ICA to the aircraft operators


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MTC Holder

• Continue to demonstrate organisational capability to be an MTC holder

• Specify product, part and appliance marking requirements

• Integrate weapons and other systems

• Conduct aircraft and propulsion system integrity assessments


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Continued Airworthiness Example


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MTC Holder – Defence context


• DASA issues MTCs for all Defence manned products

• MTC holder: Australian government organisation– Responsible for execution of holder obligations– CASG SPO

• Type Continued Airworthiness Exposition (TCAE)• Organisational structure• Assigned responsibilities• Procedures• Resources

– Holder may outsource holder obligations

• AC 006/2017 - MTC Holder Arrangements

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Subparts D and E

Changes to Military Type Certificates and Military

Supplemental Type Certificates


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Changes to Military Type Certificates

• Subpart D – Changes to MTCs and MRTCs

• Subpart E – Military Supplemental Type Certificates (MSTCs)

• Same certification principles as apply to MTCs


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Changes to Military Type Certificates


What constitutes to a change to a Military Type Certificate?

• Alteration of the Type Design Data (21.A.31)– Drawings and specifications necessary to define the configuration

and design features– Materials, processes and methods of manufacture– Defined Airworthiness Limitations– Other data necessary to determine airworthiness of later types

• Change to the Operating Limitations of the Type Certificate• Change to the Type Certification Basis• Change to the Type Certificate Data Sheet

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Classification of design (MTC) changes


• All design (MTC) changes must be classified as major or minor– Relief– Exceptions– Equivalent Safety Findings– Airworthiness Limitations– Operating Limitations– TCDS

• Design (MTC) changes maybe classified by:– DASA– Design organisations

under privilege

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Major Changes to a Type Certificate

• Applicant is MTC holder or suitable capable organisation

• CP required (tailored for change complexity)

– Establish certification basis for the change

– Propose means of compliance

– Compliance documents to be submitted to DASA

• Change complies with certification basis

• DASA will have direct involvement in the approval process

• MSTC may be issued

• Continued airworthiness requirements


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Minor changes to type design (MTC)

• Minor changes must meet certification basis

– No relief

– No exceptions

– No equivalent safety findings

– No change to AwLs, Op Lims or TCDS

• Minor changes approved by

– DASA

– MDOA holders under privilege

• Minor change approval holder - continued airworthiness


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Example change to the MTC

Installation of Becker VHF Transceiver AR 6201

• FAR 25 Primary Certification Code

• Classify change

• Establish certification basis for the change

• Propose means of compliance

• Demonstrate compliance

• Approved by:

– MDOA holder if privilege allows

– DASA otherwise


Certification Basis Means of Compliance Compliance documents

25.603 – Materials

25.611 – Accessibility provisions

25.613 – Material strength

25.773 – Pilot compartment view

25.777 – Cockpit controls

25.869 – Fire protection electrical components

25.1301 – Equipment installation

25.1309 – Systems

25.1310 – Power source capacity

25.1321 – Arrangement and visibility

25.1353 – Electrical equipment installations

25.1357 – Circuit protective devices

25.1365 – Appliance, motors and transformers

25.1431 – Electronic equipment

25.1529 – ICA

25.1581 – Aircraft Flight Manual

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Certification Basis








25.869 – Fire protection electrical components


25.1309 – Systems



25.1351 – Electrical system capacity

25.1353 – Electrical equipment installations

25.1529 – ICA

25.1581 – Aircraft Flight Manual

Certification Basis Means of Compliance

25.603 – Materials Analysis







Analysis

25.869 – Fire protection electrical components Analysis / test


25.1309 – Systems



Analysis

25.1351 – Electrical system capacity Analysis

25.1353 – Electrical equipment installations Test

25.1529 – ICA Design review

25.1581 – Aircraft Flight Manual Design review

Certification Basis Means of Compliance Compliance Documents

25.603 – Materials Analysis Material Specifications







Analysis Engineering Report

25.869 – Fire protection electrical components Analysis / test Fire Protection Test Plan / Report


25.1309 – Systems



Analysis Safety Case

25.1351 – Electrical system capacity Analysis Electrical Loads Analysis

25.1353 – Electrical equipment installations Test EMI Test Plan / Report

25.1529 – ICA Design review ICA supplement

25.1581 – Aircraft Flight Manual Design review AFM supplement

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Subpart M

Repairs


Subpart M Repairs

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Subpart M - Repairs

• Repairs (i.e. those not already approved in a SRM) are similar to design changes

– Return aircraft to an airworthy state– Must comply with applicable certification basis

• Repair designs are classified according to the same criteria as design changes

• Repair design approval by:– DASA– Design organisation under privilege

Subpart M Repairs

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Subpart M - Repairs

• Applicant for repair design approval must demonstrate organisational capability

• Prepare compliance documents to show compliance with the applicable TCB

• Applicant must declare compliance

• Holder of a repair design approval to carry out continued airworthiness obligations (21.A.451)

Subpart M Repairs

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Static Strength

25.301 – Loads

25.303 – Factor of safety

25.305 – Strength and deformation

25.307 – Proof of structure

25.619 – Special factors

Fatigue Strength

25.571 – Damage tolerance and

fatigue evaluation

Materials



Processes

25.605 – Fabrication methods

23.609 – Protection of structure

Operating limitations and information

25.1529 – ICA

Example Structural Repair Design


Static Strength

25.301 – Loads





Analysis

Fatigue Strength


fatigue evaluationAnalysis

Materials


25.613 – Material strengthAnalysis

Processes


23.609 – Protection of structureDesign Review


25.1529 – ICA Design Review



Static Strength

25.301 – Loads






Fatigue Strength


fatigue evaluationAnalysis Engineering Report

Materials


25.613 – Material strengthAnalysis Material Specification

Processes


23.609 – Protection of structureDesign Review Engineering Report


25.1529 – ICA Design Review ICA Supplement


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Subpart M - Repairs

• Repair parts can be manufactured:

– Under Subpart F (production without MPOA)

– By an organisation approved under Subpart G (MPOA)

– By an appropriately approved maintenance organisation

• Embodiment can only be carried out by:

– An approved maintenance organisation

– An approved production organisation (MPOA) under privilege

Subpart M Repairs

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Subpart M - Repairs

• Unrepaired damage

– Usually the TC or STC Holder (if not, justification on basis of information is required)

– Necessary limitations transmitted to operator in accordance with approved repair procedures

Subpart M Repairs

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Subpart K

Parts and Appliances


Subpart K – Parts and Appliances

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• Four means to have any given part or appliance be included in approved design data:

– In conjunction with the certification processes for major/minor changes

– Under the AUSMTSO Authorisation process

– Use of standard parts

– For equipment not subject to airworthiness standards, by demonstration that integration does not adversely affect airworthiness

• All new parts and appliances should be identified in the certification programme

Subpart K – Parts and Appliances

Parts and Appliances












25.1309 – Systems








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Subpart O

Australian Military

Technical Standard Order Authorisations



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AUSMTSO Authorisations

• Technical Standard Order (TSO)– Airworthiness specification detailing the minimum safety

performance standard for specified articles– Issued by NAA / NMAA (e.g. FAA, EASA)

• TSO Item– Appliance certified and manufactured to a TSO

• TSO Authorisation– Authorisation awarded to an organisation that can demonstrate:

• The design of a TSO item meets the minimum safety performance standard

• The organisation has the capability to manufacture the item


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• For the design of the article:– Applicant must show compliance with the TSO– Applicant must declare compliance via the Declaration of

Design and Performance– DASA will issue the AUSMTSO Authorisation– Holder of the AUSMTSO Authorisation must carry out the

continued airworthiness obligations for the item (21.A.609)

• For production of the article:– Applicant must hold MPOA under DASR 21 Subpart G, or– A Letter of Agreement under DASR 21 Subpart F


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These aircraft lights meet TSO C96a design specifications and EXCEEDthe requirements of TSO C96a, SAE AS 8037 and AS8017A, plus DO-160.



Anti‐collision light system

25.1401(a) – Approved anti‐collision lights TSO C96a EASA.21O.10055069

25.1401(b) – Field of coverage Analysis Engineering Report

25.1401(c) – Flashing characteristics TSO C96a EASA.21O.10055069

25.1401(d) – Colour TSO C96a EASA.21O.10055069

25.1401(e) – Light intensity TSO C96a EASA.21O.10055069

Equipment


25.1309 – Systems








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Subpart H

Certificates of Airworthiness and Restricted Certificates of

Airworthiness


Subpart H MCoA & MRCoA

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• Certifies that a particular aircraft (tail no.) conforms to its type design at the date of issue


Subpart H – Certificates of Airworthiness

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• Operating organisation should apply

• Application must include data that substantiates conformance with the Type Design

• Issued by DASA (or delegate)

• Holder must ensure ongoing validity


Subpart H – Certificates of Airworthiness

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• CoA / RCoA remain valid as long as the aircraft

– Complies with its type design, applicable ADs and ICA

– Remains on the Defence register

– All modifications and repairs are approved under DASR M.A.304

– MTC (and other design/repair approvals) remain valid

– Not surrendered or revoked by DASA


CoA validity

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Subpart P

Military Permits to Fly


Subpart P – MPTF

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Military Permit To Fly (MPTF)

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• Normal operations occur within the bounds of ICA and limitations

– Operating limits (Flight Manuals)

– Maintenance requirement (Maintenance Manuals)

– Damage limits (Structural Repair Manuals)

– Fatigue / usage considerations (Aircraft Flight Manual, MEL)

• Operations outside of the defined boundary – MPTF

– Examples: development of major mods, type certification: demonstration of compliance, ferry flights, etc

– A formal mechanism to manage elevated risk for safe flight

Subpart P – MPTF

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Subpart P – Military Permits to Fly

• Required in lieu of an MCoA

• Aircraft is still capable of safe flight under prescribed conditions

• Applicant must declare that aircraft is safe to fly under prescribed conditions

– Requires both technical and operational endorsement

• Flight conditions approved by either:

– DASA, or

– MDOA holder under privilege

• Holder must ensure flight conditions are satisfied

Subpart P – MPTF

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Subpart J

Military Design

Organisation Approval

(MDOA)


Subpart J – Military Design Organisation Approval

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Outline

• Eligibility

• Design Assurance System (DAS)

• Design Organisation Exposition (DOE)

• Issue of Military Design Organisation Approval (MDOA)

• Terms of approval

• Privileges

• Obligations


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Eligibility

• One means demonstrate capability to apply for or hold a

− Military Type Certificate (MTC)

− Military Supplemental Type Certificate (MSTC)

− Major Repair Design Approval

− AUSMTSO Authorisation for APUs

• Or the means to obtain privileges to approve

− Minor changes

− Minor repair designs













25.1309 – Systems








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Design Assurance System


• Basis of Military Design Organisation Approval (MDOA)

• Described in the Design Organisation Exposition (DOE)

• Provide planned and systematic actions to

– design products, or parts

– demonstrate and verify compliance

– declare compliance

• Defined in terms of

– Organisational structure

– Responsibilities assigned

– Procedures

– Resources

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Design Assurance System (DAS)

• DAS minimum elements

– ensure the design of products, parts and appliances, design changes and repair designs comply with the applicable type-certification basis (TCB)

– independent checking of showings of compliance

– independent monitoring and improvement of the Design Assurance System


– account for design input provided by other organisations

– Safety Management System (SMS)

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Organisational structure and Responsibilities

• Chief Executive

• DASR Form 4 holders

– Head of Design Organisation

– Chief of the Office of Airworthiness

– Chief of Independent System Monitoring

• Authorised signatories

– Compliance Verification Engineers (CVEs)

– Other authorised signatories


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Management staff: Head of Design Organisation


• Responsibilities

– responsible for Design Organisation output

– signs the declaration of compliance (or authorised representative)

– can be the same person as the Chief Executive

• QTE requirements

– tertiary qualified Bachelor of Engineering

– Chartered Professional Engineer (CPEng)

– ten years aviation experience

– two of ten years at DGTA-ADF/DASA or an organisation holding a Design Organisation Approval under DASRs, CASA, EASA or EMARs

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Management staff: Chief of Office of Airworthiness



– Preparation of CPP

– Liaison with DASA during Type Investigation

– Management of DOE

– Interpretation of airworthiness requirements

– Classification of design changes and repair designs

– Independent checking of showings of compliance

– Collection of design failure and defect information

– Assisting in preparation of Airworthiness Directives

– Approval of minor changes and repair designs

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– Tertiary qualified Bachelor of Engineering

– Chartered Professional Engineer (CPEng)

– Eight years aviation experience

– Two of eight years at DGTA-ADF/DASAor an organisation holding a DesignOrganisation Approval under DASRs,CASA, EASA or EMARs

Management staff: Chief of Office of Airworthiness

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Management staff: Chief of Independent System Monitoring



– continual evaluation of the Design Assurance System to

ensure it remains effective

– function can be achieved throughcorporate quality assurance system

– must cover design suppliers


– Lead Auditor training

– Eight years aviation experience

– Two of eight years at DGTA-ADF or an organisation holding a Design Organisation Approval under DASRs, CASA, EASA or EMARs

– Three years experience in aviation quality management

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Compliance Verification Engineers


• Conduct the independent checking function of all compliance data including:

• Test plans

• Means of compliance

• Compliance documents

• Approve the technical content of:

– Flight manual changes

– Airworthiness limitations

• Must be independent to those authoring compliance documents

• CVE function can be outsourced












25.1309 – Systems








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Other authorised signatories

– Change classification

– Compliance document preparation

– Declaration of compliance

– Design change approval / repair design approval

– Release of design change / repair implementing instructions

– Documentary changes to AFM


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Procedures

– Design procedures

– Compliance documents

– Independent checking procedures (CVE function)

– Independent monitoring procedures

– Accounting for external input

– Selection, training, ongoing competence and identification of authorised signatories (including CVEs)


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• Satisfy certificate or other design/repair approval, i.e. DASA instrument holder obligations

– Military Type Certificate (MTC) (21.A.44)

– Military Supplemental Type Certificate (MSTC) (21.A.118A)

– Minor change approval (21.A.109)

– Major/minor repair design approval (21.A.451)

– Australian Military Technical Standard Order (AUSMTSO) Authorisation (21.A.609)


Procedures

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• Required for exercising MDOA privileges

– Design change / repair classification procedure

– Approval of minor design changes or minor repair designs

– Issue of implementing instructions and ICA

– Approval of changes to flight manual

– Approval of major repair designs

– Approval of flight conditions (if awarded)

– Issue Military Permit to Fly (if awarded)


Procedures

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Resources

– Human resources

– Equipment

– Tools

– Facilities

– Design data etc.


- Design of PPA

- Design Changes

- Repair Designs

Show compliance with Certification

Basis

Independent check of all compliance

data

Independently monitor and

improve system

Classification

Privileges

CISM COAw

CHANGE CLASSIFICATION

PROCEDURE

ISM PROCEDURES

DESIGN PROCs

IC PROCsISM PPL

ENGRs

DESIGN TOOLS / DATA

SELECTION PROCEDURE

CONTROL SUB-CONTRACTORS

PROCEDURE

Approval by DASA

HDO

DESIGN APPROVAL

PROCEDURE

Auth Sign.

CVE Declaration of compliance

major

Approval by privilege

minor

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Subpart J - Organisational Approval Design Assurance System Elements

Organisation– Design organisation– Independent system monitoring– Office of airworthiness

Procedures– Design procedures– Independent checking procedures– Authorised signatory (including

CVE) selection– Independent system monitoring– Change classification procedure– Design Approval procedure– Control of subcontractor product

Resources

– Design Engineers

– Design tools and data

– Compliance Verification Engineers

– Independent system monitoring personnel

Responsibilities

– Head of Design Organisation

– Chief of Independent System Monitoring

– Chief of Office of Airworthiness

– Compliance Verification Engineers

– Authorised signatories


Design Assurance System elements

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Terms of Approval

• Scope of approval

• Categories of products (platforms)

• List of products

• Privileges

• Limitations

The Terms of Approval are stated on the certificate issued by DASA


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Example Organisational Structure 1

HDO

Design Officeof Aw

ISM


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HDO

Design Quality

Officeof Aw

ISM


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Technical Management

Quality Management

HDO

Office of Aw

TestingDesign Other

ISM


UNCLASSIFIED

UNCLASSIFIED


CEO

Dir. of Eng Dir. of MaintDir. of Prod

Design TestingCert Mgr

QualityISM


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Design Organisation Exposition

• Describes the organisation, the relevant procedures and the products, or changes to products to be designed

• Describes the Design Assurance System (DAS)

• May be completely or partially integrated into the company organisation manual


DAS elements Examples

Organisation Scope of work, DO / PO coordination

Responsibilities Management staff, authorised signatories

Procedures Design, compliance demonstration, independent checking, design approval

Resources Facilities, equipment, human resources

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Safety Management


SMS

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What is a safety management system?

Definition:

‘A systematic approach to managing aviation safety, including the necessary organisationalstructures, accountabilities, policies and procedures’.

ICAO Annex 19

SMS

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A mature SMS will complement the regulatory controls…

SMS

Top Event

Hazard

Regulated Control

Regulated Control

Regulated Control

SMS Identified Controls

Regulated Control


Regulated Control



Regulated Control

Regulated Control


TH

RE

AT

S

CO

NSE

QU

EN

CE

S

An SMS aims to assist organisations inidentifying control measures that are specificto their operations.

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DASR SMS STRUCTURE

SMS

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Applicable Organisations

SMS

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Process regulations are only so effective…

ONLY COMMON HAZARDS ARE MITIGATED

• Process regulation provides minimum protection against hazards, with overall effectiveness limited by technical, organisational, environmental and human factors

• A safety management system provides a higher level of safety by supporting and extending the protection afforded through process regulation alone.

SMS

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DASR SMS is based on the ICAO Framework

SMS

4. Safety promotion4.1. Training and education

4.2. Safety communication

1. Safety policy and objectives1.1. Management commitment1.2. Safety accountability and responsibilities1.3. Appointment of key safety personnel1.4. Coordination of emergency response planning1.5. SMS documentation

2. Safety risk management2.1. Hazard identification2.2. Safety risk assessment and mitigation

3. Safety oversight and improvement3.1. Safety performance monitoring and measurement3.2. The management of change3.3. Continuous improvement of the SMS

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SMS Assessment – Application of PSOE to Maturity Indicators

SMS

Present (10%)

Suitable (20%)

Operating (40%)

Effective (30%)

• PSOE (Present, Suitable, Operating & Effective) is a graduated approach to determining if policies, procedures and systems are actually effective.

• ‘Suitable’ and ‘Effective’ – SUBJECTIVE– ENCOURAGES CRITICAL THINKING.

– PREVENTS ‘PAPER SAFETY’.

Plan

Execute Maturity score is the average across all PSOE AMC scores.

P – Present

S – Suitable

O – Operating

E – Effective

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LEGISLATED RISK MANAGEMENT PROCESS

- CONTAINED IN DASR SMS, AFSM, DASM & AC 03/2018

SMS

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Key Change - The Safety Risk Management Process

SMS

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UNCLASSIFIED

SMS

UNCLASSIFIED

UNCLASSIFIED

SMS

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UNCLASSIFIED

SMS

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PREMATURE CEASING OF SRM PROCESS BECAUSE ASSESSED

RISK IS WITHIN PRE-ESTABLISHED ‘ACCEPTABLE’ OR ‘TOLERABLE’

LIMITS.

ASSUMING THAT WHS IS ASKING YOU TO EITHER ELIMINATE OR

MINIMISE—THERE IS AN ORDER THAT MUST BE FOLLOWED.

PERFORMING COST V BENEFIT ANALYSES RATHER THAN GROSSLY

DISPROPORTIONATE ASSESSMENTS.

ASSUMING THAT ‘COST’ IS (1) PURELY FINANCIAL AND (2)

RELATIVE TO YOUR ABILITY TO PAY.

ASSUMING THAT RISK ASSESSMENTS REMAIN SAFE

SFARP AFTER THEIR INITIAL USE.

ASSUMING THAT SUBSTITUTION, ISOLATION AND ENGINEERING

CONTROLS SHOULD BE CONSIDERED SEPARATELY.

THINKING THAT LIKELIHOOD AND DEGREE OF HARM ARE THE ONLY

MEASURES FOR A RISK.

Common Mistakes that are made in Safety Risk Management

SMS

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Subparts F & G

Production


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Production assurance in the DASP


Manufacture

Conformity Documentation

DASR Form 1

Approved Design Data

Minor change approval

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Production

• Four means to assure production in the DASP:

• Recognition

• Military Production Organisation Approval (DASR 21G)

• Letter of Agreement (DASR 21F)

• DASR 145 approval

• Manufacturer must own, or have access to, the approved design data


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Military Production Organisation Approval (MPOA)

• Quality System

• Show conformity of manufactured items with approved design data

• Must include independent quality assurance function

• Defined in terms of:

• Organisational structure

• Responsibilities assigned

• Procedures

• Resources


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Quality System Responsibilities

• Accountable Manager

• Management staff (DASR Form 4 holders)

• Responsible manager(s)

• Quality Manager

• Certifying staff


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Production Organisation Exposition (POE)

• Describes Quality System ORPR

– Binding instruction– Identifies AM, RM(s) and QM (including QTE)– Organisational chart– List of certifying staff– Human resources– Locations and facilities– Scope of work– POE amendment process– Quality system and QA function– External input– Safety management


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• Certify its own production

– DASR Form 52 – Statement of Conformity

– DASR Form 1 – Authorised Release Certificate

• Other privileges

– DASR Form 53 – Certificate of Release to Service

– Approve flight conditions

– Issue MPTF

MPOA Privileges


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• Production Inspection System

– Show conformity of manufactured items with approved design data

– Incoming materials (and parts):

• Conform with the approved design data

• Are properly identified

– Manufacturing processes used are agreed by DASA

– Parts are inspected for conformity with the approved design data

Production without MPOA – Letter of Agreement (DASR 21F)


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• Describes the Production Inspection System

– A description of the production inspection system– A description of making conformity determinations– A list of the certifying staff

Production Inspection System Manual


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• Certify its own production

– DASR Form 53 – Statement of Conformity

– DASR Form 1 – Authorised Release Certificate

• Other privileges

– DASR Form 53 – Certificate of Release to Service

– Approve flight conditions

– Issue MPTF

• DASA must countersign all conformity documentation

Letter of Agreement Privileges


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• Non-conforming materials and parts are:

– Identified

– Segregated

– Prevented from installation

– Reported to the Design Approval Holder

– Subject to a production concession process

Non-conforming items


UNCLASSIFIED

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Further reading

DASR 21 Practitioner Course

• www.defence.gov.au/DASP

– Key documents (left hand menu)

• Advisory Circulars

• DASA Factsheets

– Aircraft Certification and Production (button)

• Product Certification

• Continued Airworthiness

• Design and Production Organisations

• Aircraft Flying Instruments

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