0.1 Table of Contents Table of contents and list of effective chapters have been combined since the issue date is printed and after a revision, complete chapter shall be updated.
Part 0 General Organisation Owner 0.1 Table of Contents EQA 0.2 Record of Revision EQA 0.3 List of Effective Pages EQA 0.4 Cross References EQA 0.5 Distribution List EQA 0.6 Purpose of MOE EQA 0.7 Access to Facilities DE&M
Part 1 Management Owner 1.1 Corporate Commitment by the Accountable Manager MD (PIA) 1.2 Safety and Quality Policy MD (PIA) 1.3 Management Personnel MD (PIA) 1.4 Duties and Responsibilities of the Management Personnel MD (PIA) 1.5 Management Organisation Chart MD (PIA) 1.6 List of Certifying Staff EQA 1.7 Manpower Resources MD (PIA) 1.8 General Description of the Facilities at Each Address Intended to be Approved MD (PIA) 1.9 Organisations Intended Scope of Work MD (PIA)
1.10 Notification Procedure to the Competent Authority Regarding Changes to the Organisation’s Activities / Approval / Location / Personnel MD (PIA) / EQA
2.1 Supplier Evaluation and Subcontract Control Procedure DE&M, EQA, P&L
2.2 Acceptance / Inspection of Aircraft Components and Material From Outside Contractors EQA, P&L, AWM
2.3 Storage, Tagging and Release of Aircraft Components and Material to Aircraft Maintenance All Divisions
2.4 Acceptance of Tools and Equipment All Divisions 2.5 Calibration of Tools and Equipment All Divisions 2.6 Use of Tooling and Equipment by Staff (Including Alternate Tools) All Divisions 2.7 Cleanliness Standards of Maintenance Facilities All Divisions
2.8 Maintenance Instructions and Relationship to Aircraft / Aircraft Component Manufacturers’ Instructions Including Updating and Availability to Staff All (Excl. P&L)
2.9 Repair Procedure All (Excl. P&L) 2.10 Aircraft Maintenance Programme Compliance All (Excl. P&L) 2.11 Airworthiness Directives Procedure All Divisions 2.12 Optional Modification Procedure All Divisions 2.13 Maintenance Documentation in Use and Completion of Same All (Excl. MOC, P&L) 2.14 Technical Record Control AWM 2.15 Rectification of Defects Arising During Base Maintenance EQA, AWM, BM 2.16 Release to Service Procedure All (Excl. MOC, P&L) 2.17 Records for the Operator AWM, BD 2.18 Reporting of Defects to the Competent Authority / Operator / Manufacturer All (Excl. MOC, P&L) 2.19 Return of Defective Aircraft Components to Store All Divisions 2.20 Defective Components to Outside Contractors DE&M, All Divisions 2.21 Control of Computer Maintenance Record Systems All Divisions 2.22 Control of Man-Hour Planning versus Scheduled Maintenance Work All (Excl. P&L) 2.23 Control of Critical Tasks AWM, BM, LM, CM 2.24 Reference to Specific Maintenance Procedures AWM, LM, BM, CM 2.25 Procedure to Detect and Rectify Maintenance Errors All (Excl. MOC, P&L) 2.26 Shift / Task Handover Procedures LM, CM, BM, PP, AV
2.27 Procedures For Notification of Maintenance Data Inaccuracies and Ambiguities, to the Type Certificate Holder All (Excl. MOC, P&L)
2.28 Production Planning Procedure All (Excl. AWM, P&L)
Part L2 Additional Line Maintenance Procedures Owner
L2.1 Line Maintenance Control of Aircraft Components, Tools, Equipment Etc. LM, CM, MOC, P&L L2.2 Line Maintenance Procedures Related to Servicing / Fuelling / De-Icing Etc. LM, CM, MOC, AWM L2.3 Line Maintenance Control of Defects and Repetitive Defects DE&M, LM, CM, AWM L2.4 Line Procedure for Completion of Technical Log LM, CM
L2.5 Line Procedure for Pooled Parts and Loan Parts LM, CM, MOC, PP, AV, P&L
L2.6 Line Procedure for Return of Defective Parts Removed From Aircraft LM, CM, MOC L2.7 Line Procedure Control of Critical Tasks LM, CM, AWM
Part 3 Quality System Procedures Owner
3.1 Quality Audit of Organisation Procedures EQA / All Divisions 3.2 Quality Audit of Aircraft EQA / All Divisions 3.3 Quality Audit Remedial Action Procedure MD (PIA) / All Divisions
3.4 Certifying Staff and Category B1 and B2 Support Staff Qualification and Training Procedures
All (Excl. MOC, BD, P&L)
3.5 Certifying Staff and Category B1 and B2 Support Staff Records EQA 3.6 Quality Audit Personnel EQA 3.7 Qualifying Inspectors EQA 3.8 Qualifying Mechanics EQA 3.9 Aircraft or Aircraft Component Maintenance Tasks Exemption Process Control EQA / All Divisions 3.10 Concession Control For Deviation from Organisations’ Procedures EQA / All Divisions 3.11 Qualification Procedure for Specialised Activities Such As NDT, Welding Etc. EQA 3.12 Control of Manufacturers’ and Other Maintenance Working Teams EQA / All Divisions 3.13 Human Factors Training Procedure EQA / All Divisions 3.14 Competence Assessment of Personnel MD (PIA) / All Divisions
Part 4 Contracted Operators Owner 4.1 Contracted Operators EBD, AWM, EQA 4.2 Operator Procedures and Paperwork All Divisions 4.3 Operator Record Completion EBD, AWM
Part 5 Appendices Owner 5.1 Sample of Documents AWM, EQA 5.2 List of Sub-Contractors 145.A.75 (b) EQA, P&L 5.3 List of Line Maintenance Locations As Per 145.A.75 (d) EQA, MOC, LM 5.4 List of Contracted Organisations As Per 145.A.70 (a)(16) EQA, MOC, P&L
Note: Divisional codes are given in the “owner” column and are decoded as follows:
0.2 RECORD OF REVISIONS Manual holders are responsible for updating their copies. Upon receipt of revision, revised pages shall be inserted, entering Revision Date, Insertion Date and Signature in appropriate blocks. Removed pages must be discarded instantly to avoid any confusion. Upon completion of this Record of Revisions, acknowledgement shall be sent through a signed copy of ‘Manual Status Letter’. Same procedure as for MOE revision / updating shall be applicable to AMP (Refer MOE Chapter 1.11 for details).
Edition No. Revision No. Revision Date Approval Reference & Date Revision Inserted by
PART – 0: GENERAL ORGANISATION Chapter Page No. Edition Revision Issue Date
MOE TITLE 1 of 2 3 3 September 2010 2 of 2 3 3 September 2010
MOE Part 0 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
0.1 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
0.2 1 of 2 3 3 September 2010 2 of 2 3 3 September 2010
0.3 1 of 6 3 3 September 2010 2 of 6 3 3 September 2010 3 of 6 3 3 September 2010
4 of 6 3 3 September 2010 5 of 6 3 3 September 2010 6 of 6 3 3 September 2010
0.4 1 of 2 3 0 April 2008
2 of 2 3 0 April 2008
0.5 1 of 2 3 2 May 2009 2 of 2 3 2 May 2009
0.6 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
0.7 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
PART – 1: MANAGEMENT
CHAPTER Page No. Edition Revision Issue Date MOE Part 1 1 of 2 3 0 April 2008
2 of 2 3 0 April 2008
1.1 1 of 2 3 1 May 2008 2 of 2 3 1 May 2008
1.2 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
1.3 1 of 2 3 2 May 2009 2 of 2 3 2 May 2009
1.4 1 of 14 3 0 April 2008 2 of 14 3 0 April 2008
3 of 14 3 0 April 2008 4 of 14 3 0 April 2008 5 of 14 3 0 April 2008 6 of 14 3 0 April 2008
7 of 14 3 0 April 2008 8 of 14 3 0 April 2008 9 of 14 3 0 April 2008 10 of 14 3 0 April 2008 11 of 14 3 0 April 2008 12 of 14 3 0 April 2008 13 of 14 3 0 April 2008 14 of 14 3 0 April 2008
PART – 1: MANAGEMENT CHAPTER Page No. Edition Revision Issue Date
1.5 1 of 4 3 2 May 2009 2 of 4 3 2 May 2009 3 of 4 3 2 May 2009 4 of 4 3 2 May 2009
1.6 1 of 2 3 3 September 2010 2 of 2 3 3 September 2010
1.7 1 of 6 3 0 April 2008 2 of 6 3 0 April 2008 3 of 6 3 0 April 2008 4 of 6 3 0 April 2008 5 of 6 3 0 April 2008 6 of 6 3 0 April 2008
1.8 1 of 14 3 0 April 2008 2 of 14 3 0 April 2008 3 of 14 3 0 April 2008 4 of 14 3 0 April 2008 5 of 14 3 0 April 2008 6 of 14 3 0 April 2008 7 of 14 3 0 April 2008 8 of 14 3 0 April 2008 9 of 14 3 0 April 2008 10 of 14 3 0 April 2008 11 of 14 3 0 April 2008 14 of 14 3 0 April 2008 13 of 14 3 0 April 2008 14 of 14 3 0 April 2008
1.9 1 of 4 3 3 September 2010 2 of 4 3 3 September 2010 3 of 4 3 3 September 2010 4 of 4 3 3 September 2010
1.10 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
1.11 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
PART – 2: MAINTENANCE PROCEDURES
CHAPTER Page No. Edition Revision Issue Date MOE Part 2 1 of 2 3 0 April 2008
2 of 2 3 0 April 2008
2.1 1 of 4 3 0 April 2008 2 of 4 3 0 April 2008 3 of 4 3 0 April 2008 4 of 4 3 0 April 2008
2.2 1 of 6 3 3 September 2010 2 of 6 3 3 September 2010
3 of 6 3 3 September 2010 4 of 6 3 3 September 2010 5 of 6 3 3 September 2010 6 of 6 3 3 September 2010
CHAPTER Page No. Edition Revision Issue Date 3.13 1 of 4 3 0 April 2008
2 of 4 3 0 April 2008 3 of 4 3 0 April 2008 4 of 4 3 0 April 2008
3.14 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
PART – 4: CONTRACTED OPERATORS CHAPTER Page No. Edition Revision Issue Date MOE Part 4 1 of 2 3 0 April 2008
2 of 2 3 0 April 2008
4.1 1 of 2 3 3 September 2010 2 of 2 3 3 September 2010
4.2 1 of 2 3 0 April 2008 2 of 2 3 0 April 2008
4.3 1 of 2 3 3 September 2010 2 of 2 3 3 September 2010
PART – 5: APPENDICES CHAPTER Page No. Edition Revision Issue Date MOE Part 5 1 of 2 3 0 April 2008
2 of 2 3 0 April 2008
5.1 1 of 10 3 3 September 2010 2 of 10 3 3 September 2010 3 of 10 3 3 September 2010 4 of 10 3 3 September 2010 5 of 10 3 3 September 2010 6 of 10 3 3 September 2010 7 of 10 3 3 September 2010 8 of 10 3 3 September 2010 9 of 10 3 3 September 2010 10 of 10 3 3 September 2010
REQUIREMENTS 0.1 Table of Contents 70(a) 0.2 Record of Revision 70(a) 0.3 List of Effective Pages 70(a) 0.4 Cross References 70(a) 0.5 Distribution List 70(a) 0.6 Purpose of MOE 70(a) 0.7 Access to Facilities 70(a) 1.1 Corporate Commitment by the Accountable Manager 70(a)1 1.2 Safety and Quality Policy 65(a), 70(a)2 1.3 Management Personnel 30(a) 3, 70(a)3 1.4 Duties and Responsibilities of the Management Personnel 30(a) (b), 70(a)4 1.5 Management Organisation Chart 30(a), 70(a)3, 5 1.6 List of Certifying Staff 70(a)6, (b) 1.7 Manpower Resources 30(c), 70(a)7 1.8 General Description of the Facilities at Each Address Intended to be
Approved 25(a)(b), 70(a)8
1.9 Organisations Intended Scope of Work 70(a)9, 75(a), 80 1.10 Notification Procedure to the Competent Authority Regarding Changes
to the Organisation’s Activities / Approval / Location / Personnel 70(a)10, 85(a)(b), 90(c)
1.11 Exposition Amendment Procedures Including, if Applicable, Delegated Procedures
70(a)11, (c)
2.1 Supplier Evaluation and Subcontract Control Procedure 65(b), 75 (b) 2.2 Acceptance / Inspection of Aircraft Components and Material From
Outside Contractors 65(b),
2.3 Storage, Tagging and Release of Aircraft Components and Material to Aircraft Maintenance
25(d), 65(b),
2.4 Acceptance of Tools and Equipment 40(a)(b), 65(b), 2.5 Calibration of Tools and Equipment 40(b), 65(b), 2.6 Use of Tooling and Equipment by Staff (Including Alternate Tools) 40(a), 65(b), 2.7 Cleanliness Standards of Maintenance Facilities 25(a)(b)(c)(d), 65(b), 80 2.8 Maintenance Instructions and Relationship to Aircraft / Aircraft
Component Manufacturers’ Instructions Including Updating and Availability to Staff
45(a)(b)(d)(f)(g),65(b), 70(a)12
2.9 Repair Procedure 45(a)(b)(c), 65(b) 2.10 Aircraft Maintenance Programme Compliance 45(c), 65(b), 70(a)12 2.11 Airworthiness Directives Procedure 45(a)(b)(g), 65(b) 2.12 Optional Modification Procedure 45(a)(b)(g), 65(b) 2.13 Maintenance Documentation in Use and Completion of Same 45(a)(e), 65(b), 70(a)12 2.14 Technical Record Control 55(a), 65(b), 70(a)12 2.15 Rectification of Defects Arising During Base Maintenance 45(a)(b)(c), 55(b), 60(a) 2.16 Release to Service Procedure 50(a)(b)(d)(f),65(b), 75(e) 2.17 Records for the Operator 55(b), 65(b), 70(a)12 2.18 Reporting of Defects to the Competent Authority / Operator /
Manufacturer 60(a)(b)(c)(d)(e),65(b),
2.19 Return of Defective Aircraft Components to Store 25(d), 65(b), 70(a)12 2.20 Defective Components to Outside Contractors 65(b), 70(a)12, 75(b) 2.21 Control of Computer Maintenance Record Systems 55(c), 65(b), 70(a)12 2.22 Control of Man-Hour Planning versus Scheduled Maintenance Work 30(c) 2.23 Control of Critical Tasks 65(b) 2.24 Reference to Specific Maintenance Procedures 65(b) 2.25 Procedure to Detect and Rectify Maintenance Errors 65(b) 2.26 Shift / Task Handover Procedures 47 2.27 Procedures For Notification of Maintenance Data Inaccuracies and
REQUIREMENTS L2.1 Line Maintenance Control of Aircraft Components, Tools, Equipment
etc. 65(b), 42(a)
L2.2 Line Maintenance Procedures Related to Servicing / Fuelling / De-Icing etc.
65(b)
L2.3 Line Maintenance Control of Defects and Repetitive Defects 65(b) L2.4 Line Procedure for Completion of Technical Log 50(a), 65(b), 50(b) L2.5 Line Procedure for Pooled Parts and Loan Parts 50(f), 65(b) L2.6 Line Procedure for Return of Defective Parts Removed From Aircraft 42(a), 65(b) L2.7 Line Procedure Control of Critical Tasks 65(b) 3.1 Quality Audit of Organisation Procedures 65(b)(c), 70(a)12 3.2 Quality Audit of Aircraft 65(b)(c), 70(a)12 3.3 Quality Audit Remedial Action Procedure 65(b)(c), 70(a)12 3.4 Certifying Staff and Category B1 and B2 Support Staff Qualification and
Training Procedures 30(g)(i)(h)(e), 35(a)(b)(c)(d)(e)(f)(g)(h)(i)
3.5 Certifying Staff and Category B1 and B2 Support Staff Records 35(j)(k)(l)(m) 3.6 Quality Audit Personnel 30(e), 65(c) 3.7 Qualifying Inspectors 30(e)(g)(h)(i), 35(a)(b)
(c)(d)(e)(f)(g)(h)(i) 3.8 Qualifying Mechanics 30(e) 3.9 Aircraft or Aircraft Component Maintenance Tasks Exemption Process
Control 65(b)
3.10 Concession Control For Deviation from Organisations’ Procedures 65(b) 3.11 Qualification Procedure for Specialised Activities Such As NDT, Welding
Etc. 30(f)(e)
3.12 Control of Manufacturers’ and Other Maintenance Working Teams 65(b) 3.13 Human Factors Training Procedure 30(e), 35(d)(e)(f) 3.14 Competence Assessment of Personnel 35(d)(e)(f) 4.1 Contracted Operators 70(a)13, (b) 4.2 Operator Procedures and Paperwork 65(b) 4.3 Operator Record Completion 65(b) 5.1 Sample of Documents 55(a) 5.2 List of Sub-Contractors 145.A.75 (b) 30(i), 70(a)14, (b), 75(b) 5.3 List of Line Maintenance Locations As Per 145.A.75 (d) 70(a)15, (b), 75(d) 5.4 List of Contracted Organisations As Per 145.A.70 (a)(16) 70(a)16, (b), 75(d)
Control No. Addressee E01 DGAC, France E02 GSAC, France E03 Director Airworthiness, PCAA E04 Controller of Airworthiness (South), PCAA E05 General Manager (Airworthiness), PCAA
0.5.2 INTERNAL DISTRIBUTION
a) Paper Format
Control No. Addressee
P01 Managing Director, PIA P02 Director (Engineering & Maintenance) P03 Reserved P04 Chief Engineer Quality Assurance P05 Chief Engineer Airworthiness Management P06 Chief Engineer Maintenance Operation Centre P07 Chief Engineer Engineering Business Development P08 Chief Engineer HR, Training & Automation P09 Chief Engineer Line Maintenance P10 Chief Engineer Base Maintenance P11 Chief Engineer Cabin Maintenance P12 Chief Engineer Power Plant Overhaul P13 Chief Engineer Avionics Overhaul P14 General Manager Procurement & Logistics P15 Deputy Chief Engineer (Quality Audit) P16– P17 Reserved
b) Electronic Copy Format
Electronic copy of Maintenance Organisation Exposition (MOE) shall be available on PIA intranet in Portable Document Format (PDF), through corporate accounts. Deputy Chief Engineer (Quality Audit) shall manage timely update of electronic copy upon approval of Maintenance Organisation Exposition and its amendments. Printing of Maintenance Organisation Exposition (MOE) is allowed in the Organisation for ease of consultation / reference. Responsibility for ensuring updates shall remain with the holder of printed copy. Such individual printed copies shall be authorised by Chief Engineer (concerned).
0.6 INTRODUCTION AND STRUCTURE OF MOE 0.6.1 INTRODUCTION
Maintenance Organisation Exposition (MOE) of PIA Engineering & Maintenance has been developed on recommendations of EASA Part – 145 requirements. This exposition includes procedures, means and methods with reference to maintenance and quality assurance of the Organisation, transposing laid down EASA Part –145 requirements.
0.6.2 PURPOSE Purpose of PIA Engineering & Maintenance MOE is to present the Competent Authority with facilities and policies / procedures, followed by personnel in the Organisation, while performing maintenance on aircraft / aircraft components. Compliance with these organisational procedures shall finally demonstrate compliance with EASA Part – 145 requirements, which is a prerequisite to acquire and maintain the EASA Part – 145 Approval for an organisation.
0.6.3 STRUCTURE Maintenance Organisation Exposition has been structured, for ease of use, as follows:
0.7 ACCESS TO FACILITIES Director (Engineering & Maintenance), being deputy to the Accountable Manager, shall make all necessary arrangements for free access for personnel from the Competent Authority to PIA Engineering & Maintenance facilities, whenever deemed necessary by the Competent Authority in relation to EASA Part – 145 Approval.
1.1 CORPORATE COMMITMENT BY THE ACCOUNTABLE MANAGER This exposition and associated referenced manuals define Organisation and procedures upon which the EASA Part – 145 Approval is based according to the Part – 145.A.70. These procedures are approved by the undersigned and should be complied with, as applicable, in order to ensure that all maintenance is being carried out under the terms of this EASA Part – 145 Approval. It is accepted that these procedures do not override the necessity of complying with any new or amended regulation published by the Competent Authority from time to time where these new or amended regulations are in conflict with these procedures. It is understood that the Competent Authority will approve PIA Engineering & Maintenance, whilst the Competent Authority is satisfied that the procedures are being followed and the work standards are maintained. The undersigned commits that the Organisation will remain in compliance with the EASA Part – 145 requirements. PIA Engineering & Maintenance shall authorise the Competent Authority, access to its facilities for assessment in this concern. The Organisation, within agreed frame of time, will pay all the charges prescribed by the Competent Authority for this EASA Part – 145 Approval. It is further understood that the Competent Authority reserves the right to suspend, limit or revoke this EASA Part – 145 Approval, if the Competent Authority has any evidence that the procedures are not followed or the standards not upheld. Being the Accountable Manager, the undersigned shall ensure that all maintenance is being financed and carried out to the standard required by the Competent Authority. Captain Mohammad Aijaz Haroon Managing Director, PIA Accountable Manager for PIA Engineering & Maintenance
1.2.1 POLICY STATEMENT PIA Engineering & Maintenance “Safety and Quality Policy” states as:
‘Airworthiness and Quality Maintenance of aircraft and aircraft components is our highest priority. We are committed to continuously improve the quality of all our products and services to our customers’ satisfaction. This includes safety, reliability, performance and customer values. Recognizing safety as a prime consideration at all times, we will ensure good maintenance practices through the application of human factor principles, and encouraging personnel to report maintenance related errors / incidents. Compliance with procedures, regulations, quality and safety standards, and cooperation with quality auditors is the responsibility of all personnel of PIA Engineering & Maintenance.’
1.3.1 GENERAL Purpose of this Chapter is to provide organisational designations, titles comparison and nominated management personnel involved in maintenance activities on aircraft / aircraft components in PIA Engineering & Maintenance. Administration of EASA Form Four and looking after arrangements are also detailed.
1.3.2 ORGANISATIONAL DESIGNATIONS AND TITLES COMPARISON Following is the comparison between existing titles in PIA Engineering & Maintenance and the management personnel titles, mentioned in AMC 145.A.30 (b):
ORGANISATIONAL DESIGNATIONS TITLES AS PER AMC 145.A.30(b)
Managing Director, PIA Accountable Manager
Director (Engineering & Maintenance) Deputy to the Accountable Manager
Managing Director, PIA is the Accountable Manager of PIA Engineering & Maintenance having overall, specifically including financial, responsibility for running the Organisation. Accountable Manager has basic understanding of EASA Part–145 Requirements and responsibilities, under EASA Part–145 Approval. Director (Engineering & Maintenance) is Deputy to the Accountable Manager for EASA Part–145 Approval. Managing Director, PIA has designated Chief Engineer (Quality Assurance) with responsibility of effective quality system monitoring, alongwith associated feedback reporting system. Management Personnel, ensuring that the Organisation remains in compliance with the EASA Part–145 requirements, shall demonstrate relevant knowledge and adequate extent of experience related to aircraft / aircraft component maintenance and the managerial activities. Due to the organisational structure, functions are segregated for effective administration and following personnel and their deputies have been nominated
Chief Engineer (Quality Assurance) shall submit credentials on EASA Form Four under confidential cover to the Competent Authority for each management personnel except for Accountable Manager. Such Form, when approved, shall be archived by Technical Assistant to Chief Engineer (Quality Assurance). Whenever, credentials for any management personnel are amended, revised EASA Form Four shall be submitted for approval of the Competent Authority, before change becomes effective. In case of an unforeseen change of management personnel, EASA Form Four shall be submitted to the Competent Authority at the earliest, but in any case within 72 hours from the occurrence date.
1.3.5 LOOKING AFTER ARRANGEMENTS In long absence, deputy to respective management personnel shall ensure that division remains in compliance with Part – 145 requirements. Whenever, both management personnel alongwith deputy leave the Organisation, senior-most Deputy Chief Engineer, available in the division, shall be appointed by management personnel to look after day-to-day activities for a specified period of time. Such nominated Deputy Chief Engineer shall also have relevant knowledge and appropriate experience related to aircraft / aircraft component maintenance to ensure compliance with Part – 145 requirements.
TITLE NOMINATED DEPUTY
Managing Director, PIA CAPTAIN MOHAMMAD AIJAZ HAROON MAQSOOD AHMED
Director (Engineering & Maintenance) MAQSOOD AHMED MOHAMMAD TARIQ FAROOQ
Chief Engineer (Quality Assurance) MUHAMMAD ASLAM TARIQ MUMTAZ AHSAN ZUBAIRI
Chief Engineer (Line Maintenance) BABAR KAMAL MUMTAZ KHALID MEHMOOD
Chief Engineer (Base Maintenance) SHAHAB KARAMAT ABDUL QAYUM KHAN
Chief Engineer (Cabin Maintenance) JAVED SARDAR KHAN SYED HASAN ZAIDI
Chief Engineer (PowerPlant Overhaul) MANSOOR AHMED KHAN MUHAMMAD ARIF
1.4.1.1 MANAGING DIRECTOR, PIA Managing Director, PIA shall be the Accountable Manager for PIA Engineering & Maintenance regarding maintenance activities for EASA Part – 145 Approval. Managing Director, PIA shall be responsible to: i. Establish PIA Engineering & Maintenance, endorse Corporate Commitment as
per MOE Chapter 1.1 and define Safety and Quality Policy for the Organisation. ii. Designate Director (Engineering & Maintenance) to assist Accountable Manager
on issues related to EASA Part-145 Approval and to deputize during long absence of the Accountable Manager for EASA Part-145 scope.
iii. Implement an independent quality assurance system and appoint Chief Engineer (Quality Assurance) in the organisation for surveillance of organisational activities to the highest standards of airworthiness and quality.
iv. Appoint / promote / transfer Chief Engineers, General Managers, Deputy Chief Engineers and Aircraft Engineers on operational / maintenance requirements.
v. Provide required manpower resources, facilities, tooling, test equipment and spares to perform maintenance and additional task that may be undertaken. Approve plans and finances for any maintenance capability enhancement in the Organisation.
vi. Administrate Management Reviews with Director (Engineering & Maintenance) and Chief Engineer (Quality Assurance) to check progress on the corrective / preventive actions and overall organisational performance, in terms of quality.
vii. Ensure that all payments related to EASA Part – 145 Approval, prescribed by the Competent Authority, are paid within agreed frame of time.
viii. Assure free access of the Competent Authority personnel to PIA Engineering & Maintenance facility, whenever called for in respect to EASA Part-145 Approval.
ix. Validate the applications (EASA Form Two), for purpose of notification regarding any change, before submission to the Competent Authority.
x. Operate within specific Statutory / Regulatory / Corporate directives for all EASA Part-145 Approval related activities and conform strictly to safety and operational requirements.
1.4.1.2 DIRECTOR (ENGINEERING & MAINTENANCE) Director (Engineering & Maintenance) shall assist the Accountable Manager for all PIA Engineering & Maintenance organisational activities. Reporting directly to Accountable Manager, Director (Engineering & Maintenance) shall be responsible to: i. Manage organisational activities, fulfilling corporate commitment by Accountable
Manager and implementing Safety and Quality Policy in the Organisation, complying with EASA Part – 145 requirements.
ii. Recommend appointment / promotion / transfer of Chief Engineers, Deputy Chief Engineers and Aircraft Engineers to Accountable Manager. However, transfer of Deputy Chief Engineers / Aircraft Engineers, within the Organisation, shall be approved by Director (Engineering & Maintenance).
iii. Review the requirements related to human resource, facilities, equipment, spares and maintenance capability enhancement. Such requirements must be brought into the Knowledge of Accountable Manager without any delay.
iv. Collaborate with Chief Engineer (Quality Assurance) for implementation of an effective quality assurance system in the Organisation to ensure that all activities are accomplished to the highest standards of airworthiness and workmanship.
v. Participate in Management Reviews to review progress on corrective / preventive actions and overall organisational performance, in terms of quality. Ensure corrective actions implementation in timely manner against any finding, observed by personnel from the Competent Authority / Engineering Quality Assurance during quality audits.
vi. Ensure that required facilities, tooling, test equipment and spares are procured, maintained and utilised as per EASA Part – 145 requirements.
vii. Ensure that all maintenance, requested by customer, shall be performed and certified in accordance as per the standard required by the EASA Part – 145 requirements and organisational procedures. Records of maintenance performed shall be archived, in a safe / secure location, for the permissible period.
viii. Establish system for review of all applicable technical standards, in order to maintain airworthiness of aircraft / aircraft components and associated systems.
ix. Initiate approval for all fee and charges related to EASA Part – 145 Approval beforehand, ensuring the payments are made within the agreed frame of time.
x. Make arrangements for free access of personnel from the Competent Authority to PIA Engineering & Maintenance facilities, whenever required in respect to EASA Part-145 approval.
xi. Represent PIA Engineering & Maintenance in his authorised position for all correspondences with the Competent Authority and other organisations.
xii. Propose plans for organisational capability enhancement in PIA Engineering & Maintenance and supervise timely accomplishment of all such approved plans.
Chief Engineer (Quality Assurance) is authorised by the Accountable Manager for surveillance of all activities ensuring that the Organization remains in compliance with EASA Part – 145 requirements. Chief Engineer (Quality Assurance) is responsible to manage company approval system for the Organisation, under delegated authority by Pakistan Civil Aviation Authority. Main responsibilities are to: i. Implement independent quality assurance system for surveillance of organizational
activities as per EASA PART – 145 requirements, through annual audit plan for procedure and product audits.
ii. Conduct scheduled audit and unscheduled product audits, request corrective actions against findings and generate audit reports as quality feedback and hence monitor implementation of remedial actions by respective divisions.
iii. Participate in management reviews to present progress on remedial actions against significant findings and quality issues. Moreover, any major deviation from EASA Part-145 requirements must be communicated to the Accountable Manager, in a timely manner.
iv. Develop ‘Maintenance Organisation Exposition’ and other associated maintenance procedures, control their subsequent amendments and submit such amendments to the Competent Authority for Approval prior to the implementation.
v. Manage effective technical qualifications system for AME Licences / Company Approvals applications processing in close liaison with the Pakistan Civil Aviation Authority and conduct examinations for various categories of Company Approvals.
vi. Issue certification authorisations to maintenance personnel, fulfilling requirements as per laid down organisational procedures and control such authorisations in the Organisation. Manage certification authorisations records and maintain the list of certifying staff for PIA Engineering & Maintenance.
vii. Evaluate and approve plans, contents, pre-qualification rules and durations for any initial and continuation training with regular review of organisational procedures effectiveness.
viii. Evaluate and approve suppliers for Approved Vendors List (AVL), administer suppliers follow up and monitor quality of contracted tasks and incoming stores.
ix. Appraise and submit the Company Capability List (CCL) of PIA Engineering & Maintenance and subsequent revisions to the Competent Authority for approval.
x. Report an unairworthy condition to the Competent Authority and request for any concession in justified cases, if deemed necessary.
xi. Devote maximum time to activities for continual improvement, in respect of quality assurance concept. Supervise personnel assigned with duties in Engineering Quality Assurance division.
xii. Represent the Organisation in authorised position for correspondences with the Authorities and other organisations.
Chief Engineer (Airworthiness Management) shall be Incharge for development of all aircraft / aircraft component maintenance specifications, modifications control and the reliability engineering activities. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Provide required engineering support for maintenance and inspection activities. Evaluate Airworthiness Directives / mandatory modifications, Service Bulletins, unscheduled tasks and Engineering Orders (EOs) related to aircraft / aircraft components, providing complete work instructions and procedures.
iv. Supervise development of maintenance specifications for maintenance tasks according to Work Order. Checking that required maintenance is carried out as per contract with customer, certified in compliance with current applicable regulations / procedures and deferred tasks have been justified.
v. Ensure that controlled maintenance data for aircraft / aircraft components shall be available, throughout the Organisation, to maintenance personnel. Administer technical libraries, update definitions and acquire all required documentation from the Authorities, manufacturers and approved sources.
vi. Analyse adequacy of tooling / equipment / material required for all maintenance activities and control of alternates in case of deviation.
vii. Develop maintenance specifications for aircraft / aircraft components, maintained by the Organisation, according to Work Order and obtain necessary approval from the Competent Authority for any proposed change.
viii. Ensure maintenance records completion, management of records archiving and issuance of such record to customer in accordance with the contract.
ix. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation).
x. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
xi. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager.
xii. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Airworthiness Management division.
xiii. Represent the Organisation in authorised position for all correspondences with other organisations.
1.4.1.5 CHIEF ENGINEER (MAINTENANCE OPERATION CENTRE) Chief Engineer (Maintenance Operation Centre) shall act as coordinator for all divisions to ensure effectiveness of major production planning activities in the Organisation. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Manage Company Capability List (CCL) for aircraft components being maintained by PIA Engineering & Maintenance. Each revised list must be submitted to Chief Engineer (Quality Assurance) for appraisal and onward submission to the Competent Authority for approval.
iv. Manage provisioning of rotables / repairables, spares and materials as per requirements for maintenance, forwarding demands to Logistics division.
v. Maintain database of adequate tooling / test equipment required by maintenance divisions according to the scope of work.
vi. Provide the Organisation with annual hangar visits plan for all aircraft checks including customer aircraft ensuring compliance of airworthiness and safety requirements within required frame of time. Revise all such plans and groundings, if required and issue the revisions accordingly.
vii. Coordinate with divisional heads, for cost analysis, to finalise proposal on annual budget. Submit such proposed budget for the approval of Accountable Manager.
viii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
ix. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
x. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager.
xi. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Maintenance Operation Centre.
1.4.1.6 CHIEF ENGINEER (ENGINEERING BUSINESS DEVELOPMENT)
Chief Engineer (Engineering Business Development) shall coordinate with all relevant divisions of PIA Engineering & Maintenance for maintenance activities on customer aircraft / aircraft components. Main responsibilities are to:
i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Develop and implement marketing / sales plans for the Organisation in an effective manner to achieve defined objectives and target revenues. Promote engineering & maintenance services and conduct surveys to explore market related to quality engineering & maintenance services.
iv. Develop feedback system to achieve customers’ satisfaction, regarding all aircraft / aircraft components maintenance activities and suggest improvement in services.
v. Administer all maintenance contracts with customer organisations in most effective manner. Manage overall control on customers’ work orders for aircraft / aircraft component maintenance.
vi. Participate in administration of organisational capability enhancement projects to attain status of self-sufficient organisation for maintenance on aircraft / aircraft components as per EASA Part-145 Approval.
vii. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation).
viii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
ix. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
x. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.
xi. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Engineering Business Development division.
xii. Represent PIA Engineering & Maintenance in his authorised position for all correspondences with the customer organisations and other related agencies.
1.4.1.7 CHIEF ENGINEER (HR, TRAINING & AUTOMATION) Chief Engineer (HR, Training & automation) shall coordinate with all divisions of PIA Engineering & Maintenance for manpower resources, trainings and automation services for technical areas. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Evaluate required manpower resources and skills for intended scope of work in coordination with divisional heads. Prepare selection criteria and obtain approval of the Accountable Manager for such induction.
iv. Prepare master Man-Hour Plan in liaison with Chief Engineers and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any shortfall of more than 25% in available man-hours during a calendar month.
v. Ensure appropriate training need analysis for management and other personnel in the Organisation. Establish pre-qualification rules for trainings and annual plans for initial and continuation trainings on annual basis. Review effectiveness of training processes through feedback system.
vi. Establish continuous liaison with Data Processing department for provisioning and regular updating of PIA Aircraft Maintenance Management Information System (PAMMIS) in the Organisation.
vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of deviation from organisational procedures and ultimately to Accountable Manager.
x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to HR, Training & Automation.
Chief Engineer (Line Maintenance) shall be Incharge for line maintenance activities, defined under the EASA Part – 145 Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Develop and implement plans to provide optimum aircraft utilisation effectively ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.
iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation).
v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR, Training & Automation) and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any shortfall of more than 25% in available man-hours during a calendar month.
vi. Ensure that all maintenance including defect rectification, in Line Maintenance division, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.
vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.
x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Line Maintenance division.
1.4.1.9 CHIEF ENGINEER (BASE MAINTENANCE) Chief Engineer (Base Maintenance) shall be the Incharge for heavy maintenance on aircraft and the aircraft structures, defined in the intended scope of work under the EASA Part – 145 Approval. Maintenance of different types of mechanically operated ground support equipment, rigs, docks and trestles as well shall also be administered by the same position. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Provide heavy aircraft maintenance to PIA and / or Customer as organisational Hangar Visit Plan within stipulated turn-around-time ensuring that the required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.
iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation).
v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR, Training & Automation) and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any shortfall of more than 25% in the available man-hours during a calendar month.
vi. Ensure that all maintenance including major checks, overhaul and modifications, in Base Maintenance division, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.
vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.
x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Base Maintenance division.
1.4.1.10 CHIEF ENGINEER (CABIN MAINTENANCE) Chief Engineer (Cabin Maintenance) shall be Incharge for appearance (cabin cleaning, disinfecting, hygiene control, etc.) and furnishing (cabin renovation, surface protection, interior upkeep, aircraft painting, etc.) of the aircraft, defined in intended scope of work, under the EASA Part – 145 Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Develop and implement plans to provide aircraft appearance / furnishing effectively and efficiently ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.
iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation).
v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR, Training & Automation) and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any shortfall of more than 25% in available man-hours during a calendar month.
vi. Ensure that all maintenance on cabin appearance / furnishing items during the aircraft line / base maintenance is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.
vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.
x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Cabin Maintenance division.
Chief Engineer (PowerPlant Overhaul) shall be Incharge for component-level maintenance on engines, APUs, landing gears, hydraulic, pneumatic and auxiliary components, defined in intended scope of work, under the EASA Part – 145 Approval. Maintenance of all types of mechanical plants and workshop equipment shall be administered by the same position as well. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Develop and implement plans to provide off-wing maintenance on engines, APUs, landing gears, hydraulic / pneumatic and auxiliary components ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.
iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation).
v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR, Training & Automation) and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any shortfall of more than 25% in available man-hours during a calendar month.
vi. Ensure that all components maintenance is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.
vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.
x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to PowerPlant Overhaul division.
Chief Engineer (Avionics Overhaul) shall be Incharge for component-level maintenance on instrument, electrical and radio / radar and auxiliary components, defined in intended scope of work, under the EASA Part – 145 Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Develop and implement plans to provide maintenance on instrument, electrical, radio / radar and auxiliary components ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.
iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation).
v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR, Training & Automation) and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any shortfall of more than 25% in available man-hours during a calendar month.
vi. Ensure that all components maintenance is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.
vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.
x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Avionics Overhaul division.
1.4.1.13 GENERAL MANAGER (PROCUREMENT & LOGISTICS)
General Manager (Procurement & Logistics) shall be Incharge for procurement of stores, storage, handling and distribution of aircraft spare parts and other engineering stores. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy
and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of
organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.
iii. Maintain Approved Vendors List (AVL) for components being maintained by PIA Engineering & Maintenance. Each revised list shall be submitted to Chief Engineer (Quality Assurance) for appraisal.
iv. Manage procurement / storage / handling distribution / subcontracting activities for aircraft spares, tooling / equipment and materials from suppliers / subcontractors in accordance with the Approved Vendor List (AVL) in close coordination with Chief Engineer (Maintenance Operation Centre).
v. Ensure that adequate security measures are adopted to protect stores against fire and deterioration during storage and at various stages of their handling.
vi. Identify slow moving / surplus / obsolete / dead inventory, provide assistance for perpetual inventory / physical stocktaking and arrange disposal of surplus / scrapped aircraft components / spares as per organisational procedures.
vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.
viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.
ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.
x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Procurement & Logistics division.
1.6 LIST OF CERTIFYING STAFF AND B1 AND B2 SUPPORT STAFF
1.6.1 GENERAL Chief Engineer (Quality Assurance) shall issue and control certification authorisations in the Organisation (Refer MOE chapter 3.4 for details). Certification authorisations for all certifying staff and B1 & B2 support staff shall be managed through controlled ‘List of Certifying Staff, providing details of certifying staff, authorised to issue Certificate of Release to service, upon completion of required maintenance on aircraft / aircraft components. List shall be considered as an associated document to Maintenance Organisation Exposition (MOE).
1.6.2 MANAGEMENT OF LIST OF CERTIFYING STAFF ‘List of Certifying Staff’, under reference # E&M/CE(QA)/CSL, shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance). Procedure for issuance, revalidation, suspension, limitation, revocation and withdrawal of Certification Authorisation is detailed in MOE Chapter 3.4. ‘List of Certifying Staff’ shall be reviewed and updated in accordance with procedure in MOE Chapter 3.5. ‘List of Certifying Staff’ shall provide, as a minimum, following information for each personnel: ♦ Name ♦ Designation / Function ♦ Location ♦ Scope and limitation of the Certification Authorisation ♦ Date of first issue of Certification Authorisation ♦ Expiry date of Certification Authorisation, if necessary ♦ Identification number of Certification Authorisation NOTE: Independence of Quality Assurance personnel from maintenance activities
shall be maintained as described in MOE Chapter 3.6.
1.7.1 GENERAL PIA Engineering & Maintenance shall ensure that sufficient manpower is available for all maintenance activities. Manpower resources deployed, explicitly for maintenance on Customer aircraft / aircraft component contracted under the EASA Part – 145 Approval, shall be selected among total manpower. Separate lists of such nominated personnel shall be controlled by Chief Engineer (Quality Assurance). Process for the manpower resources, in a sequential manner, shall be based on the following: ♦ Manpower assessment (for intended scope of work) ♦ Recruitment of new personnel (based on manpower assessment) ♦ Training Need Analysis
1.7.2 MANPOWER ASSESSMENT Chief Engineer (concerned) shall initiate manpower assessment process for next calendar year, in the month of October. Each divisional head shall determine required man-hours to develop divisional Man-hour plan. Such plan shall be submitted to Chief Engineer (HR, Training & Automation). Following shall be the basis for assessment of required man-hours: ♦ Scheduled work load pattern ♦ Hangar Visit Plan (HVP) ♦ Availability of Aircraft ground time ♦ Estimated man-hour per employee ♦ Skills / specialized services required With inputs from all divisions, Master Man-hour Plan shall be developed by Deputy Chief Engineer (HR, Training & Automation) and finalized by Chief Engineer (HR, Training & Automation), under Ref. No: E&M/CE(P&P)/MHP (Refer MOE Chapter 2.22). Chief Engineer (HR, Training & Automation) shall assess manpower requirements with existing PIA Engineering & Maintenance Human Resource Budget (HRB) in order to propose changes, if any. PIA Engineering & Maintenance Human Resource Budget (HRB) is maintained by Deputy General Manager HR (Engineering), under Ref. No: E&M/AM/HRB. Such Human Resource Budget (HRB) contains following information for each division / section / employee:
♦ Location ♦ Designation, Cadre (Technical / Administrative / Support) ♦ Area / Level of Expertise (Specialized Skill / Trade) ♦ Total available manpower (No. of employees at division level) Upon receipt of required manpower proposal from Chief Engineer (HR, Training & Automation), Deputy General Manager HR (Engineering) shall draft amendments, in existing Human Resource Budget (HRB) for calendar year and submit to Accountable Manager through Director (Engineering & Maintenance) for approval. Approved Human Resource Budget (HRB) for next calendar year shall then be prepared accordingly by the Deputy General Manager HR (Engineering).
1.7.3 RECRUITMENT OF NEW PERSONNEL Recruitment of personnel shall be reviewed on the basis of approved Human Resource Budget (HRB) for each calendar year. Recruitment policy for personnel shall be referred to PIA Personnel Policies Manual (Chapter XXXIV). PIA Engineering & Maintenance, in accordance with defined policy, shall select / appoint maintenance staff on permanent / contractual basis. Contractual staff shall be personnel without any authorisation, working under supervision of permanent personnel.
1.7.4 TRAINING NEEDS ANALYSIS Training requirements shall be analyzed for personnel, at all levels, in the Organisation. Training plan shall be developed for Initial / Basic, Type and Continuation trainings as per the procedures detailed in MOE Chapters 3.4, 3.6, 3.7, 3.8 and 3.11.
1.7.5 DETAILS OF TOTAL MANPOWER
Details of manpower distribution in each division at the maintenance base (Karachi) as per specialized skill / trades are demonstrated in the following tables. However, personnel are being transferred, depending on operational / maintenance requirements, as per provisions stated in Master Man-hour plan.
QUALITY ASSURANCE
S. No. DESIGNATION MAN POWER STATUS TOTAL
1. CHIEF ENGINEER 01 01
2. DEPUTY CHIEF ENGINEER 05 05
3. AIRCRAFT ENGINEERS 30 30
4. TRAINEE ENGINEER 03 03
5. SUPERVISORS, SR. TECH., TECH. 03 03
6. STORE INSPECTOR / RECORDS / OFFICE SUPPORT STAFF 16 16
Planning Electric Instrument Radio / IFE 3. AIRCRAFT ENGINEER
03 14 07 05 29
4. TRAINEE ENGINEER --- 03 05 05 13
5. SUPERVISORS / TECHNICIAN 18 77 62 47 204
6. ENGG. HELPER & CLEANER 08 08
7. ADMIN / SUPPORT STAFF 09 09
TOTAL 268
PROCUREMENT & LOGISTICS DIVISION
S. No. DESIGNATION MANPOWER STATUS TOTAL
1. GENERAL MANAGER 01 01
2. DEPUTY GENERAL MANAGER 03 03
3. MANAGER 01 01
4. STOCKROOM PERSONNEL 117 117
5. OTHER SUPPORT STAFF 175 175
6. STORE ATTENDANT 04 04
7. CONTRACTUAL STAFF 55 55
8. STORE HELPERS 32 32
TOTAL 388
1.7.6 MANPOWER FOR EASA PART-145 ACTIVITIES
Manpower resources for maintenance on customer aircraft / aircraft components, under EASA Part – 145 Approval, shall be selected from total manpower of PIA Engineering & Maintenance. Chief Engineer (concerned) shall assess manpower resources required and submit ‘EASA Active Employees List’ for nominated / selected maintenance personnel in the respective division to Chief Engineer (Quality Assurance) for appraisal. All lists shall be archived by Chief Engineer (Quality Assurance) and presented to the Competent Authority, whenever called for. Chief Engineer (concerned) shall regularly review the list and inform Chief Engineer (Quality Assurance) for any change in active technical manpower under EASA Part-145 scope, keeping same number of employees. However, change in the number shall be submitted to Chief Engineer (Quality Assurance) for assessment and endorsement, ensuring that the total number of active employees for the Organisation remain the same. Whenever, increase in the total number is anticipated, EASA Form 2 shall be submitted to the Competent Authority for approval of such change. Following is the table for number of active technical employees, man-hours of whom
1.8 GENERAL DESCRIPTION OF THE FACILITIES AT EACH ADDRESS INTENDED TO BE APPROVED
1.8.1 ENGINEERING & MAINTENANCE PREMISES IN KARACHI
PIA Engineering & Maintenance has its maintenance base at JINNAH International Airport Karachi, where all the maintenance shall be carried out on aircraft / aircraft components, mentioned and approved under the EASA Part - 145 Approval. Total covered area of facilities for PIA Engineering & Maintenance, located at Karachi, is 83270 m2. The premises, facility and scope of undertaking are presented as follows:
PREMISES FACILITY SCOPE OF UNDERTAKING
LINE MAINTENANCE
(Working Bays)
9260 m2
Refer [1.8.1] & [1.8.2]
• 2 bays each 49 m x 41m; 5241-m2 area for support shops, aircraft components (consumable) Stockroom, Tool Store, offices and amenities.
• Dust protection of parts is achieved by wrapping these in packing material.
• Adequate ground water drainage is available.
• Adequate lighting is being provided. Torches are issued to maintenance personnel and high intensity lamps are available in Tool Store.
• Earphones are provided to maintenance personnel for noise protection especially during engine ground run.
• Portable fire extinguishers are available with centrally controlled fire alarm system.
• Compressed air outlets & electric power pits for 110 VAC / 400 Hz are available.
• Line maintenance on B777, B747 & B737 series aircraft. - B777 & B747: Up to
Check A - B737: All Checks
incl. Check A
• Aircraft Appearance
• Stockroom – SR 81 aircraft consumables
LINE MAINTENANCE
(Working Bay)
3450 m2
Refer [1.8.1] & [1.8.3]
• 1 bay 37 m x 31m; 1 bay 37m x 23 m; 1450-m2 area for support shops, aircraft components (rotables) Stockroom, Tool store, offices and amenities.
• Dust protection of parts is achieved by wrapping these in parking material.
• Adequate ground water drainage is available.
• Adequate lighting is being provided. Torches are issued to maintenance personnel and high intensity lamps are available in Tool Store.
• Earphones are provided to maintenance personnel for noise protection especially during engine ground run.
• Portable fire extinguishers are available with centrally controlled fire alarm system.
• Metallic storage racks are available for aircraft components.
• Compressed air outlets & 400 Hz, 110 VAC electric power pits are available.
• Line maintenance on A310 & A300 series aircraft.
• Battery shop, NDT Shop, Avionics consumables and Rubberized material Stockrooms, Cardex control section.
• Air conditioning is provided in shops for dust / weather protection.
• Adequate water drains are available. • Adequate illumination is being provided. • Sections are isolated to avoid area contamination. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Compressed air and electric powers (115 VAC / 400
Hz / 28 VDC) are available with standby generator.
• Battery shop • NDT shop • Cardex Control • Technical records • Stockroom – SR 14
consumables
• Stockroom – SR 26 rubberized material
BLOCK O/H HANGAR
3370 m2
Refer [1.8.1] & [1.8.4]
• 1 bay 49 m x 15 m; 1 bay 15 m x 9 m; 1450-m2 area for support shops, Tool Store, offices and amenities.
• Sufficient weather and dust protection is available. • Ground water drains are available. • Adequate lighting is being provided with emergency
electrical power for offices and hangar. • Earplugs are available for noise protection. • Foam type fire fighting system is available with
centrally controlled fire alarm system. • Racks are available for storage of parts. • Compressed air, 115 VAC / 400 Hz electric supply,
Overhead Crane and Hot Water are available.
Heavy maintenance and major Checks on B737 series aircraft.
ISPAHANI HANGAR
35460 m2
Refer [1.8.1] & [1.8.5]
• Hangar 135 m x 96 m to accommodate one B747 and A300 aircraft simultaneously with complete docking.
• 22500- m2 area for support shops, Tool Stores, Stockrooms (Flight Pack, aircraft consumables, aircraft tyres and raw material), offices and amenities with paint booths.
• Movable hangar doors to ensure weather and dust protection especially in adverse weather condition.
• Water drains are available. • Hangar is well ventilated for appropriate working. • Adequate lighting available with stand by support. • Noise protection is achieved by closing doors of
hangar and by the use of earphones / earplugs. • Medium expansion foam fire fighting system is
hot water, central vacuum cleaning, fuel tank purging, service lifts and overhead cranes are available.
• Heavy maintenance and major Checks on: - B747: Check A & D - B777: Check C - A310 / A300: 4 / 8
yearly and Check D • Painting of aircraft
exterior, Livery and Decals (complete).
• Stockroom – SR B2 aircraft consumables
• Stockroom – SR 09 aircraft tyres
STRUCTURE REPAIR SHOP (Structure and
Composite Repair) 2543 m2
Refer [1.8.5]
• Shop equipment, offices, tool store and amenities. • Shop is provided with dust and weather protection and
comfortable working conditions. • Adequate water drains are available. • Adequate illumination is available. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Compressed air and electrical Power supplies of 220
Volts 50 HZ are available overhead cranes are also available.
• Racks are available for storage of structural Parts.
• Structural Repairs / Modifications on B777, B747, B737, A300 and A310 series aircraft.
• Seats, Galleys, Renovation, PAX survival equipment and Upholstery shops are air-conditioned for dust / weather protection. Stockroom for aircraft component / material (furnishing).
• Plastic repair shop, Sign and art shop, Interior paint shop, Tool Store, Work control centre and Check shift are well ventilated for suitable working atmosphere, providing dust and weather protection.
• Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Compressed air and electrical supplies of 220 Volts 50
HZ are available overhead cranes are also available. • Cold Water supplies is also available.
Maintenance on: • Seats (crew / PAX).
• Survival equipment
• Galleys and Toilets
• Stitching of curtains / seat covers
• Cargo nets
• Paintings of aircraft interiors / placarding
• Stockroom – SR B3 consumables
ENGINE & LANDING GEAR
OVERHAUL 14200 m2
Refer [1.8.1] & [1.8.6]
• Specialized shops, offices and amenities including, machine tools, heat treatment and processing area. Stockrooms for aircraft component / material (engine / APU / landing gear) and Chemicals.
• Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is being provided. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts and spares.
Movable trolleys are also available. Storage of complete engine is also facilitated.
• Compressed air and electric supplies available with standby generator. Overhead Cranes also available.
• Maintenance on landing gears of B747, A310, A300 and B737 aircraft.
• Stockroom – SR 04 chemicals
• Stockroom – SR 45 consumables
Q.E.C BUILD-UP 2200 m2
Refer [1.8.1]
• Offices, stores and required amenities. • Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Compressed air and electric powers are available. • Overhead Cranes are also available.
• QEC build-up of all Powerplants as per MOE Chapter 1.9
JET ENGINE TEST COMPLEX
1240 m2
Refer [1.8.1]
• Test cell, preparation area, control room, fuel foam and amenities.
• Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Adequate racks available for storage of parts / spares. • Electric power is available.
• Testing of Engines: CF6-50, CF6-80C2 and CFM56-3.
• Dust and weather protection available. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for the storage of parts / spares. • Electric power is available.
• APU Testing: 660, 700 and 85-129.
COMPONENT OVERHAUL
3500 m2
(Fuel & Misc. / Hyd. & Brakes)
Ref. [1.8.1] & [1.8.3]
• Shop equipment, offices, stores and amenities. • Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Compressed air and electrical Power supplies of 220
Volts 50 HZ available. • Cold Water supplies is also available.
• Maintenance on:
Fuel, Hydraulic & Misc. system components and Brake assemblies fitted on B747, B737, A310 and A300 series aircraft.
PNEUMATIC OVERHAUL
2300 m2 Ref. [1.8.1] & [1.8.7]
• Shop equipment, offices, aircraft component / material (pneumatic) Stockroom, stores and amenities.
• Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Compressed air and power supplies (115 VAC & 28
VDC) are available with Stand by generator.
• Maintenance on:
Pneumatic and air-conditioning system components fitted on B747, B737, A310 and A300 series aircraft.
• Stockroom – SR 89 consumables
RADIO OVERHAUL
1050 m2
Ref. [1.8.1] & [1.8.3]
• Shop equipment, offices, stores and amenities. • Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Compressed air and power supplies (115 VAC & 28
VDC) are available with Stand by generator.
• Maintenance on:
Wireless, radar & video system components on B747, A310, A300 and B737 series aircraft.
INSTRUMENT OVERHAUL
1850 m2
Ref. [1.8.1] & [1.8.3]
• Shop equipment, offices, stores and amenities. • Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Compressed air and power supplies (115 VAC & 28
Volts DC) are available with Stand by generator.
• Maintenance on:
Instruments of B747, A310, A300 and B737 series aircraft.
• Shop equipment, offices, stores and amenities. • Shop is air-conditioned for dust / weather protection. • Adequate water drains are available. • Adequate illumination is available. • Sections are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Compressed air and power supplies (115 VAC & 28
Volts DC) are available with Stand by generator.
• Maintenance on:
Electrical components fitted on B747, A310, A300 and B737 series aircraft.
TOOL
MANUFACTURE
SHOP
540 m2
Ref. [1.8.1] & [1.8.6]
• Shop, equipment including machine tools and fitting benches, offices, stores and amenities.
• Shop is adequately ventilated to ensure working of personnel is not impaired.
• Adequate water drains are available. • Adequate illumination is available. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks / Stands available for storage of parts / spares. • Pneumatic & Electric powers are available with
standby arrangements.
• Manufacture, repair and modification of special tools and fixtures.
WORKSHOP
EQUIPMENT
MAINTENANCE 1270 m2
Ref. [1.8.1] & [1.8.6]
• Shop equipment, offices, stores and amenities. • Shop is ventilated for suitable working atmosphere,
providing dust and weather protection. • Adequate water drains are available. • Adequate illumination is available. • Individual areas are isolated to suppress noise. • Portable fire extinguishers are available with centrally
controlled fire alarm system. • Racks are available for storage of parts / spares. • Pneumatic & Electric powers are available.
• Periodic maintenance on overhead cranes, fixed equipment and air compressors.
• Supply of dry air and nitrogen gas.
• Stockroom – SR 06 bulk storage (P&L Stores building)
HANGAR EQUIPMENT
MAINTENANCE
840 m2
Refer [1.8.1]
• Shop equipment, offices, stores and amenities. • Working area is open space. Dust protection achieved
by wrapping the parts in packing material. • Water drains are available. • Illumination is available. • Earplugs are available in the stores. • Portable fire extinguishers are available. • Racks are available for storage of parts and spares. • Pneumatic power is available.
• Periodic maintenance on ground support equipment (GPUs, rigs, docks, trestles, etc.)
1.8.2 HANGAR OCCUPATION / AIRCRAFT VISIT PLAN
Hangar Visit Plan shall be prepared in accordance with the maintenance schedule and availability of bays on yearly basis by Deputy Chief Engineer (Schedule & Check Planning). There are four bays altogether; three in Ispahani Hangar and one in Aircraft Overhaul Hangar. Deputy Chief Engineer (Schedule & Check Planning) shall submit the developed Hangar Visit Plan for review and approval of Chief Engineer (Maintenance Operation Centre).
Approved plan shall be issued under the Ref. No. E&M/CE (P&P)/HVP. Annual Hangar Visit Plan shall be reviewed on quarterly basis and may be revised to accommodate for the following as well:
i. For major jobs upon requirement by line maintenance ii. For customer’s aircraft major checks iii. For contingencies and reasons beyond control
Revised Hangar Visit Plan (with Revision No. / Revision date) shall be transmitted to all concerned as a controlled document, under the approved distribution list maintained by Chief Engineer (Maintenance Operation Centre).
1.8.3 APRON
An apron covering an area of approx. 121,000 m2 is located in front and on the eastern side of ISPAHANI Hangar. It provides eight additional parking / maintenance bays and two run-up bays. Run-up bays are provided with blast deflectors to divert engine exhaust and reduce noise. Parking / maintenance bays and run-up points are provided with under ground pits with service point for compressed air and 400 Hz AC power pits. Apron is well illuminated with tower mounted high-pressure sodium vapour floodlights. Ground markings and lightening fixtures are as per JEPPESSEN Manual.
1.8.4 TECHNICAL LIBRARIES
PIA Engineering & Maintenance Technical Libraries comprise of Main Technical Library at Karachi, for the management of all maintenance data from the Authorities, associated bodies, aircraft / aircraft component manufacturers, vendors and other organisations. In addition to hard copies, maintenance data is also available on manufacturers’ Digital Versatile Disc (DVD) / Compact Discs (CD). Main Technical Library has qualified librarians, assigned with functions of maintenance data ordering, managing manual updates, cataloguing and maintaining controlled copies in updated status. Facilities such as personal computers, printers, Aperture cards for drawing tools are also available. A set of applicable maintenance data is also available at the respective branch libraries, located in different divisions, at the maintenance base (Karachi).
1- Bay 2 Line Maintenance 2- Bay 1 Line Maintenance 3- Parts Control section 4- Repairable Store 5- Aircraft Appearance (Cabin Maintenance) 6- Tool Stores 7- Offices
1.9.1 GENERAL PIA Engineering & Maintenance shall perform maintenance that includes any one or combination of the overhaul, repair, inspection, replacement, modification or defect rectification of aircraft / aircraft components, under the EASA Part – 145 Approval.
1.9.2 WORK SCOPE
Summary of maintenance to be carried out under EASA Part – 145 Approval, mentioning classes, rating and the limitations is given as under:
Class: Aircraft, Rating A1 (>5700 kg)
RATING TC HOLDER AIRCRAFT MODEL LIMITATION MAINTENANCE LEVEL BASE LINE
A1 AIRBUS A300 B4-203 A300 B2-203
Airbus A300 basic model (GECF6)
Up to and including D / Base check* X X
A1 AIRBUS A310-300 Airbus A310-300 (GECF6)
Up to and including D / Base check** X X
A1 AIRBUS A310-300 Airbus A310-300 (PW4000)
Up to and including D / Base check ** X X
A1 The BOEING Company Boeing B737-300 Boeing B737-400
Boeing 737-300 / 400 / 500 (CFM56)
Up to and including D / Base check X X
A1 The BOEING Company Boeing B747-200 Boeing 747-200
(GE CF6) Up to and including
D check X X
A1 The BOEING Company Boeing B747-300 Boeing 747-200 / 300 (RR RB211)
Up to and including D check X X
A1 The BOEING Company Boeing 777-200 Boeing 777-200 (GE90-94B)
Up to and including C checks X X
A1 The BOEING Company Boeing 777-200LR Boeing 777-200LR (GE90-115B)
Up to and including C checks X X
* Quarter Base Check & Mid Base Check for A300 as per MPD
** 6 yearly & 12 yearly check for A310 as per MPD
Class: Engines, Rating: B1, B3
RATING ENGINE / APU MODEL LIMITATION MAINTENANCE LEVEL
B1 GE CF6 50 GE CF6-50 C2 GE CF6-50 E2 All Modules repair
For aircraft components (except rating C10, C11, C16, C21 & C22), refer Company’s Capability List (E&M/CE(P&P)/CCL) for part numbers.
1.9.3 DESCRIPTION OF ACTIVITIES
AREA OF ACTIVITY DESCRIPTION
BASE
The maintenance activities include: • Scheduled Heavy maintenance. • Unscheduled maintenance. • Repair and Inspection work. • Major Checks up to CHECK “D”. • Modifications, Major and Minor. • Application of approved repairs • Airworthiness Directive / modification incorporation • Restricted fabrication as per maintenance data as per Part
145.A.42(c).
AIRCRAFT Category A class ratings are subdivided into 'Base' or 'Line' maintenance.
LINE
The line maintenance activity covers: • Pre-flight / Transit. • Daily / Weekly Checks. • Defect Rectification
ENGINES / APUs
Activities comprise: • Scheduled and Unscheduled maintenance. • Routine Inspections. • Defect Rectification in accordance with the AMM, EMM or Approved
Documentation. • Testing, Repair and Overhaul.
COMPONENTS
Activities comprise: Bench test, repair and overhaul of components listed in Company’s Capability List.
1.9.4 COMPANY CAPABILITY LIST Company Capability List of PIA Engineering & Maintenance shall be maintained by Chief Engineer (Maintenance Operation Centre), under reference # E&M/CE(P&P)/CCL in tabular format. The list shall be controlled by Chief Engineer (Quality Assurance), providing following information:
♦ Category (C1 to C20; except C10, C11 & C16) ♦ ATA chapter & LRU Control No ♦ Part No. ♦ Designation ♦ Reference of the CMM ♦ Level of Maintenance ♦ Workshop
Company Capability list (CCL) shall be compiled by integrating capabilities, for maintenance on relevant components, from all divisions through Chief Engineers (concerned). This list shall be submitted to Chief Engineer (Quality Assurance) for approval, against the scope of work being approved by the Competent Authority. Approved list shall be available online (PIAC website: www.piac.com.pk). Deputy Chief Engineer (production) concerned shall maintain Shop Capability List for respective section, endorsed by Chief Engineer (concerned). Company Capability List, in hardcopy, shall be presented to the Competent Authority, whenever called for. Deputy Chief Engineer (production) concerned shall review the Company Capability list (CCL) on regular basis.
1.9.4.1 Amendment Process An amendment in Company Capability List may be addition / deletion / correction related to any aircraft component, enhancement / limitation of work scope (maintenance level) or a combination of both. Deputy Chief Engineer (production) concerned shall submit the case on ‘Request for Addition* / Deletion* / Correction* in Company Capability List’ form (Refer MOE Chapter 5.1) alongwith following details to Chief Engineer (concerned):
♦ Rating, ATA chapter & LRU Control number ♦ Part number and Designation ♦ Reference of the CMM ♦ Level of maintenance ♦ Workshop involved in maintenance ♦ Justification for amendment (addition / deletion / correction)
Chief Engineer (concerned) shall review the case and then forward the form to Chief Engineer (Quality Assurance) for endorsement.
b) Amendment affecting scope of Approval An amendment, affecting scope of Approval, such as addition of a new component rating in Company Capability List, shall be assessed by Chief Engineer (Quality Assurance). For such amendment, Chief Engineer (Quality Assurance) shall submit ‘Amendment Request Form’ (Refer MOE Chapter 5.1) accompanied by two copies of proposed
amendments to the Competent Authority regarding changes, if any. For the amendment defined in the Part 145.A.85(6), EASA Form Two (revised) must be submitted for the Approval of such amendment. Upon receipt of the Competent Authority’s Approval, Chief Engineer (Quality Assurance) shall authorise Chief Engineer (Maintenance Operation Centre) to incorporate approved amendment and update Company Capability List accordingly. Record for amendments (letter of agreement, revised EASA Part – 145 Approval Certificate, etc.) shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance). Chief Engineer (Maintenance Operation Centre) shall transmit a feedback for incorporated amendment to the originator / requester.
c) Amendment not affecting scope of Approval Amendment in Company Capability List, not affecting scope of Approval, such as addition / deletion / correction regarding an aircraft component, change in maintenance level for already listed components can be authorised by Chief Engineer (Quality Assurance). Chief Engineer (Quality Assurance), verifying that proposed amendment is not affecting scope of Approval, shall endorse such amendment. Chief Engineer (Maintenance Operation Centre) shall incorporate an authorised amendment in Company Capability List. Original of amendment request shall be retained with Chief Engineer (Maintenance Operation Centre), whereas copies are sent to the originator / requester as feedback.
1.10 NOTIFICATION PROCEDURE TO THE COMPETENT AUTHORITY REGARDING CHANGES TO THE ORGANISATION’S ACTIVITIES / APPROVAL / LOCATION / PERSONNEL
1.10.1 PROCEDURE
With due consent of the Accountable Manager, Chief Engineer (Quality Assurance) shall be responsible to notify the Competent Authority of any change, defined in the EASA Part 145.A.85, concerning organisational activities / approval / location / management personnel and implementation of the Exposition Amendment procedure.
1.10.2 NOTIFIABLE CHANGES
Following are the changes, subject to notification to the Competent Authority: i. The name of the organisation ii. The location of the organisation iii. Additional locations of the organisation iv. Any of the senior persons specified in this MOE Chapter 1.3 v. Facilities, equipment, tools, material, procedures, work scope and certifying staff
that could affect the approval.
1.10.3 EASA FORM TWO Chief Engineer (Quality Assurance) shall inform the Competent Authority for any of the above-mentioned changes. For a change, except MOE 1.10.2 (iv), application shall be made through a letter requesting such change at least 30 days ahead of incorporation date. Two copies of the MOE pages and EASA Form Two shall be submitted to the Competent Authority alongwith application. In case of Accountable Manager change, new Corporate Commitment signed by the successive Accountable Manager shall be submitted with application. Accountable Manager shall ensure disbursement of fee, related to renewal of the EASA Part – 145 Approval Certificate. An ‘Amendment Request Form’ (Refer MOE Chapter 5.1) shall be used for the purpose of notification to the Competent Authority regarding changes, if any.
1.10.4 EASA FORM FOUR For any required change, mentioned under MOE 1.10.2(iv), procedure for submission of EASA Form Four is specified in MOE Chapter 1.3.
1.10.5 INCORPORATION OF AMENDMENT In general, changes shall not be effective before notification and receipt of Approval from the Competent Authority. For an unforeseen change of staff, the Competent Authority shall be notified within shortest possible time, but not later than 72 hours from the date of change occurred. Chief Engineer (Quality Assurance) shall be responsible to notify such a change to the Competent Authority.
1.11 EXPOSITION AMENDMENT PROCEDURES INCLUDING IF APPLICABLE, DELEGATED PROCEDURES
1.11.1 MANAGEMENT OF MOE
Maintenance Organisation Exposition (MOE) has been approved by the Accountable Manager, as per the corporate commitment in MOE Chapter 1.1. Under the delegated authority, Chief Engineer (Quality Assurance) shall control amendment process of this Exposition and all associated maintenance procedures and submit any amendment in this context to the Competent Authority, for approval.
1.11.2 KNOWLEDGE OF MOE
Chief Engineer (concerned) / General Manager (Procurement & Logistics) shall ensure that personnel of respective divisions are well acquainted with contents / application of Maintenance Organisation Exposition (MOE) and other associated procedures related to job roles assigned to the individuals. Personnel in the Organisation are equally responsible to notify respective Deputy Chief Engineers / Deputy General Manager whenever there is a need for an improvement / change. Whenever, a typographic error or other discrepancy is found in any procedure, same shall be reported without any delay. In all cases, after initial assessment, Deputy Chief Engineer / Deputy General Manager shall forward recommendations to Deputy Chief Engineer (Quality Audit) for evaluation of an amendment for compliance with the Part – 145 requirements.
1.11.3 APPROVAL OF MOE AMENDMENTS Any proposed amendment in Maintenance Organisation Exposition (MOE), affecting the scope of EASA Part – 145 Approval, must be submitted to the Competent Authority for approval, prior to the incorporation. Deputy Chief Engineer (Quality Audit) shall recommend proposed amendment to Chief Engineer (Quality Assurance), if found compliant with the Part – 145 requirements. Chief Engineer (Quality Assurance) shall submit two copies of MOE proposed amendment pages with ‘Amendment Request Form’ (Refer MOE Chapter 5.1) under a covering letter. For any change defined in the Part 145.A.85, revised EASA Form Two / EASA Form Four (as applicable) must also be submitted for the approval. Whenever an alteration is recommended by the Competent Authority in the proposed amendment, Chief Engineer (Quality Assurance) shall prepare an acceptable revision for re-submission to the Competent Authority. An amendment, such as addition / deletion / correction within text, process flow or a form in Associate Maintenance Procedures (AMP), not affecting prime intent of any procedure in Maintenance Organisation Exposition (MOE), is considered as “Minor Amendment”. Any correction, made against typographic error in Maintenance Organisation Exposition (MOE), shall also be considered as ‘Minor Amendment’. Proposed ‘Minor Amendment’ shall be submitted to Chief Engineer (Quality Assurance) for indirect approval. However, Chief Engineer (Quality Assurance) shall notify such indirect approval to the Competent Authority for endorsement at the earliest, through two copies of revised MOE pages under a covering letter.
1.11.4 INCORPORATION OF AMENDMENT Upon grant of Approval from the Competent Authority for an amendment affecting scope of the EASA Part – 145 Approval, Chief Engineer (Quality Assurance) shall authorise Deputy Chief Engineer (Quality Audit) to issue an amendment as per the distribution list (Refer MOE Chapter 0.5). Deputy Chief Engineer (Quality Audit) shall maintain records for all amendments. Individual change requires revision number modification. Whereas, complete new edition of Maintenance Organisation Exposition (MOE) shall be developed for several changes. Chief Engineer (Quality Assurance) shall submit new draft of Maintenance Organisation Exposition (MOE) under a covering letter for approval.
1.11.5 DISTRIBUTION OF MOE AND ITS AMENDMENTS
a) Hard Copy Format For distribution of Maintenance Organisation Exposition (MOE), Deputy Chief Engineer (Quality Audit) shall issue a Manual Control Number (Refer MOE Chapter 0.5) to each controlled copy for traceability. Deputy Chief Engineer (Quality Audit) shall distribute amended pages to all addressees, as per distribution list alongwith ‘Manual Status Letter’ (Refer MOE Chapter 5.1), in duplicate. Reference of the Authority’s approval shall be mentioned on Maintenance Organisation Exposition (MOE). An amendment shall be incorporated by inserting new (amended) page and replacing existing page. Margin line, on left-side, will identify latest revision on each affected page. Each manual holder, upon incorporation of amendment, shall complete the ‘Record of Revisions’ (Refer MOE Chapter 0.2). Each holder of Maintenance Organisation Exposition (MOE) shall retain original Manual Status Letter in the beginning of Manual. Whereas copy of letter, duly signed by the holder, shall be returned to Deputy Chief Engineer (Quality Audit) as acknowledgement for receipt and incorporation of particular amendment. Previous Manual Status Letter and the obsolete pages must be discarded immediately to avoid any confusion.
b) Electronic Copy Format Maintenance Organisation Exposition (MOE) and Associate Maintenance Procedures (AMP) in electronic copy format shall be available on organisational intranet for secured accessibility through corporate accounts. Deputy Chief Engineer (Quality Audit) shall arrange in-time updates of electronic copy alongwith revision of Maintenance Organisation Exposition (MOE) in hard copy format. Certifying staff shall be trained on amendments in Maintenance Organisation Exposition (MOE), through continuation training program. Each manual holder shall communicate any amendment in Maintenance Organisation Exposition (MOE) to all concerned personnel of the respective division.
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part 2 Edition: 3 Revision: 0 Issue: April’ 08 Page 1 of 2
MAINTENANCE ORGANISATION EXPOSITION
PART 2: MAINTENANCE PROCEDURES
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part 2 Edition: 3 Revision: 0 Issue: April’ 08 Page 2 of 2
2.1 SUPPLIER EVALUATION AND SUBCONTRACT CONTROL PROCEDURE 2.1.1 PURPOSE
To describe PIA Engineering & Maintenance policies regarding suppliers’ evaluation, qualification, inclusion in Approved Vendor List (AVL) and performance follow-up of such approved vendors for aircraft components (rotable / repairable / consumable), material (consumable / raw), tools, test equipment and maintenance services.
2.1.2 PROCEDURE
2.1.2.1 General All new aircraft components intended to be installed on aircraft / aircraft component (NHA – Next Higher Assembly), shall be accompanying the applicable authorised release certificate issued by Original Equipment Manufacturer (OEM) or OEM Authorised Distributor explicitly EASA Form 1, FAA Form 8130-3 or TCA 24-0078 (Refer MOE Chapter 2.2 for details of authorised released certificates). For used aircraft component, acceptable release certificate shall be EASA Form 1 clearly stating the maintenance performed (Test / Inspection / Repair / Overhaul). Whenever, a component is received from Part-145 Accepted Organisation, FAA Form 8130-3 or TCA 24-0078 shall be considered as equivalent to EASA Form 1, provided such certificates are issued with double release (Refer AMP 2-1 for details). Procurement of all aircraft components, material, tooling and their maintenance services shall be made through a Purchase Order / Repair Order, only from vendors listed in the ‘Approved Vendors List’ (Refer AMP 2-1 for sample). This order shall be made priority-wise to any of the following sources, as per the laid down order / sequence: i. Original Equipment Manufacturer (OEM) of an aircraft / aircraft component ii. Vendor / Distributor (approved / authorised by OEM in the maintenance data) iii. Organisation holding valid Part-145 Approval iv. Part supplier providing aircraft components / material with applicable authorised
certificates from OEM / Part-145 Approved Maintenance Organisation (Note: Components, obtained from suppliers, shall have clear traceability.)
Material (such as fabric, adhesives or raw material) and tooling / test equipment with approved specifications that do not require airworthiness release document must be provided with certificate of conformity from the vendor’s national regulatory authority. Vendors for such material and tooling / test equipment shall only be added in Approved Vendor List (AVL), if recommended by the Original Equipment Manufacturer (OEM) in maintenance data. Maintenance services on aircraft / aircraft component including inspection, repair, modification, overhaul within scope of work (excluding pre-flight inspection to ensure that aircraft is fit for intended flight, not involving any troubleshooting) may be acquired from approved maintenance-services supplier, holding valid Part-145 Approval. Customer-provided aircraft components / material for fitment on its own aircraft, with applicable authorised release certificate showing clear traceability, shall be acceptable. Copy of authorised release certificate must be required alongwith customer serviceability documents (certificates, tags, etc.) as demonstration of component / material traceability.
2.1.2.2 Supplier Evaluation and Follow up Original Equipment Manufacturers (OEMs) and their authorised vendors / distributors (recommended in maintenance data) shall directly be included in Approved Vendor List, upon receipt of initial request from General Manager (Procurement & Logistics) / Chief Engineer (Maintenance Operation Centre), providing pertinent data / documents showing traceability for such vendor. Supplier evaluation for following categories shall be implemented prior to inclusion in the Approved Vendor List: ♦ Maintenance organisations holding a valid Part-145 Approval ♦ Part suppliers, providing aircraft components / material with applicable authorised
certificates from OEM / Part-145 Approved Maintenance Organisations
a) Preliminary Screening and Selection for Evaluation Chief Engineer (Quality Assurance), upon receipt of request from General Manager (Procurement & Logistics) / Chief Engineer (Maintenance Operation Centre), shall send ‘Vendor Approval Questionnaire’ (Refer AMP 2-1 for sample) to the potential supplier for evaluation of scope / capabilities.
b) Evaluation (Scope of Approval) Each potential vendor shall provide detailed information required in ‘Vendor Approval Questionnaire’ alongwith copies of applicable approvals / certificates for intended scope / capabilities. Deputy Chief Engineer (Quality Audit) shall evaluate information provided by potential vendor and prepare Vendor’s profile upon verification through EASA website (http://www.easa.eu.int). i. Qualification Subsequent to evaluation, supplier’s data shall be presented on ‘Supplier Qualification and Follow-up Sheet’ (Refer AMP 2-1 for sample) alongwith recommendation. Once approved, Chief Engineer (Quality Assurance) shall issue ‘Certificate of Approval’ (Refer AMP 2-1 for sample) to vendor clearly stating desired scope of work and limitations. Copies shall be sent to Originator. Record for particular vendor shall be archived three years from the date, on which last services were provided by vendor. Deputy Chief Engineer (Quality Audit) shall archive following as records for each approved vendor: ♦ Preliminary screening questionnaire ♦ Copies of Applicable Approvals / Certificates ♦ Supplier Qualification and Follow-up sheet ♦ Certificate of Approval (copy) ii. Addition to the Approved Vendor List
Qualified supplier shall be added to Approved Vendor List, maintained by General Manager (Procurement & Logistics), to control aircraft component / material / tooling / equipment / maintenance services supplied to PIA Engineering & Maintenance. iii. One-Time Approval of Vendor Whenever there arises urgent requirement for an aircraft component / material / tooling / equipment / maintenance service and in-time availability is only viable from a source out of Approved Vendor List (AVL), General Manager (Procurement & Logistics) / Chief
Engineer (Maintenance Operation Centre) shall submit request for “One Time Approval of Vendor” with pertinent information to Chief Engineer (Quality Assurance). Purchase / Repair Order for such item shall only be issued after obtaining such approval. Potential vendor shall be evaluated by Deputy Chief Engineer (Quality Audit), on priority, on the basis of provided / available information and recommendation shall be made upon satisfactory assessment. Chief Engineer (Quality Assurance) shall issue the “One Time Approval of vendor” to such vendor.
c) Suppliers Follow-up Deputy Chief Engineer (Quality Audit) shall follow vendors’ qualification recurrently by reviewing Part-145 Approvals. For vendor undergoing any change in location / scope of the approval, revised ‘Certificate of Approval’ shall be issued by Chief Engineer (Quality Assurance) on request of General Manager (Procurement & Logistics) / Chief Engineer (Maintenance Operation Centre). Quality results of supplies serve to maintain or withdraw vendor qualification. Technical Assistant to Chief Engineer (Quality Assurance) shall generate such feedback through monthly report on objections / discrepancies raised by Stores Quality Inspectors. Deputy Chief Engineer (Quality Audit), upon receipt of such reports shall recommend, by means of Supplier Qualification and Follow-up Sheet, Chief Engineer (Quality Assurance) to whether qualification of a vendor shall be maintained, withdrawn or suspended. Chief Engineer (Quality Assurance) shall provide access to Approved Vendor List and Purchase / Repair Orders, whenever deemed necessary by the Competent Authority. Access to supplier’s facility for audit shall also be arranged by Chief Engineer (Quality Assurance) with prior notification to concerned vendor.
2.1.2.3 Contracts Management
a) Contracts with Vendors Contracts shall be made with vendors for aircraft components, material, tooling / test equipment and maintenance services. Contracts shall specify at least: ♦ Scope of activity ♦ Initial provisioning / re-provisioning / shipment / stock management ♦ Specific maintenance activity ♦ Lead / Turn Around Time ♦ Warranties ♦ Competent Authority’s access to contracts and vendor’s facility for audit purpose
b) Contracts with Customer Organisations For maintenance services, prior contract shall be made with Customer organisation (Refer MOE Chapter 4.1 for details). Contracts shall be formulated in accordance with Part – 145 requirements, containing following information: ♦ List of requested maintenance tasks ♦ Applicable maintenance data ♦ Concerned aircraft / aircraft component identification ♦ Records requested by Customer ♦ Specific procedures with the Customer (responsibility for provisioning maintenance
data, components / material, work order, approved maintenance schedule, defect rectification, CRS and all continued airworthiness requirements.)
Contracted maintenance tasks shall never exceed Part-145 Approved scope of work / capability. Technical elements of each contract shall be readily available, whenever deemed necessary by the Competent Authority. Chief Engineer (Engineering Business Development) shall draft maintenance contracts, consulting Chief Engineer (Quality Assurance) with regards to Part-145 Approval. Other divisions may be contacted for issues pertaining to approved Company Capability List, continuing airworthiness and maintenance activities. Assistance on financial issues shall be obtained from Deputy General Manager (Finance) Engineering. Draft contract may be discussed with the personnel from Legal department (if deemed necessary). Unless otherwise not possible or not in the interest of the Organisation, contracts shall be non-exclusive. For all contracts (exclusive / non-exclusive), upon recommendation of Director (Engineering & Maintenance), Accountable Manager shall be the final approving authority. Chief Engineer (Engineering Business Development), upon approval, shall sign the contract on behalf of PIA Engineering & Maintenance.
2.1.2.4 Procurement of Stores ‘Purchase Order’ (Refer AMP 2-1 for sample) for any aircraft component / material / tooling / test equipment shall be generated by Deputy General Manager (Logistics) Purchases and the vendor must be listed in Approved Vendor List of PIA Engineering & Maintenance. Request for appropriate release certificates must be stated clearly on the Purchase Order to ensure receipt of parts in accordance with the MOE Chapter 2.2. ‘Repair Orders’ (Refer AMP 2-1 for sample), in a similar manner, shall only be generated from Approved Vendor List for maintenance services. Request for appropriate release certificates must be stated clearly on the Repair Order to ensure receipt of parts in accordance with the MOE Chapter 2.2.
2.1.2.5 Market Research Procurement of aircraft components (rotable / consumable), material (consumable / raw) and tooling / test equipment, etc. shall be made from vendors listed in Approved Vendor List. Deputy General Manager (Logistics) Purchase shall perform market research, if deemed necessary, for potential vendors of aircraft components, materials and tooling / test equipment. For all maintenance services on aircraft (line maintenance / technical handlings, etc.), Deputy Chief Engineer (Rotable Planning) shall perform market research for potential vendors. Deputy Chief Engineer (Repair Abroad) shall carryout market research for aircraft components maintenance.
2.2 ACCEPTANCE / INSPECTION OF AIRCRAFT COMPONENTS AND MATERIAL FROM OUTSIDE CONTRACTORS
2.2.1 PURPOSE
To define PIA Engineering & Maintenance policy regarding acceptance / inspection of aircraft components and material received from outside contractors. This procedure is also applicable to incoming customers’ components for maintenance services.
2.2.2 PROCEDURE 2.2.2.1 General
All aircraft components / material / tool / test equipment, intended for fitment to an aircraft / aircraft component, shall be subjected to an incoming inspection upon receipt (Refer AMP 2-1 for details). Conformity to the Purchase / Repair Order and physical condition of items received shall be achieved through this incoming inspection. Different cases for the receipt of aircraft components / material shall be: ♦ New aircraft component / material / tool / test equipment ♦ Used (serviceable) component / material purchased from approved vendor ♦ Aircraft component / tool / test equipment after outside maintenance (repair abroad) ♦ Customers’ aircraft components (unserviceable) for in-house maintenance
Customer ordered aircraft components / material, intended for fitment to customer’s aircraft / aircraft component, shall also be subjected to incoming inspection. However, in such cases, documents provided by customer shall be considered equivalent to the Purchase / Repair Order.
2.2.2.2 Determination of Goods Conformity
In order to determine conformity for an incoming aircraft component / material, under the supervision of Technical Assistant to Chief Engineer (Quality Assurance), Stores Quality Inspectors shall mainly follow the inspection rules provided as under:
♦ Visual inspection of packing, for possible damage occurred during transportation,
shall be performed. In case of damaged packaging, aircraft component shall undergo a more detailed inspection or quarantined for investigation (protection of aircraft component / material must be sufficient enough to avoid any possible damage to structures / systems including large aircraft components).
♦ Conformance of aircraft component / material with accompanying documents and Purchase / Repair Order such as Nomenclature, Part Number, Serial Number, quantity, life status, maintenance performed (i.e., inspected / modified / repaired / overhauled), etc.
♦ For Life Limited Parts (LLP), back-to-birth history must be checked and component shall be accepted only when such record is among the accompanying documents.
♦ Endorsement of delivery documents specified in the Purchase / Repair Order (Certificate of Conformity, Inspection / Test report, etc.).
♦ Evaluation of other delivery documents not specified in Purchase / Repair Order (conformity to PIA specifications for such products shall be assessed).
In addition to above guiding principles, Stores Quality Inspector shall carryout incoming inspection / checks for aircraft component / material according to Approved Vendor List and categories defined in the table as follows:
New (manufactured) A A N/A New (unused) N/A B B Serviceable (used) C C C Unserviceable (repairable) N/A N/A D
A: Verification that aircraft component is delivered with authorised release certificate
from Original Equipment Manufacturer (OEM) or OEM authorised distributor. B: Verification that component is received with copy of original authorised release
certificate from OEM and statement from vendor that component, has not been used and was stored as per OEM recommendations for storage.
C: Verification that component is delivered with authorised release certificate (EASA
Form 1) from EASA Part-145 Approved organisation or FAA 8130 / TCA 24-0078 (with double release) from Part-145 accepted organisation.
D: Verification that aircraft component from customer, for in-house maintenance, is
received with appropriate unserviceable tag / work order.
2.2.2.3 Airworthiness Determination
Component airworthiness shall be evident when an authorised release certificate is being presented with aircraft component, such as: ♦ EASA Form 1 for aircraft component provided as ‘NEW’ from Original Equipment
Manufacturer / OEM authorised vendor. EASA Form 1 shall be accepted for used component from Part-145 Approved Maintenance Organisation.
♦ FAA 8130-3 for an aircraft component provided as “NEW” from Original Equipment Manufacturer / OEM Authorised Vendor. FAA 8130-3 (with double release) shall be accepted for used components from FAA Part 145 Approved Repair Station that is also Part-145 Accepted organisation.
♦ TCA 24-0078 for an aircraft component provided as “NEW” from Original Equipment Manufacturer / OEM Authorised Vendor. TCA 24-0078 (with double release) shall be accepted for used component from CAR 573 Approved Maintenance Organisation, also Part-145 Accepted Organisation.
Stores Quality Inspector shall contact Deputy Chief Engineer (Technical Services Engineering) concerned, if serviceability of an item cannot be determined by visual inspection or if suspected that component was mishandled during transportation. If testing capability is available within the Organisation, Deputy Chief Engineer (Technical Services Engineering) concerned shall arrange functional tests and send back serviceable component with Certificate of Release to Service, issued by the Certifying Staff holding appropriate Certification Authorisation. Once serviceability is confirmed, Stores Quality Inspector shall issue a Certificate of Inspection (Serviceable Tag) and attach it to the component. Batch number, tag number, shelf life expiry date and any other technical data shall be recorded on the registers. If the serviceability / functionality is not confirmed, Stores Quality Inspector shall receive the component back with inspection / tests findings. For components (repairable), received from customer organisation as ‘Unserviceable’,
Stores Quality Inspector shall perform inspection as per customer Repair Order. If incoming inspection results in conformity, Stores Quality Inspector shall stamp Repair Order as “PIA INCOMING INSPECTION – PASSED”. In case of non-conformity, Deputy Chief Engineer (Sales) Component Maintenance shall be informed for further action. For customer-provided new aircraft component / material traceability, a true copy of authorised release certificate with customer’s own serviceable tag shall be required. For aircraft component, removed as ‘Serviceable’ by the customer for fitment on its own aircraft / aircraft component (component swapping), such aircraft component shall only be acceptable with authorised release certificate (EASA Form 1) issued by the customer. Conforming to incoming inspection, Stores Quality Inspector shall issue a Certificate of Inspection (serviceable tag), stamped as “CUSTOMER A/C COMPONENT”. Applicable details shall be recorded on incoming stores register. In case of non-conformity with received documents or if found physically damaged, Store Quality Inspector shall report discrepancy to Deputy Chief Engineer (Sales) concerned for further action. Such aircraft component / material, belonging to customer, shall be segregated and quarantined separately till the discrepancy is resolved as per MOE 2.2.2.4.
2.2.2.4 Aircraft component / Material Segregation
Whenever an aircraft component is either found physically damaged / unserviceable as a result of in-house inspection / testing or the status is uncertain and in-house inspection capability is not available, such item shall be rejected by Store Quality Inspector. For component / material neither in compliance with Purchase / Repair Order nor having required documents, Stores Quality Inspector shall raise ‘objection and handover item to Foreign Receipt (Logistics) with Rejection Form clearly stating reason for rejection. ‘Discrepancy Report’ (Refer AMP 2-1 for sample) shall be raised and item shall be placed in Quarantine for temporary storage. In this case a copy of Discrepancy Report shall be attached to aircraft component quarantined and vendor shall be informed accordingly (Refer AMP 2-1 for details). Deputy General Manager (Logistics) Stores shall investigate and follow-up raised discrepancy for determination of corrective actions. All rejections shall be recorded for use as quality evaluative indicators. Recording is important because quality-performance, cost-of-quality and vendor rating are largely measured from the statistics of rejections experienced.
2.2.2.5 Separation of Aircraft components sent in Batches Aircraft components (Rotables / Consumables) may be provided in batches in great quantities and provided with a single authorised release certificate. This certificate shall be used for all such components separated from this initial batch, by stamping the following statement on the certificate:
PHOTOCOPY MADE DUE TO BATCH BREAKDOWN BY
PIA ENGINEERING & MAINTENANCE Quantity from batch: PIA Release Note No: R. N. Date: Inspector Name: Insp. Permit No: Signature: Date:
Stores Quality Inspector shall indicate, on each authorised release certificate, quantity taken from batch and serial number of components accompanying each photocopy. Required fields (Inspector name, Certificate Number, date, quantity from batch and batch serial number) shall be recorded after checking batch breakdown of aircraft components and relevant documents. Note: This photocopy shall become a new certificate accompanying the separated
aircraft components.
2.2.2.6 Quarantine Store Area Any material / aircraft component, which does not meet following acceptance criteria except unserviceable aircraft components received for repair, shall be properly labelled with Discrepancy Report and routed to Quarantine Store area, until status is cleared: ♦ Aircraft component not meeting EASA, FAA or other regulatory requirements ♦ Airworthy condition cannot be determined ♦ Documentation is either missing or inappropriate. ♦ Aircraft component shows evidence of physical damage. ♦ Any other condition that renders to un-serviceability of the aircraft component Inside Quarantine Store Area, there shall be a clear segregation for aircraft components declared as ‘UNSERVICEABLE’, material declared as ‘REJECTED’ and aircraft components / material awaiting their status and marked as ‘UNDER INVESTIGATION’. An aircraft component / material shall be removed from Quarantine Store Area, when its status is cleared and Discrepancy Report shall be closed. Aircraft component / material shall be sent to the Stores Quality Inspector for inspection. Stores Quality Inspector shall issue a Serviceable Tag (Certificate of Inspection) for such item.
2.2.2.7 Bogus Items Aircraft component / material not fabricated as per the Type Certificate / Supplemental Type Certificate holder / Original Equipment Manufacturer (OEM) specifications or without their authorisation and that could hazard safety of flight, when installed on an aircraft shall be considered as ‘Bogus Item. Upon incoming inspection, Stores Quality Inspector shall identify a component / material as bogus item due to its non-conformity to design / documentation or if it is evident that component / material is fabricated through forgery avoiding aeronautical standards. Such component / material shall be immediately segregated in Quarantine Store Area and declared as ‘UNSERVICEABLE’. Discrepancy Report shall state the nature of such bogus item and Technical Assistant to Chief Engineer (Quality Assurance) shall be informed for investigation and report to the Authorities.
2.2.2.8 Acceptance / Inspection Records Stores Quality Inspector shall record following data for items received from suppliers: ♦ Purchase / Repair Order ♦ Release Note Number ♦ EASA Form 1 or FAA Form 8130-3 / TCA Form 24-0078 (with double release) ♦ Test / Inspection Reports (as applicable)
♦ Operator’s release document Records shall be kept in Stores for a period of three years from the date of receipt of component / material and shall be transferred thereafter to the Record Room. Storage of records shall be made per nature of product according to the reference number for ease of finding such records at any moment later.
2.2.2.9 Acceptance of Sizeable Aircraft Components The sizeable aircraft components such as engines, APUs, landing gears, etc. shall be sent directly on the manufacturers recommended engine-dolly / trolley to Deputy Chief Engineer (Technical Services Engineering) concerned, where the incoming inspection shall be carried out locally as per the above procedure.
2.2.2.10 Register of Components and material An inventory in computerised system shall state the reference, location and status of each component in the Stockrooms (Refer MOE chapter 2.3). Record of aircraft components in Quarantine Storage Area shall contain at least the Nomenclature, Part number, Serial number, shelf life (if applicable) and reference of the Discrepancy Report (if applicable).
2.2.2.11 Qualification of the Stores Quality Inspector
Stores Quality Inspector shall be made familiar with Part-145 requirements, applicable organisational procedures and acceptance criteria for the EASA Form 1, FAA 8130-3 / TCA 24-0078 (with double release) or Certificate of Conformity. Comprehensive initial training shall be provided to technical staff and upon assessment, Chief Engineer (Quality Assurance) shall issue authorisations to qualified staff. Such personnel, designated as Stores Quality Inspectors shall be authorised to issue Serviceable Tag (Certificate of Inspection) for incoming stores (Refer MOE Chapter 3.7). Stores Quality Inspectors shall undergo continuation training in every two-year time that shall be planned by Deputy Chief Engineer (HR, Training & Automation). Continuation training shall be accomplished through an amalgamation of classroom sessions and dissemination of information through issuance of technical publications such as Quality Control Alerts / Advisories, Technical Notices, etc. Essential topics to be covered in continuation training are as follows:
i. Amendments in Part – 145 / CAA (Pak) requirements. ii. Changes in organisational procedures. iii. Aviation legislation and Human factor issues. Deputy Chief Engineer (HR, Training & Automation) shall maintain records for initial and continuation trainings. Qualifications / authorisations record for Store Quality Inspectors shall be managed by Technical Assistant to Chief Engineer (Quality Assurance).
2.3 STORAGE, TAGGING AND RELEASE OF AIRCRAFT COMPONENTS AND MATERIAL TO AIRCRAFT MAINTENANCE
2.3.1 PURPOSE
To define PIA Engineering & Maintenance rules for identification, tagging, storage and release of aircraft components and material to maintenance personnel.
2.3.2 PROCEDURE 2.3.2.1 Stock Management and Storage of Aircraft Components / Material
Incharge Stockroom, reporting to Deputy General Manager (Logistics) Stores, shall be responsible for day-to-day operation of Stockroom. He shall control and maintain all inventories according to requirements defined by the manufacturer. Stockroom Incharge (concerned) shall update inventory in computerized and manual system whenever aircraft component / material is received in Stockroom. Record shall contain all relevant information, such as Part number, Serial number, location, shelf life, etc. During storage, all aircraft components / material shall be tagged properly (Refer AMP 2-1 for details). It shall be ensured that:
♦ Large enough, strong and sufficient storage facilities for aircraft components and
material are provided and that material is segregated as per nature of product to avoid mutual damage.
♦ All aircraft component and material, subjected to deterioration / shelf life limitations are preserved appropriately.
♦ Suitable protective covering are provided for all components to guard against physical damage and environmental effects.
♦ All serviceable aircraft components and material are segregated and identified appropriately in the stockroom.
♦ Supplies bearing valid certificate / tag are issued to maintenance.
Stockrooms shall have an identified area for unserviceable components / material, which are found as either life-expired or damaged. Such component / material shall be sent to concerned section for further processing on daily basis. While sending a component with expired life, Stockroom Incharge shall declare component as “LIFE EXPIRED” on LRU Tracking Tag / Serviceable Tag and put his signature, date and staff number. Aircraft components and material shall be stored in accordance with manufacturers’ recommendations / industry standards to provide protection against humidity, extreme temperatures, dust, rough handling or other damages. It shall be ensured by all personnel that wherever practical, aircraft components / material shall remain packaged in protective material to minimize damage during handling.
Sensitive electronic / electrical components shall be stored in a cool, dust free and humidity controlled environment as per manufacturers’ recommendations. For storage of Electro Static Discharge Sensitive (ESDS) devices, all electrical-connection pins shall be blanked with proper protective covering and component placed in a specifically made container / bag bearing ESDS label.
Stockroom shall be a permanent building constructed for storage purpose. It shall have proper cover, firm flooring, sufficient area and height required for equipment to be stored and removed with use of MHE (Mechanical Handling Equipment) like forklifts, etc. particularly for heavy equipment. It shall have adequate doorways, which can be
secured when needed. There should be adequate lighting, unless otherwise specified due to nature of equipment or material to be stored. However, direct sunlight shall not be allowed. Aircraft components such as Engines, APUs, landing gears and other heavy structural parts shall be stored as per the manufacturer instructions at designated areas on appropriate trolleys or stands.
2.3.2.2 Control of Access
Aircraft components / material must be stored in secured areas under restricted access to authorised personnel only. For incoming stores and stockrooms, authorisations shall be controlled through a list maintained by General Manager (Procurement & Logistics). Authorised personnel shall be: ♦ Staff working in the Procurement & Logistics division ♦ Stores Quality Inspectors ♦ Personnel performing quality audits Deputy Chief Engineer (production) concerned shall ensure that appropriate storage conditions are observed, while handling serviceable aircraft components and material during aircraft / aircraft component maintenance. All such locations shall be marked in each maintenance area. Access to such components shall be restricted to authorised personnel, working in concerned area.
2.3.2.3 Airworthiness Directives Control for Stored Items Aircraft components in serviceable Stockroom shall remain compliant to the applicable Airworthiness Directives and all other applicable mandatory modifications. Process for accomplishment of all mandatory modifications on aircraft components in serviceable stockrooms is detailed in MOE Chapter 2.11.
2.3.2.4 Inventories Aircraft components / material in Stockroom shall be listed on computerized inventory. Perpetual inventory check / stocktaking shall be made for correcting deviations in nature of product, references and quantity of all components / material in entire stockrooms (Refer AMP 2-1 for details), under supervision of Deputy General Manager (Inventory Control & Stocktaking). Any inventory for customer components / material shall be maintained / handled in a similar manner, described in this procedure.
2.3.2.5 Control of Shelf lives Aircraft components / material with shelf life shall be checked against their documents upon receipt from vendors / suppliers / workshops (Refer AMP 2-1 for sample). Incharge Stockroom (concerned) shall monitor rack life on monthly basis by taking printout of rack life record from ‘PAMMIS’ (PIA Aircraft Maintenance Management Information System) and ‘POSS’ (PIA Online Stores System). Aircraft component / material reaching rack life expiry or found physically damaged shall be segregated by Incharge Stockroom (concerned) and placed at designated location (Unserviceable / Quarantine) within Stockroom, prior to its despatch for disposal.
2.3.2.6 Distribution of Material to Maintenance Aircraft Engineer (production) concerned shall demand repairable and consumable items
separately on ‘Internal Demand & Issue Voucher’ (Refer AMP 2-1 for samples). While drawing component / material from Stockroom, maintenance personnel or material controller shall check for following before accepting item and signing in “Material Received” column of Internal Demand & Issue Voucher: ♦ Appropriate Serviceable Tag with the item, carrying a Release Note ♦ Physical condition of the item and proper packing (as applicable) ♦ Part Number and Quantity issued are same as those demanded ♦ Part and Serial Numbers are same as those indicated on Serviceable Tag ♦ Item bears required / applicable modification status
After issuance of material, Incharge Stockroom (concerned) shall record transaction and update inventory record. Incharge Stockroom (concerned) shall ensure that chemicals are issued with applicable expiry date stickers. Incharge Tool Store (concerned) shall ensure that chemicals stored are having such expiry date stickers and control register is being maintained for monitoring of chemicals rack life on regular basis and life-expired chemicals are discarded in a timely manner. When inter-stockroom transfer of any aircraft component / material takes place, it is responsibility of respective Stockroom Incharges to complete recording and appropriate paper work (Refer AMP 2-1 for details). Computerized on-line inventory control shall be maintained to assist users in their day-to-day functions.
2.3.2.7 Return of Serviceable Items to Stockroom Aircraft components / material, drawn but not used, shall immediately be returned to respective Stockroom with “Stock Return Voucher” (Refer AMP 2-1 for sample). Aircraft Engineer (production) concerned shall clearly record / reason(s) alongwith signature, date and authorisation stamp, on reverse of LRU Tracking Tag / Serviceable Tag. Aircraft Engineer (production) concerned, returning such aircraft component / material, must ensure that item is handed over to Incharge Stockroom (concerned) in original packing alongwith applicable release document and no sub-assemblies / spares have been removed / cannibalized. Copy of “Stock Return Voucher” shall be archived at the section for future reference. After receipt of serviceable aircraft component / material in Stockroom, Incharge Stockroom (concerned) shall record transaction in computerized or manual register and update inventory record accordingly.
2.3.2.8 Storage of Dangerous Goods In hangar / workshop, fluids such as fuel, hydraulics, solvents and cleaning agents being used during maintenance shall be classified as ‘Dangerous Goods’. Dangerous goods shall be grouped with respect to separation between types of risks as prescribed below: ♦ Flammable ♦ Irritant ♦ Oxidising ♦ Noxious / Toxic ♦ Corrosive (in this case, segregation between acidic and alkaline products) For all such dangerous goods, dedicated Stockroom including both for transit and scraping shall be provided, conforming following conditions: ♦ Permanently controlled restriction to Chemicals Stockroom, using lock ‘n’ key
♦ Placards of Warning Notice for such storage at the entrance ♦ Operational and safety / emergency instructions placed in the close vicinity ♦ List of personnel authorised to access such area ♦ Name and phone number of Incharge Stockroom (for contact purpose) Chemical Stockroom shall be equipped with ventilation and retention system as per level of risks. An effective fire protection system shall be established to avoid any unforeseen mishap. Flammable items shall be placed in fire resistant shelves and for Noxious / Toxic material, storage shall be made inside a locked shelve. A label shall be affixed on each individual area showing the type / nature of risk and the handling instructions. Warning Notice, at the entrance, shall be as follows:
“DANGEROUS GOODS AREA RESTRICTED ACCESS
HANDLE SAFELY” Personnel in Chemical Stockroom shall be trained for handling of dangerous goods. Maintenance staff shall be trained for handling dangerous goods during aircraft / aircraft component maintenance through in-house recurrent training sessions.
2.3.2.9 Control of Alternate Materials During maintenance on aircraft / aircraft components, manufacturer recommended material as per maintenance data shall be used. If procurement of such material is not practicable, Deputy Chief Engineer (production) concerned shall inform Deputy Chief Engineer (Technical Engineering Services) concerned to make correspondence with the manufacturer for possible alternates. Upon receipt of manufacturer’s recommendation / consensus, Deputy Chief Engineer (Technical Engineering Services) concerned shall establish alternate material and inform Deputy Chief Engineer (Material Management) to workout availability and procurement of such material. Alternate materials in individual maintenance areas shall be controlled through a list, maintained by Deputy Chief Engineer (Technical Engineering Services) concerned. Controlled list shall be provided to Deputy Chief Engineer (production) concerned for raising demand in accordance with the list. Whenever, new alternate is ascertained, list shall be updated and disseminated to Deputy Chief Engineer (production) concerned for raising demand in accordance with revised controlled list.
2.4 ACCEPTANCE OF TOOLS AND EQUIPMENT 2.4.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding acceptance of tools and equipment received from relevant manufacturers, suppliers or maintenance service providers.
2.4.2 PROCEDURE
2.4.2.1 Generalities Tools and equipment may include: ♦ Standard tools and equipment ♦ Ground support equipment / access steps / platforms ♦ Servicing tools and equipment ♦ Jigs or special fixtures ♦ Any other special tools and equipment required according to maintenance data ♦ Precision tools, equipment and measuring instruments including test equipment
2.4.2.2 Tools and Equipment Procurement Tools and equipment shall be procured from approved vendors and maintenance of such tools and equipment shall be performed either by PIA Engineering & Maintenance or approved vendors. Approved Vendor List (AVL) for tools and equipment shall be maintained by General Manager (Procurement & Logistics) and controlled by Chief Engineer (Quality Assurance). Evaluation, approval and follow-up of vendors for tools and equipment shall be performed as per MOE Chapter 2.1.
2.4.2.3 Management of Suppliers for Tools and Equipment For procurement of new tools and equipment, Deputy Chief Engineer (production) concerned shall identify need for tools and equipment in accordance with applicable maintenance data and coordinate with Deputy Chief Engineer (Repair Abroad) for availability of such tools and equipment in the Organisation. If new procurement is required, Deputy Chief Engineer (production) concerned shall raise “Capital Expenditure Sanction” (CS) / “Internal Requisition” (IR) for management’s approval. The approved documents shall then be forwarded to Deputy General Manager (Logistics) Purchase for processing and follow up of Purchase Order. Acquisition of tools and equipment maintenance services shall be managed through Deputy Chief Engineer (Repair Abroad). For maintenance services of tools and equipment, contracts shall be made with service providers in similar manner as described for component maintenance in MOE Chapter 2.1.
2.4.2.4 Acceptance of Tools and Equipment Tools and equipment shall be categorized as follows: ♦ New, received from approved vendor ♦ Acquired by the Organisation, on loan from an approved external source ♦ Loaned to other organisation and is received back
♦ Received after repair, modification and / or calibration Store Quality Inspector, while performing incoming inspection on the tool / equipment, shall check for any physical damage / deterioration / packaging and conformance to: ♦ Tool / equipment identification number with documents ♦ Internal Requisition (IR) / Capital Expenditure Sanction (CS) ♦ Supplier serviceability document and valid Calibration Certificate (if applicable) ♦ Availability of test report (if applicable) For acceptance inspection, Store Quality Inspector may seek assistance from Incharge Standard Lab / Deputy Chief Engineer (production) concerned. On acceptance, Store Quality Inspector shall issue a Serviceable tag and handover the tool / equipment to Incharge Tool Store / Deputy Chief Engineer (production) concerned, against Internal Demand Voucher alongwith vendor Serviceable tag, provided applicable data and Calibration certificate / test report (if applicable). Store Quality Inspector shall maintain record of all such inspections. For a received tool / equipment, not conforming in any respect with relevant demand or valid calibration, Store Quality Inspector shall handover item to Foreign Receipt section (Logistics) with Rejection Form clearly stating the reason for rejection. Foreign Receipt section shall place rejected tool / equipment in quarantine. (Refer AMP 2-2 for details).
2.4.2.5 Tool Stores Inventory Management On receipt, Incharge Tool Store (concerned) shall record tool / equipment on Tool Store inventory while positioning such tool / equipment in Tool Store. Deputy Chief Engineer (production) concerned shall be informed regarding availability of the required tool / equipment. Lists of tools and equipment shall be maintained by Incharge Tool Store, under supervision of Deputy Chief Engineer (production) concerned. Tools and equipment storage shall conform to applicable environmental conditions, recommended by manufacturers. Incharge Tool Store (concerned) shall maintain and archive following documents or copies (as applicable): ♦ Serviceable Tag issued by Store Quality Inspector ♦ Calibration certificate / Test report ♦ Any other data, provided with tools and equipment Tool lists (Refer AMP 2-2 for sample) shall be maintained for ensuring proper inventories throughout the Organisation. All types of tools and equipment shall be stored at designated locations in respective Tool Stores. Tool / equipment may be issued to any workstation / team due to nature of task / workload on permanent basis with complete traceability. However, such issued tool / equipment shall be monitored by Incharge Tool Store (concerned). Complete inventory check of Tool Store shall be performed every six months. In order to ensure objectivity, Deputy Chief Engineer (production) concerned shall nominate a team within the section excluding Tool Store personnel. Incharge Tool Store (concerned) shall resolve the highlighted discrepancies on priority. Deputy Chief Engineer (production) concerned shall supervise entire process and maintain records for Inventory checks.
2.5 CALIBRATION OF TOOLS AND EQUIPMENT 2.5.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding inspection, calibration and maintenance of tools and equipment, including control of scheduled maintenance.
2.5.2 PROCEDURE
2.5.2.1 General This procedure is applicable to tools and equipment, in order to ensure conformity with specifications. This includes all measuring equipment to be used for test, inspection and calibration. Tools and equipment, prior to induction, shall go through acceptance and inspection procedure as per MOE Chapter 2.4. Tools and equipment requiring calibration shall be included in central calibration record on PIA Aircraft Maintenance Management Information System (PAMMIS), maintained by Standard Lab (concerned). Upon induction, Deputy Chief Engineer (concerned) shall send the tool / equipment to Standard Lab (concerned) for calibration and inclusion in central calibration record. Applicable calibration certificates, received with tool / equipment, shall be submitted to Standard Lab (concerned) for update of central calibration records. Calibration of mechanical test / precision equipment shall be performed in Mechanical Standard Lab located in Engine Overhaul shop. Electronics Standard Lab, located in Electrical Overhaul shop, shall perform calibration of electrical and electronic test / measuring equipment. Calibration shall be performed by authorised personnel as per procedures recommended by manufacturers of such test / measuring equipment. Standard Labs are traceable for carrying out calibration by NPSL (National Physical & Standard Lab) through APMP (Asian Pacific Meteorological Program, Singapore) that is affiliated with BIPM (Bureau of International Physical Weights & Measurements, Paris). Tools and equipment used within the Organisation are subjected to servicing, calibration, inspection and scheduled maintenance at intervals, recommended by the manufacturer of tools and equipment. Records for calibrations, inspections, servicing and scheduled maintenance shall be managed by Incharge Tool Store (concerned).
2.5.2.2 Centralized Control on Tools and Equipment Calibration For centralized control on calibration, all tools and equipment requiring calibration shall be monitored and calibrated in-house by Standard Lab (concerned) in the Organisation. If the facility is not available for a tool / equipment, such item shall be sent to approved vendor for calibration / repair by Deputy Chief Engineer (concerned), through Deputy Chief Engineer (Repair Abroad). Upon return of calibrated / repaired tooling, Deputy Chief Engineer (concerned) shall inform Standard Lab (concerned) to update record. Incharge Tool Store (concerned) shall monitor next calibration due dates for tools and equipment, requiring calibration. In case any due date is skipped by Incharge Tool Store, Deputy Chief Engineer (production) concerned shall be informed by Incharge Standard Lab (concerned) to immediately stop usage with an advice to despatch tool / equipment for calibration. This step shall be considered a sort of double check to avoid usage of any tool / equipment without calibration in the Organisation.
2.5.2.3 Process Calibration of tools and equipment on periodic basis shall adhere to following criteria: ♦ Manufacturers’ recommendation (frequency as per tool / equipment manual) ♦ Design limit for specific tool / equipment, method and usage. If there is no source of information available to establish calibration intervals, Incharge Standard Lab (concerned) shall establish frequency through past experience considering results of calibrations (recorded) and usage of tool / equipment. However, in case of any finding related to tolerance during calibration, Incharge Standard Lab (concerned) shall revise and re-establish the frequency. Record for each category of tools and equipment shall be maintained by Incharge Tool Store (concerned), providing information such as tool / equipment identification number, next calibration / service / check due date, last calibration / service / check date, etc. (Refer AMP 2-2 for details) During last week of each month, Incharge Tool Store (concerned) shall perform following tasks as regard to tools and equipment requiring calibration / servicing: ♦ Review calibration / servicing / check due dates for tools and equipment ♦ Notify sectional / group incharge (concerned) regarding tool / equipment due for
calibration / servicing during next month Upon notification by Incharge Tool Store (concerned), tool / equipment shall be removed from usage and returned to Tool Store. It shall than be transported in their original boxes to Standard Lab (concerned) alongwith ‘Calibration / Repair Tag’ (Refer AMP 2-2 for sample). Incharge Standard Lab (concerned), shall acknowledge the receipt of tool / equipment on list provided by Incharge Tool Store. Where tool / equipment maintained under calibration program requires any repair, it shall be sent through Deputy Chief Engineer (production) concerned. In PIA Engineering & Maintenance, standard tags and stickers shall be used for labelling and identification to show that whether a tool / equipment is: ♦ Serviceable ♦ Calibrated ♦ Calibration not required Standard Lab (concerned) shall maintain ‘Inspection and Calibration Record for Mechanical Standard Lab’ / ‘Test Equipment History Sheet for Electronics Standard Lab’ (Refer AMP 2-2 for samples). Records shall demonstrate calibration history of tools and equipment. It shall also contain information about work performed, personnel involved and details of standard used for calibration of tool / equipment. Details of work performed is recorded on ‘Work Sheets’ (Refer AMP 2-2 for sample) / Registers. After calibration check, Incharge Standard Lab (concerned) shall ensure proper labelling of tool / equipment and update central calibration record. Each item is accompanied with ‘calibration sticker’ and ‘Inspection / Calibration Certificate’ (Refer AMP 2-2 for samples), identifying allotted number, next calibration due date and Inspector’s approval number with signature. Valid calibration certificates are to be filed at Tool Store (concerned). Incharge Tool Store (concerned) shall receive calibrated tool / equipment and maintain
calibration related records. Tools and equipment requiring only servicing / schedule maintenance and not the calibration, shall be maintained by designated sections. All maintenance personnel shall be responsible to check tools and equipment, before use, for valid calibration, serviceability and next calibration / service due date. In case of any doubt, they shall return such tool / equipment to Incharge Tool Store (concerned) for calibration. In case of missing calibration / serviceability certificate or if serviceability becomes doubtful, such tool / equipment shall be sent to Standard Lab (concerned) for verification and issuance of new certificate. In case of loss of tool / equipment, under calibration program control, Incharge Tool Store (concerned) shall report to Deputy Chief Engineer (concerned) for administrative action. Incharge Standard Lab (concerned) must be informed in order to update central calibration records. Record of calibrations shall be archived for a period of service life of tool / equipment by Incharge Standard Lab (concerned), containing following information: ♦ Tool / equipment description ♦ Tool / equipment Part number ♦ Tool / equipment identification or Serial number ♦ Calibration personnel Authorisation number ♦ Tool or equipment location (shop or store) ♦ Tool / equipment status ♦ Calibration frequency ♦ Last and next calibration due dates Detailed work records on ‘Work Sheets’ / Registers shall be archived for two years. Use of personal instruments / measuring equipment, not under calibration control of the Organisation, is never permitted under any circumstances.
2.5.2.4 Recall of Components Controlled with Tool / Equipment found out of Tolerance If a tool / equipment is found with expired calibration while being used on aircraft / aircraft component, Deputy Chief Engineer (Technical Services Engineering) concerned and Incharge Standard Lab (concerned) shall be informed immediately. Such reporting shall be considered as proactive action and must be appreciated by the Organisation. Deputy Chief Engineer (Technical Services Engineering) concerned, in coordination with Incharge Standard Lab (concerned), shall investigate through calibration results. If found out-of-tolerance, duration of the use for that particular tool / equipment in such status shall be ascertained and all pertinent data about aircraft / aircraft components released to service using subject tool / equipment shall be collected. If a tool requiring tolerance limit check before every use is found out-of-tolerance limit, user shall inform Deputy Chief Engineer (Technical Services Engineering) concerned to ascertain the time when such tool became out-of-tolerance and collect all pertinent data about components released to service from such time. In each case, aircraft / aircraft components released to service by using out-of-tolerance tooling / equipment shall be declared un-airworthy by Deputy Chief Engineer (Technical Services Engineering) concerned with intimation to Chief Engineer (Quality Assurance) providing pertinent information regarding such aircraft / aircraft components.
Chief Engineer (Quality Assurance) shall direct all concerned to recall immediately the affected aircraft / aircraft component for re-certification. Occurrence reporting to the Competent Authority and operator shall be processed as per MOE Chapter 2.18.
2.5.2.5 Calibration by Contracted Organisation Tools and equipment may be sent for calibration checks to an organisation that is either the Original Equipment Manufacturer (OEM) or their recommended vendors (Refer MOE Chapter 2.1 for details). After calibration, tool / equipment shall be received back with following information / documents: ♦ Description and identification number of equipment ♦ Next due date corresponding to calibration performed ♦ Results obtained ♦ Limits of tolerated error, limitations of use (if any) ♦ Calibration certificate / Test report signed by authorised personnel Loaned tooling from outside organisations are subject to individual agreements between the organisations concerned, but must have a valid servicing / calibration status.
2.6 USE OF TOOLING AND EQUIPMENT BY STAFF (INCLUDING ALTERNATE TOOLING)
2.6.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding management of tools and equipment and usage of such tools and equipment by maintenance staff.
2.6.2 PROCEDURE 2.6.2.1 Management of Tooling and Equipment
Deputy Chief Engineer (production) concerned shall ensure availability of all required tooling and equipment during scheduled maintenance on aircraft / aircraft components. For this purpose, list of required tools shall be maintained by Deputy Chief Engineer (production) concerned and reviewed upon induction of an aircraft / aircraft component. Reference documents for establishing such list of required tooling / equipment shall be based upon maintenance data such as: ♦ AMM, CMM, TSM, Task / Work cards, Worksheets, etc. ♦ Tooling Equipment Manuals (TEM) ♦ Service Bulletins (SB) ♦ Repair Instructions (RI) Deputy Chief Engineer (production) concerned shall ensure that the manufacturer instructions are followed for storage of tooling and equipment, including temperature / humidity / dust control. Special care shall be observed for the electronic / computerised tooling and equipment (Refer AMP 2-2 for details). Incharge Tool Store (concerned) shall make all necessary arrangements for proper storage of tooling and equipment at designated locations with placards for following: ♦ Tools / equipment requiring calibration ♦ Tools / equipment requiring service ♦ General tools ♦ Consumable material (if any) Records for each category shall be maintained, stating calibration / service intervals, etc. All tooling and equipment requiring calibration / service should have next calibration / service due date stickers or marking. Unserviceable tooling / equipment (if any) shall be segregated and placed at clearly marked location. Access to unserviceable tooling and equipment storage area shall be kept to authorised personnel. Availability of required consumable material shall be maintained by Incharge Tool Store (concerned) to a level designated / authorised by Deputy Chief Engineer (production). Deputy Chief Engineer (production) concerned shall ensure availability and use of ‘Standard Operating Procedure (SOP)’ or operating instructions for tooling / equipment requiring such data. Maintenance personnel shall be provided with operating instructions alongwith particular tooling / equipment. In case, where tool / equipment is to be acquired on loan from any organisation, Deputy Chief Engineer (production) concerned shall contact Deputy Chief Engineer (Repair Abroad) for arrangement of such tooling.
2.6.2.2 Trainings on Tooling and Equipment Upon induction of new tooling / equipment, Deputy Chief Engineer (concerned) shall
establish a need of training for staff. Deputy Chief Engineer (HR, Training & Automation) shall be contacted for such arrangements. In case of tooling / equipment that is already in use, training shall be provided to maintenance personnel during recurrent training sessions and records shall be maintained by Deputy Chief Engineer (production) concerned.
2.6.2.3 Distribution / Use / Return of Tooling and Equipment Tool Store personnel shall maintain ‘Issue and Receipt Register’ under supervision of Incharge Tool Store (concerned), in which pertinent information for issuance of tooling / equipment is entered, i.e. identification of person receiving tool, tooling / equipment nomenclature and serial number, aircraft registration, etc. Standard Operating Procedure (SOP) / operating instructions (if any) shall be issued alongwith tooling / equipment. Prior to use a tooling / equipment, maintenance staff shall check following: ♦ Tooling / equipment identification ♦ Calibration / Service validity ♦ Physical condition ♦ Functionality / Compatibility Maintenance personnel shall use manufacturer’s recommended tooling and equipment with utmost care. For traceability, identification / serial number of calibrated tooling / equipment being used shall be recorded on the worksheets, during aircraft component maintenance. Once used, maintenance staff shall check tooling / equipment for any damage, clean and if necessary, recondition for next use, before returning the used tooling / equipment. Tool Store personnel shall accept tooling / equipment from maintenance staff after thorough inspection and shall report, if found damaged. Transfer of tooling / equipment from one Tool Store to other shall be made through normal tooling issue / receipt procedure. During such transfer, tooling / equipment shall remain in their original containers or boxes. Heavy / large sized tooling shall be made available near work area at specifically marked locations. All large tooling / equipment shall be provided with legible identification plates and marked service due date, if required. Maintenance staff shall confirm serviceability of tooling / equipment prior to use. Incharge Tool Store (concerned) shall be informed immediately for replacement for damaged / illegible identification plates to avoid any confusion. Deputy General Manager (Hanger Equipment Maintenance) shall ensure that the serviceability of hangar equipment (Refer AMP 2-2 for details). Loaned tooling / equipment, after usage, shall be returned by Deputy Chief Engineer (production) concerned to Despatch section (Logistics), through Deputy Chief Engineer (Repair Abroad).
2.6.2.4 Use of Alternate Tooling and Individual Toolkits Use of alternate tooling shall be done with utmost precautions. Alternate tooling may be authorised only when it has been established in the Organisation that maintenance can be accomplished in a safe way with such alternate tooling. Demonstration, given by Deputy Chief Engineer (production) concerned shall be crosschecked with specifications of original tooling for a proper use of alternate tooling. Deputy Chief Engineer (Technical Services Engineering) concerned shall issue a ‘Certificate of Tool / Equipment’ (Refer AMP 2-2 for sample), when such demonstration has been provided.
Alternate tooling shall be allotted with specific identification numbers, clearly marked on the tooling. Deputy Chief Engineer (production) concerned shall manage list of alternate tools with references to maintenance data. Toolkits, issued to maintenance personnel in the Organisation for ease of usage are categorised as ‘Personal toolkits’. As a policy matter, no personal toolkit may carry tools that require calibration. Such toolkits shall be subjected to verification / inspection by Deputy Chief Engineer / Aircraft Engineer (production) concerned, every six months and recorded on the list of tools issued to maintenance staff.
2.6.2.5 Unserviceable Tooling and Equipment Tooling / equipment found damaged or unserviceable shall be returned to Tool Store personnel. Incharge Tool Store (concerned) shall place such tooling / equipment with ‘Calibration / Repair Tag’ (Refer AMP 2-2 for sample) at designated area for limited time. Deputy Chief Engineer (production) concerned, when informed, shall categorize tooling / equipment either as repairable or scrapped. Tooling / equipment requiring repair shall be sent to concerned repair shop, with a detailed work order. Scrapped items information shall be sent to Deputy Chief Engineer (Repair Abroad) to update comprehensive list of available tools. Deputy Chief Engineer (production) concerned shall ensure that the list of available tools of section is updated by Incharge Tool Store (concerned). Deputy Chief Engineer (production) concerned shall investigate to find out reasons for such damage and take measures to avoid recurrence.
2.6.2.6 Tooling Modifications Tooling / equipment shall not be modified unless authorised by Deputy Chief Engineer (Technical Services Engineering) concerned. Incharge Tool Store (concerned) shall maintain record of modified tooling. Authorisation for modifying a tool shall be granted only when it has been demonstrated that such modification is: ♦ Useful and does not change use of tooling / equipment from its intended use. ♦ Not affecting the quality of maintenance being carried out.
2.7 CLEANLINESS STANDARDS OF MAINTENANCE FACILITIES 2.7.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding provision of cleanliness standards for facilities and awareness of safety standards in the Organisation.
2.7.2 PROCEDURE 2.7.2.1 General Facilities and Cleaning
Facilities shall remain in a condition that promotes healthy working atmosphere and proper air-conditioning is provided, where required. Protection from weather elements such as dust, hail, rain shall be ensured according to requirements. Deputy Chief Engineer (concerned) shall ensure that offices, planning and production areas are illuminated with sufficient light fixtures. Additionally, an emergency / standby electrical power is supplied in areas where jobs are performed on round-the-clock basis, or nature of job needs uninterrupted electrical power supply. Deputy General Manager (Hangar Equipment Maintenance) shall ensure serviceability / provisioning of docks, trestles, tow-bars, etc. Serviceability of machines and fixed equipment is ensured by Deputy General Manager (Workshop Equipment Maintenance). Cleaning staff required for facilities including work area, docks, equipment, offices, etc. shall be arranged by Deputy General Manager (Office Services). Deputy Chief Engineer (concerned) shall ensure that cleaning staff clears all waste bins, disposes off rubbish at allocated disposal area, sweeps hanger / shop floor daily, at prearranged schedule and thoroughly cleans the floor when notified of oil / fuel spill over. Deputy Chief Engineer (concerned) shall arrange lockers for staff to keep protective clothing and other personal gears. All personnel shall also be provided with meal facilities within the Organisation and service shall be extended to off days / night hours.
2.7.2.2 Safety Issues
a) Fire Protection Provisioning of fire extinguishers with clear identification at obstacle-free locations shall be ensured in the Organisation. Inspection of fire extinguishers shall be performed on periodic basis with check date certificate of each extinguisher. Deputy Chief Engineer (production) concerned shall ensure availability of first aid kits in respective section. Base Maintenance hangar is provided with a fire control room, which monitors activities throughout working hours. Fire Protection personnel perform periodic checks on the system. Additionally hangars have assembly areas and fire alarm bells. Fire drills shall be carried out on periodic basis under supervision of Manager (Fire Protection).
b) Hazardous Waste Management Waste shall be considered as hazardous if it has one or more characteristics / effects such as corrosive, explosive, oxidant, radioactive, reactive, toxic or poisonous and more specifically if it harms or may cause a harm to people directly or indirectly.
Management of hazardous wastes generated during fueling / defueling, maintenance, etc. strictly follows regulations governing treatment, storage, and disposal. Deputy Chief Engineer (production) concerned shall develop list of hazardous materials being used / generated in respective section and safe handling of such material / waste. Maintenance personnel shall be made aware of hazardous materials handling and disposal. Locations for collection of hazardous waste in each section (where applicable) shall be identified / marked, having separately maintained and labelled containers for each type of waste being generated in that section. Deputy General Manager (Logistics) Stores shall ensure that containers are being collected from different sections for disposal through contracted organisations as per country’s regulations.
c) Environmental Safety All personnel are equally responsible to closely observe environmental safety in the Organisation. An observed environment / safety hazard shall immediately be notified to Deputy Chief Engineer (production) concerned, who must take an immediate corrective action. A detailed report shall be sent for taking appropriate preventive measures to the management with a copy to Chief Engineer (Quality Assurance).
d) Safety Equipment Staff working in sheet metal, welding / heat treatment, machining / bench fitting areas shall be provided with recommended safety equipment. Personnel working at elevations, in particular working on aircraft, must be provided with safety straps / belts, shoes, etc. Deputy Chief Engineer (production) concerned shall make all personnel aware of the importance and usage of safety equipment, through re-current training sessions. Appropriate usage of such safety equipment shall be monitored through spot checks and record shall be maintained by Deputy Chief Engineer (production) concerned.
2.7.2.3 Specific Facilities Hangar bays shall be supplied with 115 V / 400 Hz Electrical power source, integrated pneumatic supply, mobile air-conditioning and 3000 psi hydraulic source for use on the aircraft systems during maintenance activities. Harmful vapours being produced in areas such as, Electroplating shop, Hydraulic shop, etc. are avoided through well ventilation. Complete dust proofing is provided for overhaul shops such as Avionics, Component and Pneumatic Overhaul Shops. Temperature and humidity at Standard Labs, ATEC area and rubberized Stockroom must be maintained to specified tolerances. Recorders of temperature and humidity are placed in areas to check variation of parameters.
2.7.2.4 Personnel Awareness and Clothing All personnel shall be made aware of organizational procedures regarding facilities and safety issues through re-current training. Training record shall be kept with Deputy Chief Engineer (concerned). Fire protection team shall provide fire fighting training and record for each individual shall be kept by Deputy Chief Engineer (concerned). A copy shall be sent to Deputy Chief Engineer (HR, Training & Automation) for archiving centralised training records. Personnel working in Line / Base Maintenance shall be provided with coveralls and in component maintenance areas, maintenance staff shall wear dustcoats in general and lint free coats alongwith caps and shoe covers in white rooms specifically.
2.8 MAINTENANCE INSTRUCTIONS AND RELATIONSHIP TO AIRCRAFT / AIRCRAFT COMPONENT MANUFACTURERS’ INSTRUCTIONS INCLUDING UPDATING AND AVAILABILITY TO STAFF
2.8.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding management of technical documentation issued by the Competent Authority / Manufacturer / Operator / Quality Assurance and other organisations as standards. It also defines management of working documents derived from such standards and quality documentation.
2.8.2 PROCEDURE
2.8.2.1 Generalities Deputy Chief Engineer (Technical Publication & Records) shall ensure availability of standards and maintenance data in the Organisation, received from following sources: ♦ Competent Authorities ♦ Aircraft / aircraft components manufacturers ♦ Organisations such as ICAO, IATA, ATA, etc ♦ Engineering Quality Assurance division ♦ Airworthiness Management division
Maintenance data may be distributed in hard copies, Compact Disks, etc. However, Deputy Chief Engineer (Technical Publication & Records) shall ensure availability of adequate number of personal computers with printing facility in all technical libraries. For PIA aircraft, maintenance data is provided onboard, if despatched to line station not having any library facilities. Maintenance data reading and printing facility shall be made available at such location. Main Technical Library shall receive maintenance data and revisions, which shall further be distributed to all branch libraries in the Organisation (Refer AMP 2-4 for details). Manager (Technical Publications) shall maintain distribution list, for maintenance data. Maintenance data and revisions shall also be sent to Deputy Chief Engineer (Technical Services Engineering) concerned for review / revision of aircraft component worksheets in a timely manner. English shall be the only acceptable language for maintenance data. PIA Engineering & Maintenance shall assure provisioning of maintenance data either by customer for customer aircraft / aircraft components or shall be arranged on behalf of customer under an agreement. In case of line maintenance, the operator shall provide maintenance data. Deputy Chief Engineer (Sales) concerned, shall forward customer-provided maintenance data to Deputy Chief Engineer (Technical Publication & Records) for verification. Maintenance data, not found updated to latest issue / revision, shall be returned to customer with request for update.
2.8.2.2 Requirements / Needs, Ordering / Subscription and Distribution Deputy Chief Engineer (production) concerned shall send requirements of maintenance data for aircraft / aircraft component to Deputy Chief Engineer (Technical Publication & Records). Manager (Technical Publications) shall process subscription from applicable sources. Deputy Chief Engineer (Technical Publication & Records) shall finalize requirement and process for financial approval. Upon financial approval, Deputy Chief Engineer (Technical Publication & Records) shall send requisition to Deputy General
Manager (Logistics) Purchases for placement of Purchase Order and follow up, through following actions: ♦ Record all technical publications / microfilms / Compact Discs received, in a
register / card under Part number and relevant vendors / publishers name. ♦ Record amendments in revision control card / register ♦ Distribute received manuals to all required locations within ten days of receipt ♦ Despatch immediately, upon receipt of all Airworthiness Directives / Alert Service
Bulletins to all concerned for information / review / processing.
2.8.2.3 Updating Documents and Microfilms Librarian (concerned) must sign Amendment Record Proforma after receiving documents from Main Technical Library and send the acknowledgement to Manager (Technical Publications) for records of distribution. Old / obsolete pages must be destroyed by Librarian (concerned) after document is updated. Revision shall be recorded on revision status page of each document. For AMM, WDM, SRM, etc., a list of revised pages shall also be filed alongwith documents. Old / obsolete microfilms shall be returned to the Main Technical Library upon receipt of updated version.
2.8.2.4 Management of Master Index and Inventory of Documents
PIA Engineering & Maintenance also subscribes Master Index of vendor documents to keep track of revisions issued by the publishers. Master Index of the maintenance data relating to aircraft manufacturers are kept and controlled at Main Technical Library with Manager (Technical Publications). However, for maintenance data relating to aircraft components, Master Index is issued to Librarian (concerned) to ensure status of documents (CMM, etc.) in the shop. In cases, where master index is not supplied, queries regarding documents update are generated for vendors / publishers by Deputy Chief Engineer (Technical Publication & Records). Inventory check of technical libraries shall be carried out on annual basis to ensure physical availability of standards and maintenance data, under supervision of Deputy Chief Engineer (Technical Publication & Records). Inventory checks shall be recorded at Main Technical Library. Quality Audits of all libraries shall also be performed to ensure compliance with the organisational procedures on periodic basis.
2.8.2.5 Management of Quality Documentation
Distribution of Quality documents such as Maintenance Organisation Exposition (MOE) and Associated Maintenance Procedures (AMP) shall be made according to distribution list of each document by Deputy Chief Engineer (Quality Audit). Distribution list shall be maintained as to ensure adequacy of these documents where required. Recipient on receiving update should sign manual status letter, update revision record and insert amended pages. Recipient shall discard obsolete pages and send feedback on manual status letter to Deputy Chief Engineer (Quality Audit).
2.8.2.6 Working Documents Derived from the Maintenance Data
To ease maintenance process, working documents either provided by the manufacturer
or generated in-house shall be used. In-house generated documents shall be approved by Chief Engineer (Airworthiness Management) or the nominee. Task cards, Work cards and Worksheets are issued in the form of Hard copies (Refer AMP 2-4 for details). Deputy Chief Engineer (Maintenance Program & Reliability) shall develop Maintenance Program Task cards. Task cards are used to translate Aircraft Maintenance Program into detailed instructions. Cross-references are used to ensure traceability to updated maintenance data. Upon receipt from Technical Record Officer (concerned), work packages are checked by Aircraft Engineer (planning) concerned to ensure correctness of Task cards index before organizing working files for aircraft maintenance. Whenever an inaccuracy / ambiguity is observed in maintenance data, the manufacturer shall be notified prior to use of modified instructions by maintenance personnel (Refer MOE Chapter 2.27 for details).
a) Task cards (work packages)
Task cards shall be used in aircraft maintenance checks and generated by Technical Record Officer (concerned) against Bill of Work (Refer MOE Chapter 2.28 for details). All Task cards must have clear reference to maintenance data. Complete work package should have index and covering page for ensuring traceability. Master Task cards shall be stored with Technical Record Officer (concerned). Task cards shall be reviewed and updated in accordance with the manufacturer recommendations and whenever changes occur in the maintenance data.
b) Work Cards (Aircraft Maintenance)
Work cards shall be generated for effective accomplishment and record keeping of periodic aircraft maintenance jobs. Work card shall be derived from maintenance data only and shall translate a complex maintenance task into a number of simplified tasks. Each work card is assigned with specific number to ensure traceability and revision status. Work cards are reviewed periodically or whenever referenced maintenance data (CMM, AMM etc) is updated. Work cards shall be used in aircraft / aircraft component maintenance for repeated tasks such as engine or APU change. Work cards shall be generated / reviewed by Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned. Technical Record Officer (concerned) is responsible for timely distribution of Work cards to respective aircraft / aircraft component maintenance.
c) Worksheets (Aircraft Component Maintenance) Worksheets are generated for effective accomplishment and record keeping of regular / periodic maintenance tasks on aircraft components. Worksheets are derived from approved maintenance data only and shall translate a complex maintenance task into a number of simplified tasks. Deputy Chief Engineer (Technical Services Engineering) concerned shall manage development process for worksheets, ensuring proper control for master documents. Specific reference numbers shall be used to ensure traceability. Cross-references on worksheets shall demonstrate use of current / updated maintenance data.
To describe PIA Engineering & Maintenance policies regarding repair on aircraft / aircraft component and process of restricted fabrication as per Part 145.A.42(c).
2.9.2 PROCEDURE
2.9.2.1 General Repair and maintenance on aircraft / aircraft components shall be performed in accordance with aircraft and component maintenance data provided by the manufacturer and organisational procedures. Maintenance data shall be available in workshops and maintenance areas accessible to concerned personnel. Once defect has been logged, appropriate facilities, tools, equipment and maintenance data are then defined and prepared to perform work in conformity with approved repair data. All repairs shall be carried out keeping in view of the approved scope of work. For customer aircraft, when defect / damage is detected during maintenance, customer / operator shall be informed through defect report. Repair shall then be carried out after review of Repair Order of customer. If customer / operator do not agree for repair, certifying staff shall assess airworthiness of aircraft due to subject damage and follow procedure of MOE Chapter 2.16, before issuing Certificate of Release to Service. In case of agreement, following process shall be followed:
2.9.2.2 Repair Process Defects found shall be recorded on appropriate Technical Logbook / Aircraft Repair Order (ARO) / Work card / Worksheet by Aircraft Engineer (production) concerned. Area involved shall be inspected thoroughly for hidden damage, including areas adjacent to obviously damaged parts. Structure Repair & Modification group / Aircraft Engineer (production) concerned shall perform assessment of structural damage / defect mentioned in the ARO / Work card / Worksheet in accordance with relevant maintenance data. Aircraft Engineer (production) concerned is responsible for definition of repair solution. Repair solution is either: Case I: Replacement of damaged parts in accordance with relevant maintenance data Case II: Repair solution already given in relevant maintenance data, hence approved Case III: Repair solution does not exist in the relevant maintenance data For cases ‘I & II’, repair solution defined by AMM / SRM / CMM shall be implemented as any other maintenance task.
a) Case III: Repair Solution does not exist in the Relevant Maintenance Data Aircraft / aircraft component shall be assessed by Aircraft Engineer (production) concerned for damage and all relevant information shall be recorded. Pertinent information and drawings of damaged area shall be sent to the Original Equipment Manufacturer (OEM) alongwith proposed repair solution (if any) and to the Competent Authority of aircraft registration. Manufacturer (or organisation appropriately approved to classify the repair) and the Competent Authority of aircraft registration, shall classify repair as ‘Major’ or ‘Minor’.
For minor repair, solution shall be implemented after endorsement of manufacturer and approval of the Competent Authority of aircraft registration. In case, the Competent Authority does not approve this repair, Deputy Chief Engineer (Technical Services Engineering) concerned will seek assistance from Type Certificate holder / Part – 21 Approved Organization for repair solution and approval of by the Competent Authority. For the repair solution classified as ‘Major’, solution shall be implemented only after obtaining repair design data from the Type Certificate holder / Part – 21 Approved Organisation, approval from the Competent Authority of Type Certificate holder and the Competent Authority of aircraft registration. All documentation, approved repair solution and maintenance data involved in the repair shall be controlled and used as per MOE Chapter 2.13. Certificate of Release to Service, after repair, shall be issued in accordance with MOE Chapter 2.16. Records of repairs performed shall be maintained as per MOE Chapter 2.14. Records for the operators shall be managed as per MOE Chapter 2.17.
2.9.2.3 Restricted Fabrication Process As a policy, PIA Engineering & Maintenance can only fabricate a restricted range of parts to be used in course of undergoing work within its own facilities. Process does not allow the Organisation to perform such manufacturing for customer aircraft / aircraft components, as parts shall never qualify for EASA Form 1 certification. Furthermore, locally fabricated parts shall physically be segregated and excluded from any delivery certification. Following shall be examples of fabrication that may be carried out in PIA Engineering & Maintenance: ♦ Fabrication of bushes / sleeves and shims ♦ Fabrication of secondary structural elements and skin panels ♦ Fabrication of control cables ♦ Fabrication of flexible and rigid pipes, electrical cable looms and assemblies ♦ Formed or machined sheet metal panels for repairs ♦ Secondary interior / decorative plastic / fiber glass panels, seat covers and curtains Prior to all fabrication processes, Deputy Chief Engineer (production) concerned shall ensure the following: ♦ Fabrication, inspection, assembly and test should be clearly within technical and
procedural capability of the Organisation. ♦ All required data to fabricate such part, should be approved either by the
Competent Authority or the Type Certificate (TC) / Supplemental Type Certificate (STC) holder or Part – 21 Approved Organisation approval holder. Data may include repair procedures involving fabrication of parts. Sufficiency of data to facilitate fabrication shall also be ensured.
♦ Work order for fabrication, shall clearly specify use of the fabricated part “FOR PIA FLEET ONLY”.
Materials to be used within fabrication processes shall follow specifications given within maintenance data and incoming inspection requirements shall be fulfilled as per MOE Chapter 2.2. Where special processes or inspection procedures, defined in maintenance data are not available in the Organization, part shall not be fabricated unless an approved alternative is provided by Type Certificate (TC) / Supplemental Type Certificate (STC) holder.
Details such as part numbering, dimensions, materials, processes, and any special manufacturing techniques, special raw materials with reference to approved data are filled in the ‘Aircraft Parts Fabrication Package’ (Refer AMP 2-4 for sample). Aircraft Parts Fabrication Package shall contain an inspection stage, which should establish full compliance with relevant manufacturing data and the part shall be identified unambiguously as fit for use by stating conformity to approved data. Aircraft Engineer (Technical Services Engineering) concerned shall sign completion statement before a serviceability tag is issued to component / part. All parts, except those having not enough space, should carry a part number and the Serviceable Tag shall also contain Release Note Number (R. N. No.). Part number given shall clearly relate to manufacturing / inspection data where possible. All locally fabricated items shall be provided with PIA Engineering & Maintenance identification number for traceability purposes. Documentation and approved data for such fabrication processes shall be controlled and used in accordance with MOE Chapter 2.13. Records such as Aircraft Parts Fabrication Package, work cards and continuation sheets shall be archived Technical Record Officer (concerned) following the process detailed in MOE Chapter 2.14. If dedicated technical record officer is not available, Deputy Chief Engineer (Technical Services Engineering / planning) concerned shall mange archiving of such records.
2.10.1 PURPOSE To define PIA Engineering & Maintenance policies regarding compliance with the approved Aircraft Maintenance Program, establishing specific maintenance schedule for each aircraft / aircraft component.
2.10.2 PROCEDURE
2.10.2.1 General Aircraft Type Certificate holder / manufacturer, provides initial Maintenance Planning Document (MPD) and updates, in view of in-service experience, production / design, quality issues and airworthiness requirements. Aircraft Maintenance Program shall be developed from Maintenance Planning Document to follow maintenance instructions by aircraft manufacturer. PIA Engineering & Maintenance shall respect these minimum maintenance requirements and ensure that all maintenance is carried out in conformance with the manufacturers’ documentation / instructions.
2.10.2.2 Definition Certification requirements for commercial aircraft call for establishing, prior to issue of Type Certificate, minimum scheduled maintenance task list, in order to provide operators with preventive / corrective instructions for in-service aircraft (Refer ICAO Annex 8 “Airworthiness” / Part 26 “Additional Airworthiness Requirements for Operation” / FAR 25-1529 & Appendix ‘H’ to Part 25 "Instructions for Continued Airworthiness").
2.10.2.3 Maintenance Program Creation Maintenance Planning Document (MPD), provided by the aircraft manufacturer and duly approved by the Authorities, shall be used by the Organisation to develop maintenance program for aircraft / aircraft components, subject to Approval of Competent Authority of aircraft registration. Maintenance Program shall comprise of:
a) Scheduled Tasks Scheduled tasks shall be performed respecting Maintenance Planning Document (MPD) at defined threshold and repeat intervals. General threshold / intervals quoted are: ♦ Calendar life (Month, Year, multiples, etc.) ♦ Flight Cycles (FC) ♦ Flight Hours (FH) ♦ Landings ♦ Applicable Vendor and / or National Requirements (VR / NR). PIA Engineering & Maintenance shall maintain aircraft / aircraft components, as per manufacturers’ Maintenance Planning Document (MPD). Prior to implementation, the Organisation shall develop an Aircraft Maintenance Program and obtain approval of the Competent Authority. Aircraft Maintenance Program shall encompass all aircraft components (engine, APU,
landing gear, flight controls, accessories, instruments, electrical / radio equipment and all associated systems / installations). It shall define the period at which a component shall be removed from aircraft for replacement, inspection, test or overhaul. It shall also be expressed in terms of a criteria, related to usage (i.e., a given period of time, number of cycles, landings or hours), the aircraft component shall undergo cleaning / lubrication / inspection / functional check / adjustment (as applicable).
b) Unscheduled Tasks Unscheduled tasks (Refer MOE Chapter 2.15 for details) are defined as the result from particular additional requirements from the Authorities, manufacturers or customer. Such additional requirements, particularly, are: ♦ Airworthiness Directives / Service Bulletins (SBs) / AOTs ♦ Continuous follow up of acceptable / justified deferred defects ♦ Organisation Bulletins / Orders requiring periodical check or inspection ♦ Maintenance reports ♦ Pilot Reported (PIREP) defects Maintenance Program for aircraft / aircraft components shall have clear reference to the maintenance manuals provided by aircraft / aircraft component manufacturer or vendor.
2.10.2.4 Maintenance Program update Preamble of Aircraft Maintenance Program shall be submitted to the Competent Authority for approval. Maintenance program shall be revised on the basis of following: ♦ Experience related to scheduled and un-scheduled maintenance ♦ Reliability program analysis related to aircraft / aircraft components ♦ Manufacturer recommendations (MPD revisions) ♦ Environmental factors
2.10.2.5 Aircraft Maintenance Program Launching and Achievement Aircraft Maintenance instructions, contained in Maintenance Program, shall be translated into Task cards, arranged to develop work packages according to check interval. Such work packages, translated and developed by Deputy Chief Engineer (Maintenance Program & Reliability), shall be entered in PIA Aircraft Maintenance Management Information System (PAMMIS). In case of provisioning of complete work package by the manufacturer, Deputy Chief Engineer (Maintenance Program & Reliability) shall forward such work package to Technical Records Officer (concerned). Deputy Chief Engineer (Schedule & Check Planning) shall forecast and schedule aircraft maintenance checks. Upon completion of a work package, following documentation shall be made available to maintenance personnel by Deputy Chief Engineer (Technical Publication & Records) through Manager (Technical Publications) and Technical Records Officer (concerned): ♦ Aircraft maintenance data related to each Task card ♦ Tooling and test equipment List ♦ Copies of Airworthiness Directives / Service Bulletins ♦ Cross-referenced SBs, AOT's, ECOs, etc Aircraft component maintenance instructions, contained in Maintenance Program, shall be translated in the form of Component Life List. Incharge Cardex Control shall update
relevant Major Item Change (MIC) sheets to ensure in time removal of components from the aircraft. Component Life List is referred in Overhaul shops for maintenance program compliance.
2.10.2.6 Customer Aircraft Aircraft Operator is primarily responsible to develop Maintenance Program, approved by the Authority and work package definition for the aircraft. Depending upon the contract, PIA Engineering & Maintenance shall either perform maintenance in accordance with work package provided by the customer or shall process for development, approval and work package definition of Aircraft Maintenance on behalf of customer. In first case, the customer shall provide work package, based upon Aircraft Maintenance Program, approved by the Competent Authority of aircraft registration and data related to Airworthiness Directives / mandatory modifications. In second case, Aircraft Maintenance Program for customer aircraft shall be developed and submitted for approval of the Competent Authority of aircraft registration by Deputy Chief Engineer (Maintenance Program & Reliability). Once approved, work package shall be defined and implemented. Maintenance records shall be provided to customer / operator, upon completion of work package (Refer MOE Chapter 2.17 for details).
2.10.2.7 Documents controlled by PIA Availability of maintenance data in the Organisation shall be ensured by Deputy Chief Engineer (Technical Publication & Records) through periodic inventory checks. Process for such management of maintenance data is detailed in MOE Chapter 2.8.
To define PIA Engineering & Maintenance policies for incorporation of the Competent Authority mandated modifications / inspections through Airworthiness Directives during maintenance on aircraft / aircraft components.
2.11.2 PROCEDURE 2.11.2.1 Generalities
Airworthiness Directives shall be received by the Organisation periodically. An update of all Airworthiness Directives shall be verified twice a week through web at Main Technical Library. Manager (Technical Publications) shall despatch the recorded Airworthiness Directive immediately to Deputy Chief Engineers (concerned) as per distribution list. Deputy Chief Engineer (Technical Publication & Record) shall send monthly report to Deputy Chief Engineer (concerned) at the end of each month, mentioning Airworthiness Directives issued. Copy of report shall be marked to Deputy Chief Engineer (Quality Audit) for surveillance. Deputy Chief Engineer (concerned) shall send feedback for timely evaluation of received Airworthiness Directives to Deputy Chief Engineer (Technical Publication & Record) at the earliest but not later than two working days from receipt of monthly report. During communication, Chief Engineer (Airworthiness Management) shall be kept informed for effective supervision. Deputy Chief Engineer (Technical Services Engineering) concerned shall monitor the incorporation of Airworthiness Directive / mandatory modification in coordination with Deputy Chief Engineer (Development Engineering) concerned and report to Chief Engineer (Airworthiness Management), in case a discrepancy is observed. Incorporation of Airworthiness Directive shall be documented as per MOE Chapter 2.13. Certificate of Release to Service after incorporation of Airworthiness Directive shall be issued in accordance with MOE Chapter 2.16. Records for embodiment of Airworthiness Directive shall be managed as per MOE Chapter 2.14 and Chapter 2.17. Information / training of relevant personnel on Airworthiness Directive shall be covered through continuation training as described in MOE Chapter 3.4. MOE Chapter 2.20 shall be referred for despatch and receipt of aircraft components from contracted maintenance organisation (Refer AMP 2-3 for process flow).
2.11.2.2 Development Engineering Aircraft Engineer (Development Engineering) concerned shall determine relevance of Airworthiness Directive within scope of work to generate ‘Service Literature Evaluation Form’ and ‘Evaluation Notice’ (Refer AMP 2-3 for samples) for incorporation. For Airworthiness Directive, not applicable to PIA fleet, ‘Evaluation Notice’ shall be issued for information to personnel. Aircraft Engineer (Technical Services Engineering) PowerPlant shall evaluate Airworthiness Directives / mandatory modifications related to aircraft powerplant systems.
Information regarding procurement of modification kits / tooling required by Airworthiness Directive shall be conveyed to Incharge Modification Planning. Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned shall coordinate with Deputy Chief Engineer (production) concerned in Line / Base / Cabin Maintenance for installation of modified components on aircraft to ensure in-time incorporation of Airworthiness Directive. Inspection Task card shall be prepared by Aircraft Engineer (Development Engineering / Technical Services Engineering) concerned, whenever Airworthiness Directive calls for an inspection on aircraft at different intervals or one-time basis. Deputy Chief Engineer (Maintenance Program & Reliability) shall assist Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned for inclusion of Inspection Task cards in aircraft work package.
2.11.2.3 Modification Planning Cell Where Airworthiness Directive requires modification kit, Incharge Modification Planning shall initiate the process by requesting Engineering & Maintenance Committee (EMC) for approval of procurement. Incharge Modification Planning shall coordinate with Deputy General Manager (Logistics) concerned for procurement follow up. Incharge Modification Planning shall coordinate with Deputy Chief Engineer (planning) concerned, Deputy Chief Engineer (Rotable Planning) and Deputy Chief Engineer (Schedule & Check Planning) for finalizing action plan of modification accomplishment on aircraft components. Incharge Modification Planning shall issue ‘Modification Scheduling Advice’ (Refer AMP 2-3 for sample) to all concerned with information of modification kit / tooling availability on ‘Modification Material / Kit Availability Advice Form’ (Refer AMP 2-3 for sample). Incharge Modification Planning shall perform periodic review of modification status of aircraft with respect to Airworthiness Directives. Such review shall include status of modification kits availability and aircraft components modification through Overhaul shops (in-house) and / or contracted maintenance organisations (repair abroad). Upon receiving ‘Modification Accomplishment Advice’ (Refer AMP 2-3 for sample) from Deputy Chief Engineer (planning) concerned in Line / Base Maintenance, Incharge Modification Planning shall ensure update of Airworthiness Directive record registers with Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned and records on PIA Aircraft Maintenance Management Information System (PAMMIS).
2.11.2.4 Aircraft / Aircraft Components Maintenance Section Deputy Chief Engineer (planning) concerned, in coordination with Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned and Deputy Chief Engineer (Schedule & Check Planning) shall finalise grounding of aircraft for incorporation of Airworthiness Directive, ensuring timely compliance. For modification required on aircraft components as per Airworthiness Directive, Deputy Chief Engineer (Technical Services Engineering) concerned in coordination with Deputy Chief Engineer (production) shall generate ‘Service Literature Evaluation Form’ (Refer AMP 2-3 for sample). Deputy Chief Engineer (Development Engineering) concerned shall issue ‘Evaluation
Notice’ whereas Deputy Chief Engineer (Technical Services Engineering) PowerPlant shall issue ‘Evaluation Notice’ for Airworthiness Directives / mandatory modifications related to aircraft powerplant systems. Procurement of tooling (if any), required for accomplishment of modification on aircraft components, shall be managed by Deputy Chief Engineer (production) concerned. Where aircraft components are required to be modified in-house, Deputy Chief Engineer (planning) concerned in Overhaul Shop, shall coordinate with Deputy Chief Engineer (Rotable Planning) for retrieving unmodified aircraft components installed on aircraft or stored as serviceable in Stockroom. In any case, after compliance period, no unmodified component shall either be found installed on aircraft or held in Stockrooms. After modification accomplishment, Deputy Chief Engineer (planning) concerned shall send “Modification Accomplishment Advice’ (Refer AMP 2-3 for sample) to Incharge Modification Planning and Deputy Chief Engineer (Rotable Planning) for updating PIA Aircraft Maintenance Management Information System (PAMMIS) record. Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned, after receiving information from Incharge Modification Planning about status of modified components in Stockroom, shall coordinate with Deputy Chief Engineer (Schedule & Check Planning) and Deputy Chief Engineer (production) concerned from Line / Base / Cabin Maintenance) for installation of modified components on aircraft. For modification under Airworthiness Directive to be performed during line maintenance or base check, concerned planning section shall prepare ‘Modification Signature Sheet’ (Refer AMP 2-3 for sample) and ensure availability of modification kit or modified aircraft component. ‘Modification Signature Sheet’ in case of aircraft, shall be forwarded to Incharge Modification Planning by Deputy Chief Engineer (planning) concerned.
2.11.2.5 Airworthiness Directive on Aircraft Components by Contracted Organisation In case of aircraft component to be sent abroad for modification, Deputy Chief Engineer (planning) concerned shall coordinate with Deputy Chief Engineer (Repair Abroad) and prepare aircraft component for despatch as per MOE Chapter 2.20. For aircraft components under ‘Component Exchange Program’, Chief Engineer (Airworthiness Management) and Chief Engineer (Maintenance Operation Centre) shall supervise the process of modification accomplishment, records management and in-time availability / installation of modified components on aircraft. For modified aircraft component under exchange program, received from contracted organisation, Deputy General Manager (Logistics) Stores shall send copy of receiving documents to Deputy Chief Engineer (Rotable Planning), for generating advice to update PIA Aircraft Maintenance Management Information System (PAMMIS) record. For modified components received from contracted organisation as per MOE Chapter 2.20, Deputy General Manager (Logistics) Stores shall send such aircraft component to Parts Control section and copy of receiving documents to Deputy Chief Engineer (planning) concerned in Overhaul Shop for updating aircraft component records at shop. Upon receipt of modified component in Stockroom, Deputy Chief Engineer (planning) concerned in Overhaul Shop, with respect to received documents, shall intimate Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned,
to coordinate with Deputy Chief Engineer (Schedule & Check Planning) for installation of modified component on aircraft. Deputy Chief Engineer (planning) concerned in Line / Base / Cabin Maintenance shall send accomplishment information through ‘Modification Signature Sheet’ to Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned for update of Airworthiness Directive records register.
2.11.2.6 Technical Records Section Inspection Task cards against Airworthiness Directives are scheduled through aircraft work package or Major Item Change (MIC) sheet. Technical Record Officer (concerned) shall send all Airworthiness Directive Task cards to Deputy Chief Engineer (planning) concerned alongwith work package or Major Item Change (MIC) sheet. After compilation of records, Technical Records section shall file Airworthiness Directive incorporation record separately from work package and update the aircraft / engine / APU / components record accordingly. Where any Task card requires feedback, Deputy Chief Engineer (production) concerned shall ensure that such Proforma is properly filled by Aircraft Engineer (production) concerned. Deputy Chief Engineer (planning) concerned shall despatch the feedback to Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned for further action as required by maintenance data.
2.11.2.7 Procedure for Customers’ Aircraft / Aircraft Component Aircraft operator / aircraft component customer is responsible to specify all applicable Airworthiness Directives to be incorporated on aircraft / aircraft component in Purchase / Repair Order. However, Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned shall review the Purchase / Repair Order, to determine that all required Airworthiness Directives are included and shall send feedback to customer in case any Airworthiness Directive is missed out. In case customer is unwilling for incorporation of any applicable Airworthiness Directive / mandatory modification, then only Compliance Certificate shall be issued by certifying staff for completion of required work. Prior to issue of Certificate of Release to Service, if certifying staff notices a non-incorporate / non-embodied Airworthiness Directive (affecting airframe, engines, APU or other aircraft components), customer shall be informed immediately for this Unairworthy condition. Incorporation of Airworthiness Directive on customer’s aircraft, when required shall follow same procedures as for PIA aircraft. Additionally, records of incorporation shall be forwarded to customer alongwith other maintenance records.
To define PIA Engineering & Maintenance policies for evaluation and accomplishment of optional modifications during maintenance on aircraft / aircraft components.
2.12.2 PROCEDURE 2.12.2.1 General
Sources of optional modifications are Type Certificate holders recommending modifications through Service Bulletins (SB), Service Letters (SL), Air Operators Telexes (AOT) and a modification initiated by the Organisation in form of Engineering Order (EO), etc. Manager (Technical Publications), upon receipt of Service Bulletins / letters and their subsequent revisions, shall despatch such literature to Chief Engineer (Airworthiness Management), Deputy Chief Engineer (Development Engineering) / (Technical Services Engineering) concerned and relevant sections (Refer AMP 2-3 for process flow).
2.12.2.2 Optional Modification Evaluation Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned shall assess applicability of literature. If modification is not applicable on any aircraft type under approved scope of work, evaluation notice shall be issued for information only (Refer AMP 2-3 for details). For aircraft components listed in Company Capability List, Deputy Chief Engineer (Technical Services Engineering) concerned, in coordination with Deputy Chief Engineer (production) concerned and Deputy Chief Engineer (planning) concerned, shall generate ‘Service Literature Evaluation Form’ (Refer AMP 2-3 for sample), decide on applicability and assist Deputy Chief Engineer (Development Engineering) concerned in generating ‘Evaluation Notice’ (Refer AMP 2-3 for sample). Deputy Chief Engineer (Technical Services Engineering) PowerPlant shall decide on applicability and generate ‘Evaluation Notice’ for modifications related to aircraft powerplant systems. Committees are dedicated to perform evaluation of applicable modifications (Refer AMP 2-3 for details). Such committees shall analyse service literature against approved scope of work, flight safety, passenger comfort, system reliability and economic feasibility. On the basis of such analysis, compliance priority of modification shall be evaluated. Once optional modification is finalized for accomplishment on PIA aircraft, process detailed in MOE Chapter 2.11 shall be followed for modification accomplishment. Aircraft Engineer (Development Engineering) concerned shall evaluate ‘Request for Change’ and refer to service literature for modification required. If service literature does not address such request, Deputy Chief Engineer (Development Engineering) concerned shall obtain No Technical Objection (NTO) from Original Equipment Manufacturer (OEM) and develop an ‘Engineering Order (EO)’ (Refer AMP 2-3 for sample). In case of Engineering Order for accomplishment of local modification, all pertinent information and drawings alongwith justification shall be submitted to the Competent Authority of aircraft registration and manufacturer for approval. Justifications are those means of compliance, necessary to provide answers to applicable technical certification conditions as Part – 25 or any other authoritative design requirements.
For all modifications, solution shall be implemented only after obtaining modification data from Type Certificate holder or Part – 21 Approved Organization and approval from the Competent Authority of Type Certificate holder and aircraft registration.
2.12.2.3 Modification Accomplishment Process of modification accomplishment after finalization and generation of records shall remain same as detailed in MOE Chapter 2.11 with following additional requirements in case of local modifications. If change is required, in an aircraft / aircraft system through local modification, proposal shall be forwarded to Deputy Chief Engineer (Development Engineering) concerned alongwith full justification, on ‘Request for Change Form’ (Refer AMP 2-3 for sample). Decision to incorporate optional modification on customer aircraft / aircraft component shall depend on Purchase / Repair Order. Customer shall provide all information in the Order to check origin of optional modification and its approval status by the Competent Authority. Decision for accomplishment of optional modification on customer aircraft lies with the customer. Evaluation of an optional modification on customer aircraft / aircraft component can be delegated to PIA Engineering & Maintenance depending on contract. Information / training of relevant personnel on service literature shall be covered through Continuation Training detailed in MOE Chapter 3.4
2.13 MAINTENANCE DOCUMENTATION IN USE AND COMPLETION OF SAME
2.13.1 PURPOSE To define PIA Engineering & Maintenance policies regarding use of maintenance documentation and requirements related to control, management and completion of documentation during maintenance activities.
2.13.2 PROCEDURE
2.13.2.1 General PIA Engineering & Maintenance have a system of working files for all aircraft, engines, APUs, landing gears and other aircraft components. Deputy Chief Engineer (planning) concerned shall generate work packages / working files by incorporating worksheets and other working documents, to ensure completeness of maintenance instructions to the effect that customer Work Order is complied with. Deputy Chief Engineer (Planning) concerned shall manage indexing of aircraft / aircraft component working files. During maintenance of aircraft / aircraft components, use of updated maintenance data must be ensured at all levels. Deputy Chief Engineer (Production) concerned shall impart training to maintenance personnel, with regard to records generation. Differences in customer’s documentation and its completion shall be clearly identified. Customer provided Task cards / Work cards / Worksheets shall be forwarded to Deputy Chief Engineer (Planning) concerned in advance by Deputy Chief Engineer (Sales) concerned, to review appropriateness of Task cards / Work cards / Worksheets for required maintenance and comprehension by maintenance personnel.
2.13.2.2 Documentation for Aircraft Base Check Documentation for base maintenance activities shall be presented as work package consisting of planned maintenance program Task cards and additional local Task cards specifying maintenance requirements. Work package for scheduled base maintenance, issued as Task cards, shall be computer generated / manually compiled. Work Package for a base check, based on “definition inputs”, in relation to routine tasks such as routine cards, checklists for Transit / Daily / Weekly checks, component cards shall be handed over by Technical Records Officer (concerned) to Deputy Chief Engineer (Planning & Development). For non-routine tasks such as modifications / special inspections / critical tasks, inputs shall be from Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned. On each Task card, Release statement shall be printed for particular task under the requirements of CAA (PAK). Deputy Chief Engineer (Planning), upon receipt of work package, shall review all Task cards and compile them as “Working File” (work package) for aircraft check by placing cards in predefined systematic order. All elements of work package shall be accounted for and controlled by individual Task card serial number being recorded on a Master Task Card index and updated for completion on daily basis. Regarding modification accomplishment, Aircraft Engineer (Planning) concerned shall
develop ‘Modification Signature Sheet’ for inclusion in Work package. List of all working documents shall be placed in the beginning of file, to facilitate maintenance personnel. When additional details of maintenance performed are to be recorded, then continuation sheets may be used by maintenance personnel and attached with particular Task card, where required. Continuation sheets shall not be used as an independent document for recording of inspection / removal / installation of aircraft components. Only Aircraft repair Order (ARO) shall be used for all such purposes. Each working file shall be on standard format with front page providing general information for particular aircraft type, registration, level of check, flight hours, flight cycles, landings, dock-in / speculated dock-out dates and bay / docking number (Refer AMP 2-4 for details). Front page shall be filled by planning staff, before distribution of the package to maintenance personnel. For aircraft base check, all inspection tasks as a result of Airworthiness Directive / modifications shall be incorporated in inspection file for particular aircraft base check. This file shall be different from basic working file for routine tasks. Formal tasks such as aircraft components removal (Work cards) and tasks generated from inspection as per routine Task cards shall also be included in inspection file (Refer AMP 2-4 for details). Aircraft Repair Order (ARO) shall be raised for each defect arising and serialised by Certifying / Support Staff during inspection. ARO serial number shall be systematically entered in the ARO index of inspection file. All indexes shall have a clear reference to aircraft work package. Continuation sheet is standard document raised to record work where task has multiple stages and insufficient space is available to record details of all work. Continuation sheet is regarded as an extension sheet to primary document and must always be referred (e.g. by ARO serial number or Work card number). Serial number of additional Work card shall be mentioned on primary document, to which it is attached or technical logbook entry to which it relates, as a cross-reference. Upon issuance of Aircraft Certificate of Release to Service after base check, Aircraft Engineer (Technical Services Engineering) concerned shall compile ‘Aircraft Base Check Report’ (AMP 2-3 for sample) to ensure completeness of maintenance tasks during base check. Deputy Chief Engineer (Technical Services Engineering) concerned shall finalise and archive the completed report.
2.13.2.3 Documentation for Line Maintenance In respect of line maintenance, primary documentation used is the operator's Aircraft Technical Logbook. Additionally pre-printed Work cards are issued by Technical Records Officer (concerned) to Deputy Chief Engineer (planning) concerned, upon requirements for specific lengthy jobs (such as engine / APU change, etc.). Continuation sheets can only be used with Work cards to record additional details. However, inspection / installation / removal shall only be recorded in Aircraft Technical Logbook. Additional Work cards, as and when required, shall be used with appropriate references and traceability to and from aircraft Technical Logbook page serial number. Additional Work card must be firmly attached to the copy of relevant Technical Logbook page prior to despatch to Technical Records section. A duplicate copy of additional Work card is to be attached to Technical Log slip (green)
that shall be retained at line station. Non-routine Task cards when accomplished in Line Maintenance division shall be referred in aircraft Technical Logbook before release to service is signed. Line maintenance personnel shall always use the Operators’ Technical Logbook. A copy (Green) of sector record page, for PIA aircraft, shall be retained at line station and at the base as well. Aircraft component removal and modification accomplishment, whenever performed as per ‘Major Item Change (MIC)’ sheets, certifying staff shall sign respective MIC entry with proper reference of applicable Technical Log slip / maintenance record. Acceptable deferred (carried forward) defects shall be recorded in the Aircraft Technical Logbook and second copy (Blue) shall be placed in Hold Item List (HIL) pocket. Third copy (Pink) shall be submitted to Technical Record section for recording in PIA Aircraft Maintenance Management Information System (PAMMIS) and archived as hard copy.
2.13.2.4 Documentation for Engine / APU / Landing Gear Maintenance For component-level maintenance on engine / APU / landing gear, component shall be received with LRU Tracking / Repair Tag (Refer AMP 2-1 for samples). Deputy Chief Engineer (Planning) shall develop ‘Bill of Work’ (Refer AMP 2-4 for sample) defining extent of maintenance (repair / modification / overhaul), in coordination with Deputy Chief Engineer (Technical Services Engineering) concerned and Deputy Chief Engineer (production) concerned. Bill of Work is based on applicable inputs such as incoming inspection, Major Item Change (MIC) sheet, Life Limited Parts (LLPs) list, component history data, engine trend monitoring data, modules / components soft life thresholds, number of landings / calendar life (for landing gears), etc. List of all scheduled / unscheduled tasks shall be addressed in such Bill of Work. For Airworthiness Directives / modifications / special inspections, input shall be from Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned. In case of customer engine / APU / landing gear, component shall be routed through Deputy Chief Engineer (Sales) component maintenance with ‘Outside Party Work Order’, with details of work to be performed. Deputy Chief Engineer (Sales) component maintenance shall verify maintenance capability for component with scope of work and Company Capability List, before issuance of work order for each aircraft component. Work order shall be stamped for requirement for EASA Form 1. Bill of Work shall be developed on the basis of customer Purchase / Repair Order. For completion of maintenance on engine / APU / landing gear, Deputy Chief Engineer (Technical Services Engineering) concerned shall control master worksheets to ensure timely update with maintenance data. Master worksheets and subsequent amendments for all processes shall be handed over to Deputy Chief Engineer (planning). In all cases, these worksheets shall be linked and identified with particular Shop Manual task (Refer AMP 2-4 for details). Deputy Chief Engineer (planning) shall develop Working file for particular engine / APU / landing gear as per agreed Bill of Work and relevant worksheets shall be distributed to Deputy Chief Engineer (production) concerned. Working file for engine / APU / landing gear shall be maintained on a standard format with front page providing information such as nomenclature / type, serial number, life done (cycles / hours / landings), shop-in date and speculated shop-out / test date. For engine modules, working file shall further be broken up into Module working files
(sub-files), by sorting out applicable worksheets. Upon engine build-up at final assembly stage, these files shall be incorporated into working file for engine. Engine and modules serial numbers shall be printed on both files to establish the link and traceability. Deputy Chief Engineer (Technical Services Engineering) concerned shall issue ‘Work Completion Certificate’ (Refer AMP 2-4 for sample) upon confirmation that maintenance is performed as per agreed Bill of Work. LRU Tracking / Serviceable Tag for engine / APU / landing gear, generated by shop planning shall be signed by certifying staff holding appropriate certification authorisation. In case of component-level maintenance on engine / APU / landing gear, inspection tasks at piece part level shall be incorporated in Inspection File, compiling all View Room inspection sheets. Approved repair tasks generated as result of such inspections shall be requested through ‘Repair Tag / Fractional Work Order’ (Refer AMP 2-1 for samples). Upon satisfactory completion, such repair task shall be recorded on Worksheets. This Worksheet alongwith Repair Tag, LRU Tracking Tag / Repair Tag (for replaced components) and relevant data shall be incorporated in Inspection File for a particular engine / APU / landing gear. For issuance of EASA Form 1, required by customer / operator or requested in customer Purchase / Repair Order, Aircraft Engineer (Technical Services Engineering) concerned shall follow ‘Checklist for Component Records’ (AMP 2-3 for sample) to ensure the completeness of component maintenance and records and shall submit signed copy of checklist to Deputy Chief Engineer (planning) for printing of EASA Form 1.
2.13.2.5 Documentation for Aircraft Components Maintenance Documentation during aircraft component maintenance (Avionics, Pneumatic, Hydraulic, Fuel, etc.) includes Work Order and Component Work Package, Continuation sheets and pre-printed Worksheets, derived from maintenance data. Aircraft components, removed from an aircraft / aircraft component, shall be received by shop planning with LRU Tracking / Repair Tag attached. ‘UNSERVICEABLE’ portion of LRU Tracking / Repair Tag serve the purpose of work order for component maintenance. ‘Fractional Work Order’ (Refer AMP 2-1 for details) shall be used for aircraft component not listed in Company Capability List and the task is of fractional nature, not requiring an authorised release certificate. Aircraft components, received from customers are routed through Deputy Chief Engineer (Sales) component maintenance with ‘Outside Party Work Order’, with details of work to be performed. Deputy Chief Engineer (Sales) component maintenance shall verify the maintenance capability for component in Company Capability List, before issuance of work order for each aircraft component. Work order shall be stamped for requirement for EASA Form 1. Working file for component maintenance shall be ‘Component Work Package’ (Refer AMP 2-4 for sample), consisting different portions such as removal details, bill of work, progressive work recording, parts / sub-assy replaced, out going information and Certificate of Release to Service (Refer AMP 2-4 for sample). Maintenance personnel, nominated to perform maintenance, shall keep ‘Component History Card’ (Refer AMP 2-4 for sample) with the component for defect assessment and corrective action planning purposes (Refer AMP 2-4). Wherever applicable, ‘Component
Modification Record Card’, ‘Component Release Data Card’ and ‘Component Release Note Master Card’ (Refer AMP 2-4 for samples) are also maintained. Aircraft Engineer (production) concerned, on completion of visual inspection and testing, shall complete Bill of work portion of ‘Component Work Package’ alongwith shop findings and recommendations with reference to maintenance data. Progressive work recording portion of package shall be used for work details, generated during inspection / maintenance. For jobs requiring more detailed recording and rework, ‘Component Rework / Continuation Sheet’ (Refer AMP 2-4 for sample) shall be used, ensuring traceability of record. LRU Tracking Tag for component shall be generated by shop planning and signed by certifying staff holding relevant certification authorisation. For issuance of EASA Form 1, required by customer / operator or requested in customer Purchase / Repair Order, Aircraft Engineer (Technical Services Engineering) concerned shall follow ‘Checklist for Component Records’ (AMP 2-3 for sample) to ensure the completeness of component maintenance and records and shall submit signed copy of checklist to Deputy Chief Engineer (planning) for printing of EASA Form 1. Additional planning cards / sheets, not specifically referred in organisational procedures, may be generated locally for aircraft component maintenance to facilitate maintenance staff. Such document, duly approved by Deputy Chief Engineer (Technical Services Engineering) concerned, shall be used only for record keeping purpose and not for any airworthiness related records. Deputy Chief Engineer (Technical Services Engineering) concerned shall control such documents, ensuring reference number and controlled use.
2.13.2.6 Documentation Completion Aircraft Technical / Cabin Logbook is primary maintenance record during line / cabin maintenance activities. Deputy Chief Engineer (production) concerned shall ensure proper upkeep of Aircraft Technical / Cabin Logbook, including physical condition of the folder and its pockets. Once an entry is made in Aircraft Technical / Cabin Logbook and all other technical records, it shall always remain legible for clarity of entries. Use of correcting fluid must be avoided during record completion within the Organisation. Entries made as technical records in any documentation shall only be crossed once, if required to be omitted. Any maintenance task, recorded on documentation, shall be converted into maintenance record. Hence, Deputy Chief Engineer (production) concerned shall ensure the required control / security of working files and continuously monitor progressive completion of maintenance tasks alongwith recording in the working files. Any maintenance sub task, required to be omitted shall be marked as ‘Not Applicable’. Marking shall only be made by Aircraft Engineer (planning) concerned with signature and stamp bearing designation. Whenever, maintenance sub task is not required as a result inspection / rework, Aircraft Engineer (production) concerned shall mark such sub task as ‘Not Required’. For customer’s aircraft / aircraft component, prior consent shall be sought from the customer and recorded in work package. Maintenance task performed shall be recorded with proper reference of maintenance data. Completion of Task card / ARO / Worksheet shall be ensured as soon as task is physically accomplished. Findings / results shall be declared in detail, clearly identifying observed values, levels, etc. For traceability, maintenance personnel shall record the
identification / serial number of calibrated tooling / equipment being used on worksheets, during aircraft component maintenance. Upon accomplishment of maintenance task, maintenance staff shall sign in relevant column of Work cards / Task cards / ARO / Worksheets with date and staff number. Aircraft Engineer (production) concerned shall sign in appropriate column alongwith authority stamp and date to provide clear traceability to maintenance carried out. Completed maintenance documentation shall be recorded in PIA Aircraft Maintenance Management Information System (PAMMIS) and hard copies shall be archived with Technical Record section. During component maintenance, Deputy Chief Engineer (production) concerned shall ensure progressive recording of maintenance tasks. Deputy Chief Engineer (Technical Services Engineering) concerned shall manage records archiving and temporary storage of ‘HOLD ITEMS’ worksheets with Technical Records Officer (concerned). Revision of working file shall be on the basis of inputs from Deputy Chief Engineer (planning / production) concerned. Whenever work package requires addition / deletion of any Task card, working file shall be revised accordingly. Aircraft Engineer (production) concerned shall be responsible for record completion. Spot checks for progressive maintenance recording shall be performed by Deputy Chief Engineer (production) concerned on daily basis. Discrepancies found during spot checks shall be recorded with corrective action taken. Deputy Chief Engineer (production) concerned shall arrange recurrent trainings with regards to good maintenance practices, progressive maintenance recording and records completion. Discrepancies noted during spot checks shall be discussed during these recurrent training sessions.
To define PIA Engineering & Maintenance policies regarding management of technical records in a manner to cover all maintenance performed on aircraft / aircraft components and archiving of complete operational / maintenance history.
2.14.2 PROCEDURE
2.14.2.1 General Technical Records for all maintenance being performed on aircraft / aircraft components in the Organisation such as the line / base / cabin maintenance, the component-level maintenance and the logistic supports shall be kept in hardcopy format. Original for PIA fleet and copies of customer aircraft / aircraft component maintenance records must be retained for a minimum of three years from the date aircraft / aircraft component is last released to service. Computerized records shall be archived in PIA Aircraft Maintenance Management Information System (PAMMIS) for a period from three years upto a maximum of seven years (Refer MOE Chapter 2.21 for details). Records such as Aircraft / Engine / APU Logbooks, component release data / history and modification records shall be kept for longer time to provide back-to-birth history. Such records shall be archived for a period of another three years from the date, an aircraft / aircraft component is withdrawn from service permanently. Records are mainly consisting of Technical / Aircraft / Engine / APU Logbooks and work package, including the following: ♦ List and Completed task cards and completed Worksheets ♦ Lists and copies of incorporated Airworthiness Directives and modifications ♦ List of parts installed or replaced ♦ List of additional tasks performed over and above work package (if any) ♦ List of acceptable deferred items ♦ Copies of ‘Certificate of Release to Service (CRS)’ / ‘EASA Form 1’ ♦ Copies of correspondence with Competent Authority and manufacturer. ♦ Task cards / worksheets shall be stored after Aircraft Engineer (Technical Services
Engineering) concerned performs review for completion.
2.14.2.2 Technical Records Storage Location of storage, in Technical Record room at working bays of line maintenance, is protected against fire, flood and theft. Disposal of any document shall be authorised by Deputy Chief Engineer (Technical Publication & Records). Storage racks in adequate number are provided for archiving technical records. Access to building is restricted to personnel authorised by Chief Engineer (Airworthiness Management). Records from aircraft maintenance (Line / Base / Cabin) are archived in FIFO (First In - First out) pattern, traceable through date and aircraft registration number. Records of component maintenance are also archived on FIFO basis, traceable by part number, serial number, description or date (Refer AMP 2-4 for details).
2.14.2.3 Technical Records of Aircraft Components At component overhaul shops, designated areas are provided to respective Deputy Chief Engineer (Technical Services Engineering) concerned for archiving records of aircraft component maintenance. Technical Record Officer (concerned) shall follow the rules for archiving same as for aircraft maintenance records. Additionally, in case of consumables / subassemblies held up during aircraft component maintenance, Deputy Chief Engineer (Technical Services Engineering) concerned shall temporarily archive worksheets of ‘HOLD ITEMS’, ensuring progressive recording of completed tasks.
2.14.2.4 Special Cases In case of customer aircraft / aircraft component, the Organisation shall provide originals to customer / operator (Certificate of Release to Service / EASA Form 1) including basic details of maintenance performed with requested airworthiness tags and data used for repairs / modifications / additional tasks carried out. Copies of such records shall be archived with Technical Records section. In case of lost or destroyed records, Chief Engineer (Quality Assurance) shall nominate a team for reconstruction of lost / destroyed records through different means such shift handing over registers, memos, vouchers, dirty fingerprints, etc. Re-constructed records shall be submitted to the Competent Authority of aircraft registration for acceptance.
2.15 RECTIFICATION OF DEFECTS ARISING DURING BASE MAINTENANCE 2.15.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding process for rectification of defects arising during base maintenance of aircraft as well as deferment of non-rectified defects.
2.15.2 PROCEDURE 2.15.2.1 Recording of Defects
Defects may be classified as follows: ♦ Pilot Reported (PIREP) defect, entered in Aircraft Technical Logbook ♦ Defect observed during line maintenance, entered in Aircraft Technical Logbook ♦ Defect observed during base check, reported on Aircraft Repair Order (ARO). Defect, arising during base check, shall be recorded by Aircraft Engineer (concerned) on Aircraft Repair Order (ARO) that contains reference of Task card / work package. Serial number of Aircraft Repair Order (ARO) shall also be recorded on Task card to ensure its traceability (Refer MOE Chapter 2.13 for details).
2.15.2.2 Rectification of Defects When a defect is reported or observed during maintenance task, defect investigation / troubleshooting shall be performed by Aircraft Engineer (production) concerned with appropriate certification authorisation. Maintenance data such as AMM, SRM, CMM, etc. shall be referred for all troubleshooting and rectifications. In case, repair is not possible through solution given in maintenance data, Aircraft Engineer (Technical Services Engineering) concerned shall be informed to workout for viable solution, in coordination with Type Certificate holder / Original Equipment Manufacturer (OEM) and the Competent Authority of aircraft registration (Refer MOE Chapter 2.9 for details). For customer aircraft, Repair Order shall be referred to verify that aforementioned repair is already addressed. If deemed necessary, customer’s Work / Repair Order shall be modified to include such additional task, with assurance that rectifications shall be performed within the approved scope of work. Deputy Chief Engineer (Planning) concerned shall ensure provisioning of additional manpower, tooling and other facilities for unscheduled tasks during scheduled base maintenance activities.
2.15.2.3 Reporting of Defects Defects that are considered hazardous to safety and airworthiness must be reported to Deputy Chief Engineer (Technical Services Engineering) concerned. The Competent Authority, Type Certificate holder and customer / operator shall be informed for such unairworthy condition (Refer MOE chapter 2.18 for details).
2.15.2.4 Deferments of Defects Rectification Reference to Minimum Equipment List (MEL) provided by operator shall be made when a rectification is deferred. Any defect raised and not rectified during scheduled
maintenance due to justified reason shall be considered as deferred defect. Deputy Chief Engineer (planning) concerned shall report all deferred defects to Deputy Chief Engineer (Technical Publication & Records) for recording in PIA Aircraft Maintenance Management Information System (PAMMIS) to ensure their rectification on priority. Such deferred defects shall be listed and clearly mentioned on aircraft maintenance records.
To describe PIA Engineering & Maintenance policies, regarding issuance of Certificate of Release to Service for aircraft / aircraft components after maintenance.
2.16.2 PROCEDURE 2.16.2.1 Generalities
Certifying staff, qualified to issue Certificate of Release to Service as per scope of certification authorisation, is mentioned on "List of Certifying Staff" (Refer MOE Chapter 1.6 for details). Certifying Staff shall be trained and qualified as per MOE Chapter 3.4. Deputy Chief Engineer (production) concerned shall maintain record of certifying staff working in the section to ensure continuity of certification authorisation and determination of training needs. When “Certificate of Release to Service” is issued for an aircraft / aircraft component, it means that: ♦ Maintenance performed, within approved scope of work for the Organisation. ♦ All maintenance was executed in accordance with customer / operator work order
and approved maintenance data. ♦ Appropriate support staff has signed all maintenance work. ♦ No work, other than that justified, has been deferred. ♦ No reportable defect is apparent that could hazard aircraft / aircraft component’s
safety and airworthiness. ♦ All non-conformities have been fully and correctly investigated and rectified. ♦ Release from maintenance base means that all defects reported / rectified at line
stations within period from last base release have been rechecked and recorded in Technical Logbook.
2.16.2.2 Aircraft Line / Cabin Maintenance
After completion of line / cabin maintenance, certifying staff shall issue Certificate of Release to Service for particular job, when satisfied that all required maintenance has been performed in accordance with requirements of Competent Authority, maintenance data and organisational procedures. Certificate of Release to Service is not issued after Pre-flight inspection, if no maintenance is performed on aircraft as a result of any inspection / defect reporting. For customer aircraft, original certificates are sent to customer / operator (Refer MOE Chapter 2.17 and Chapter 4.2). To ensure this, operator’s ‘Aircraft Technical Logbook’ should be used. Certifying staff, while making entry in customer’s Aircraft Technical Logbook, must mention EASA Approval number (EASA.145.0004) alongwith signature, date and certification authorisation number. Aircraft Technical Logbook is used for all line maintenance activities and line station releases. Work cards are used for minor scheduled maintenance and tasks like engine / APU change. Entries are made in Aircraft Technical Logbook with Work card reference. Certifying staff (Refer MOE Chapter 3.4), holding appropriate qualification, shall issue Certificate of Release to Service. When an aircraft is released after scheduled line maintenance activities, reference to Task cards (for periodic checks) is also provided
alongwith Certificate of Release to Service statement in aircraft Technical Logbook. For Check ‘A’ in Line Maintenance division, Certificate for Release to Service for aircraft shall be issued as defined in MOE 2.16.2.3, except for ‘Aircraft Base Check Report’. Critical tasks procedure shall also be applicable as per MOE Chapter 2.23 and Chapter L2.7 (Refer AMP 2-3 for process flow).
2.16.2.3 Aircraft Base Maintenance Certificate for Release to Service, for base check, shall be issued on ‘Aircraft Certificate of Release to Service’ (Refer MOE 5.1 for sample). Base Maintenance Certifying Staff, equivalent to Part – 66 (category ‘C’), shall issue such Certificate of Release to Service containing following information: ♦ Aircraft Type, Registration, Manufacturer Serial No, Operator ♦ Aircraft Total Flight Hours and Cycles ♦ Type of Check performed, Location, Date Check completed ♦ Reference to work package that includes schedule / unscheduled maintenance,
incorporated Airworthiness Directives and accomplished modifications ♦ Reference to Maintenance Organization and Part – 145 Approval Number ♦ Signature, Name and authorisation (AME / Approval) No. of Authorized person Original Certificate of Release to Service is placed in front pocket of Aircraft Technical Logbook. Whenever aircraft technical logbook is to be used for certification, procedure detailed in MOE 2.16.2.2 shall be applicable. Where customer / operator procedures are different from organisational procedures, the operator’s documents and base check completion certificate shall be used. For critical tasks during base check, certifying staff shall refer MOE Chapter 2.23 for details. During base check, progress is monitored and all non-scheduled jobs are also recorded in separate lists. Operators other than PIA shall be informed about non-accomplished tasks and asked for obtaining exemption approval from their Authority related to such maintenance tasks as specified in MOE Chapter 3.9. Acceptance shall be taken from the Operator, in writing, for records. Upon completion of base check, Deputy Chief Engineer / Aircraft Engineer (production) concerned shall sign ‘Document Completion Certificate’ (Refer AMP 2-3 for sample), ensuring that all related tasks have been completed and signed off. Certifying staff in category ‘C’ shall issue Aircraft Certificate of Release to Service. Prior to despatch of relevant maintenance record to Technical Records section for archiving, Aircraft Engineer (Technical Services Engineering) concerned shall compile ‘Aircraft Base Check Report’ (Refer AMP 2-4 for sample). ‘Certificate of Maintenance Review’ (C of MR) for Pakistan registered aircraft are issued by certifying staff, authorised by Pakistan Civil Aviation Authority, where required, by Aircraft Maintenance Program.
2.16.2.4 Engine / Component Maintenance EASA Form 1 – Issue 2 (Refer MOE 5.1 for sample) shall be used for all aircraft components to be released under EASA Part – 145 Approval, providing following details:
♦ Name and country of the Approving Competent Authority (block 1; only “EASA” must be stated for components released under Part – 145)
♦ Form tracking number (block 3) and Customer work order / contract / invoice reference (block 5)
♦ Full name and address of approved Maintenance Organisation (block 4) ♦ Details for particular aircraft component (block 6, 7, 8, 9 & 10) ♦ Status of maintenance performed (block 11) ♦ Reference of maintenance data with revision status (statement as ‘in accordance
with CMM’ is not acceptable), compliance with airworthiness directives or service bulletins, repairs, modifications, parts replacements, life limitation status, batch number for traceability, customer agreed deviations from work order and statement required to support shipment with shortages or re-assembly after delivery. Release statement may be entered for any other Civil Aviation Authority regulation as well, if required besides Part-145 release (block 12)
♦ Block 13a to 13e must be shaded / crossed: Not required for maintenance release ♦ “ Part 145A.50 Release to Service” must clearly be marked for release to service
under Part – 145 (block 14a). If component is released under another regulation then “ Other regulation specified in block 12” shall be marked. At least one box must be marked whereas for dual release, both boxes may be marked as applicable. Marking shall be done through a Tick “ ”
♦ Authorised Signature of appropriately qualified certifying staff with authorisation stamp (block 14b), Certification / Approval Ref. No. printed as “EASA 145.0004” (block 14c), certifying staff official name in capital letters (block 14d) and Date in the format “dd mmm yyyy” – where dd is two digit date, mmm is first three letters (capital) of the month and yyyy is four digit year (block 14e)
Certifying staff shall be trained on contents of EASA Form 1 during continuation training. Shop planning shall make arrangements for printing of the EASA Form 1, ensuring that all above-mentioned points have been catered for. Prior to sign any EASA Form 1, certifying staff must check completeness of component maintenance records and verify correctness of details, provided in the EASA Form1. Deputy Chief Engineer (planning) concerned shall despatch all pertinent information for each issued EASA Form 1 to Deputy Chief Engineer (Sales) Component Maintenance. For components not requiring EASA Form 1, only LRU Tracking Tag / Serviceable Tag shall be issued (Refer AMP 2-3 for process flow). PIA Engineering & Maintenance, in no case, shall issue an EASA Form 1 for aircraft component removed as serviceable from any aircraft. Such component, prior to issuance of an EASA Form 1, must be routed through allocated component shop. Customer aircraft component, released by the shop, shall be held in a designated area for serviceable components within shop. Deputy Chief Engineer (Planning) concerned shall intimate availability of component to Deputy Chief Engineer (Sales) Component Maintenance for delivery to customer. When required by the customer, Deputy Chief Engineer (Sales) Component Maintenance concerned shall inform Parts Control section for collection of aircraft component from shop and transportation to delivery point.
2.16.2.5 Release of Aircraft with Deferred / Carried Forward Defects Aircraft may be released to service with deferred / carried forward maintenance tasks, only where it is permitted through the Minimum equipment list (MEL). Records of such maintenance tasks shall be made in Aircraft Technical Logbook. For PIA aircraft, Aircraft Engineer (production) concerned shall also make record of
carried forward defect on PIA Aircraft Maintenance Management Information System (PAMMIS). A copy (BLUE) of Log slip with details of carried forward defect / MEL reference shall be placed in Hold Item List (HIL) pocket and entry shall be made in carried forward defect list of Technical Logbook (Refer MOE Chapter L2.3). Deferment of scheduled maintenance tasks shall only be permitted through approval of Chief Engineer (Quality Assurance), who is responsible for making correspondence in this regard with the Competent Authority and manufacturer. In case of customer aircraft, approval shall be sought from the Competent Authority of aircraft registration (Refer MOE Chapter 2.9 and Chapter 2.10).
2.16.2.6 Completion of Maintenance Tasks without Release PIA Engineering & Maintenance shall ensure that issuance of Certificate of Release to Service should only take place when all requirements are fulfilled. In cases, where complete details of maintenance / modification history for customer aircraft are not provided or customer Work Order does not require incorporation of an Airworthiness Directive / mandatory modification or completion of maintenance task, only Certificate of Maintenance completion is issued for the same.
2.16.2.7 Release of Aircraft with Component not having EASA Form 1 When an aircraft is grounded at a location other than maintenance base due to non-availability of an aircraft component with appropriate release certificate, it is permissible to temporarily fit such aircraft component without appropriate release certificate for a maximum of 30 flight hours or until aircraft first returns to maintenance base, whichever is earlier. This condition is subject to customer / operator contract and only applicable when said component is available with suitable serviceability tag and in compliance with EASA Part-145 requirements. Such aircraft component, in all cases, must be removed before predefined time unless an appropriate release certificate (EASA Form 1) has been obtained in the meantime.
To define PIA Engineering & Maintenance policies for transmitting maintenance records to the customer / operator.
2.17.2 PROCEDURE
2.17.2.1 General
Maintenance on customer’s aircraft / aircraft component shall be performed under an agreement (Refer MOE Chapter 2.1 for details). Chief Engineer (Engineering Business Development) in coordination with Chief Engineer (production) concerned shall ensure that all maintenance on such aircraft / aircraft components must adhere to the regulatory requirements issued by the Competent Authority of aircraft registration. Maintenance contracts shall specify documents to be provided by customer alongwith aircraft / aircraft components and documentation to be presented upon completion of required maintenance. Records for aircraft / aircraft components maintenance in the Organisation shall generally be managed as per MOE Chapter 2.14. Deputy Chief Engineer (Technical Publication & Records) shall provide all technical record (in original) to customer / operator, through Deputy Chief Engineer (Sales) concerned. Such technical record shall consist of: ♦ List of scheduled and unscheduled maintenance work carried out ♦ Information on aircraft as regard to ageing aircraft maintenance program ♦ ‘Engineering Orders (EO)’ accomplished on customer aircraft ♦ Certificates of Release to Service (CRS) / EASA Form 1, issued ♦ Specific approved data used for any specific repair / modification ♦ List of incorporated Airworthiness Directives and modifications ♦ Details of contracted maintenance, if any ♦ Validated list of deferred defects ♦ Any other document specified in the maintenance contract
2.17.2.2 Maintenance Records Retention
Whenever the customer / operator demands the Organisation to archive Certificates of Release to Service (CRS) and other maintenance record, the retention period for such records shall be in compliance with the regulator requirements issued by the Competent Authority of aircraft registration (Refer AMP 2-4 for details).
2.18 REPORTING OF DEFECTS TO THE COMPETENT AUTHORITY / OPERATOR / MANUFACTURER
2.18.1 PURPOSE
To define PIA Engineering & Maintenance policies for reporting of defect, discovered during maintenance on aircraft / aircraft component that could seriously hazard safety of aircraft. Reporting shall be made to the Competent Authority, Original Equipment Manufacturer (OEM), Authority of registration of aircraft and Operator / Customer.
2.18.2 PROCEDURE
2.18.2.1 Definition and List of Reportable Defects, in Relation to Part 145.A.60 Occurrences considered as Technical Incidents / Reportable Defects are: ♦ Damage on aircraft structure that could seriously hazard the aircraft or cause an
un-airworthy condition ♦ Crack triggering permanent deformation or corrosion (level 3 according to Aircraft
Maintenance Manual / Structure Repair Manual) ♦ Burn stain due to electrical abnormal operation, burning or deformation of aircraft
♦ Failure of any emergency system during scheduled testing ♦ Defect / malfunction on aircraft system / engine / component, which if undetected
could seriously hazard safety of aircraft
2.18.2.2 Reporting of Unairworthy Conditions Objective of occurrence / defect reporting system is to identify factors contributing to incident causing unairworthy conditions and to make system resistant to similar errors. If any of the above defects is discovered, Aircraft Engineer (production) concerned must report immediately the assumed incident / occurrence / defect to Deputy Chief Engineer (Technical services Engineering) concerned on ‘Occurrence / Incident Reporting Form’ (Refer AMP 2-3 for sample) containing all pertinent information, available. Deputy Chief Engineer (Technical Services Engineering) concerned shall establish that whether such event comes under defined criteria of Technical Incident / Reportable defect as per Part 145.A.60. Once established, Deputy Chief Engineer (Technical services Engineering) concerned shall notify Technical Incident / Reportable defect to Chief Engineer (Quality Assurance) within twenty-four hours. Deputy Chief Engineer (Technical Services Engineering) concerned shall perform thorough investigation and results shall be presented to Chief Engineer (Quality Assurance) on ‘Delay / Defect / Incident Report’ (Refer AMP 2-3 for sample) containing all relevant information. Technical Assistant to Chief Engineer (Quality Assurance) shall raise EASA Form 44 ‘Technical Occurrence Report’ to notify such Technical Incident / Reportable defect at the earliest but in any case within seventy-two hours, to the Competent Authority through email ([email protected], [email protected]) and aircraft registration Authority, with a copy to GSAC Inspectors in charge of PIA Engineering & Maintenance. Information regarding Technical Incident / Reportable defect shall also be despatched to the Original Equipment Manufacturer (OEM) and the Operator. The EASA Form 44 is available on EASA web site (http://www.easa.europa.eu/ws_prod/c/c_orgapprocao.php).
2.18.2.3 Investigation / follow-up of Technical Incident Where investigation of Technical Incident / Reportable defect is not concluded at time of reporting, Technical Assistant to Chief Engineer (Quality Assurance) shall ensure that all concerned, are kept abreast of progress and final report is submitted on completion of investigation. Investigation shall be aimed to identify root cause and reports shall be discussed with the concerned divisional heads / sectional Incharges, so that an appropriate corrective / preventive action can be taken.
2.18.2.4 Unairworthy Conditions Reporting Records Technical Assistant to Chief Engineer (Quality Assurance) shall maintain records pertaining to un-airworthy conditions / technical occurrences reported to the Competent Authority, the Authority of aircraft registration, Original Equipment Manufacturer (OEM), and Operator / Customer. Records shall include complete documentation from initial finding till reporting of such unairworthy condition / technical occurrences.
2.19 RETURN OF DEFECTIVE AIRCRAFT COMPONENTS TO STORE
2.19.1 PURPOSE To define PIA Engineering & Maintenance policies regarding removal, handling and return of defective aircraft components to stores, during maintenance on aircraft / aircraft components.
2.19.2 PROCEDURE
2.19.2.1 Defective Aircraft Components Removal Aircraft component removed due to life limitation, failure, excessive error or abnormality shall be considered as “Defective Aircraft Component” and attached with applicable tag, serving the purpose of Work / Repair Order. Defective component may be removed in any of the following situations:
a) Components Removed During Line / Base Maintenance During aircraft maintenance, defective aircraft component / Line Replaceable Unit (LRU), allotted with LRU control number for tracking on one-to-one replacement basis, shall be despatched with attached ‘LRU Tracking Tag’ (Refer AMP 2-1 for sample) to Parts Control section. Aircraft Engineer (production) concerned shall fill “UNSERVICEABLE” portion (received with replacement) with signature, date and certification authorisation number. During base check (generally during open-up) or when aircraft grounding is required, a defective aircraft component may be removed without any substitution. In such cases, Aircraft Engineer (concerned) shall generate ‘Repair Tag’ (Refer AMP 2-1 for sample) for such component.
b) Components Removed During Component Maintenance / Structure Repair During component-level maintenance, defective aircraft component (with LRU control number) removed from ‘Next Higher Assembly’ (NHA) shall be despatched by Aircraft Engineer (production) concerned with Repair Tag to Parts Control section. Defective aircraft component (without any LRU control number) shall be despatched with ‘Fractional Work Order’ (Refer AMP 2-1 for sample). For fractional task, not requiring any Certificate of Release to Service (CRS), the same work order shall be used and defective aircraft component shall be transported directly to concerned shop.
c) Components Received in Incoming Stores An incoming aircraft component (new / repaired / overhauled) with uncertain status, requiring inspection / testing, shall directly be sent to Deputy Chief Engineer (production) concerned with Repair Tag. Technical Assistant to Chief Engineer (Quality Assurance), upon request by Stores Quality Inspector, shall generate the applicable tag.
d) Consumables Removed from Aircraft / Aircraft Component Consumables (packing, seal, tube-light, bulb, filter, fastener, etc.) shall be mutilated upon removal, whenever required by maintenance data. Aircraft Engineer (production) concerned shall ensure that consumables, except those containing hazardous material,
are properly discarded. Deputy General Manager (Logistics) Stores shall be contacted, periodically, for disposal of such discarded consumables. High-cost consumables (blade, vane, windshield, ignition lead, relay, etc.), removed from aircraft / aircraft component (NHA), shall be despatched with applicable tag (attached) to Parts Control section. Deputy Chief Engineer (Rotable Planning) shall despatch repairables to allocated shop. Otherwise, Deputy Chief Engineer (Rotable Planning) shall make arrangements for mutilation through Deputy Chief Engineer (planning) concerned. Deputy General Manager (Logistics) Stores shall be contacted, periodically, for disposal of such consumables.
2.19.2.2 Defective Aircraft Components Handing Over Defective aircraft components (with LRU control number), removed from aircraft / aircraft component (NHA), shall be handed over to Parts Control section with list providing Part No., Serial No. and Quantity. Maintenance staff shall get acknowledgment signature with date and staff number of recipient on the list (copy). All lists shall be archived by Deputy Chief Engineer (production) concerned for a minimum period of six months from date of handing over.
2.19.2.3 Defective Aircraft Components Allocation Parts Control section shall load defective aircraft component, alongwith applicable tag, to allocated shop planning section. Parts Controller shall hand over aircraft components to allocated shop planning section with list providing Part No., Serial No. and Quantity. Planning staff shall acknowledge through signature with date and staff number on the list. Lists shall be archived by Deputy Chief Engineer (Rotable Planning) for a period of six months from handing over date.
2.19.2.4 Defective Aircraft Components Handling
For maintenance purpose, defective aircraft component is categorised as:
a) Defective Aircraft Component (Unserviceable) Defective aircraft components shall be quarantined by Parts Controller, before despatch. “Repair Abroad” components shall be processed for shipment to approved vendor (Refer MOE Chapter 2.20 for details). Allocated shop planning shall inspect defective aircraft component for required maintenance such as testing / modification / repair / overhaul.
b) Defective Aircraft Component (Rejected)
Defective aircraft component shall be recommended for rejection, if found damaged or un-repairable due to any of the following reasons: i. Repair of component is beyond economical / manufacturer’s repair limit. ii. For extent of damage, no repair scheme can be developed / approved. iii. Component rejected by manufacturer / vendor. Component established as “Not
Repairable / Rejected” by manufacturer, shall be declared as “Scrapped”.
Component / material shall be quarantined at designated location and returned to vendor for warranty replacement, if any of the following situations occurs: ♦ New component, from vendor is found damaged during transportation, etc.
♦ Material received as new and found non-compliant with Purchase Order. When defective aircraft component is rejected, “Scrap / Rejection Certificate” (Refer AMP 2-1 for sample) shall be generated by Deputy Chief Engineer (production) concerned. Deputy Chief Engineer (Technical Services Engineering) concerned and Chief Engineer (concerned) shall scrutinize defective aircraft component and certificate for endorsement. All aircraft components (valued US$ 10,000/- and above), recommended for scrapping, shall be evaluated for possible salvage action by relevant Scrap Review Committee, comprising of Chief Engineer (Base Maintenance), Chief Engineer (Quality Assurance) and Deputy General Manager (Technical Services) Finance. The Committee may seek services / judgement for any particular speciality relevant to defective aircraft component under consideration. Deputy Chief Engineer (production) concerned shall be responsible for mutilation of “Scrapped” aircraft component to a point where such component becomes unusable. Deputy Chief Engineer (Technical Services Engineering) concerned shall monitor the mutilation process whereas Deputy Chief Engineer (planning) concerned shall despatch mutilated components to Deputy General Manager (Logistics) Stores. Deputy General Manager (Logistics) Stores, upon receipt of such component, shall ensure that the scrapped aircraft component is received alongwith the “Scrap / Rejection Certificate” duly certified by authorised personnel and mutilated as per the Part – 145 requirements. During transit, aircraft components shall be stored / segregated in a quarantined area observing restricted access to authorised personnel only. An aircraft component, scrapped / rejected, may be sent to manufacturer / approved vendor, to investigate cause of failure, prior to disposal (if necessary). Customer’s defective aircraft component shall be evaluated for possibility of rejection. If rejected, such component shall be segregated and the customer shall be contacted for further action.
c) Aircraft Components Removed Due to Life Limitation Parts Control section receiving defective aircraft component during aircraft / aircraft component maintenance, shall computerise all data in ‘PAMMIS’ and send defective aircraft component to allocated shop for any of the following actions: ♦ Maintenance (inspection / repair / overhaul) – Shop shall process defective aircraft
component (unserviceable) as per procedure 2.19.2.4 (a). ♦ At its end of life – Shop shall process defective aircraft component (rejected) as per
procedure 2.19.2.4 (b).
2.19.2.5 Loaned Aircraft Components Management Upon operational requirements at line stations, aircraft component shall only be obtained with EASA Form 1 or FAA 8130-3 / TCA 24-0078 (with double release) to avoid any grounding. Deputy Chief Engineer (Rotable Planning) shall arrange required aircraft component from approved vendor located at particular line station. In case of non-availability of component with such vendor, other approved vendors may be requested in close vicinity of grounded aircraft (Refer MOE Chapter L2.5 for details). On receipt of pool / loan information, Deputy Chief Engineer (Rotable Planning) shall
send list of outstanding pool / loan components to Incharge Parts Control. Aircraft Engineer (production) concerned in Line Maintenance shall receive a memorandum for removal of pool / loan aircraft component from aircraft, upon its arrival at maintenance base. Aircraft Engineer (production) concerned shall handover removed component to Part Control section with Serviceable Tag clearly marked as “Pool / Loan Item”. Pooled item shall be handed over to Despatch section (Logistics), alongwith a letter from Deputy Chief Engineer (Rotable Planning), for shipment to aircraft component provider through cargo department, transmitting despatch information to the component provider. Parts Control section, in case of a loaned component, shall review return conditions through contract. For restoration of serviceability (if applicable), aircraft component shall be despatched to allocated shop. Loaned component, following sufficient maintenance, shall be despatched to Parts Control section with applicable release certificate issued by Aircraft Engineer (production) concerned holding appropriate certification authorisation. Parts Control section shall arrange shipment of serviceable aircraft component to donor as per contract / agreement.
2.19.2.6 Aircraft Components Storage Conditions
Defective aircraft components (unserviceable) pending their allocation / transportation to shop / vendor shall be quarantined in Parts Control section. Unserviceable components, received by shop, shall be kept at a location segregated from serviceable components. Defective aircraft component declared as “Scrapped” shall be marked, tagged and stored in restricted area during transit period. Defective or ambiguous aircraft component in Logistics division shall be segregated from serviceable components during transit to allocated shop or vendor for inspection / testing / repair / scrapping. Deputy Chief Engineer (production) concerned shall ensure that appropriate storage conditions are observed, while handling defective aircraft components during aircraft / aircraft component maintenance. Access to such components shall be restricted only to authorised personnel. Control of access to unserviceable and quarantined aircraft components and material, throughout the Organisation, shall be exercised in a similar manner. Authorisations for access to such areas shall be controlled by Chief Engineer (concerned) for respective division through lists of authorised personnel.
2.20 DEFECTIVE COMPONENTS TO OUTSIDE CONTRACTORS 2.20.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding control of Repair Orders and shipping procedure of defective aircraft components to outside contractors.
2.20.2 PROCEDURE
2.20.2.1 General Defective aircraft component, requiring repair abroad shall be sent to outside contractor. Deputy Chief Engineer (planning) concerned shall arrange outgoing inspection and despatch such defective aircraft component to Deputy Chief Engineer (Repair Abroad), in compliance with standard ATA 300 (packaging). This may affect aircraft component in any of the following situations: ♦ Removed during maintenance and sent to contracted organisation ♦ Rejected as a result of incoming inspection (Refer MOE Chapter 2.2) ♦ Provided by the customer for its own aircraft and found unserviceable ♦ Airworthiness Directive / modification accomplishment by contracted organisation
2.20.2.2 Issuance of the Repair Order
Deputy Chief Engineer (planning) concerned shall post ‘Shop out’ data in computerised records, for defective aircraft component, requiring maintenance in respect of Permanent Repair Abroad (PRA) list alongwith applicable details for Deputy Chief Engineer (Repair Abroad). Repair Order is generated by Deputy Chief Engineer (Repair Abroad), against ‘Preferred Agency’ list (extracted from Approved Vendor List). For defective aircraft component, not covered in Permanent Repair Abroad (PRA) list, Deputy Chief Engineer (Repair Abroad) shall generate Repair Order, after approval from Director (Engineering & Maintenance) on ‘Authorization for One Time Repair Abroad’ form (Refer AMP 2-1 for sample). Defective aircraft component, under warranty repairs, is sent with Repair Order, generated by Deputy Chief Engineer (Schedule & Check Planning). Repair Order shall be generated (six copies) in compliance with contract requirements and to be distributed as follows: ♦ Original copy to Approved Vendor (listed in Approved Vendor List) ♦ 2nd copy to be received as acknowledgement from vendor (for record) ♦ 3rd copy to Originator ♦ 4th copy to Despatch (Logistics) section ♦ 5th copy to Foreign Receipt (Logistics) section ♦ 6th copy to Deputy General Manager (Logistics) New York Repair Order shall specify systematically the following information regarding defective aircraft component: ♦ Part No., serial No., description, quantity, and defect / work required ♦ Any supplementary forms (if applicable) ♦ Required authorised release / delivery documents
Defective aircraft component shall be sent to Despatch section (Logistics) for shipment documents and fulfilment of despatch formalities including custom clearance. Item shall be despatched through cargo under valid documentation. Similar process shall be adopted to return a defective aircraft component to customer.
2.20.2.3 Despatch / Receipt and Monitoring of Unit Movement
Deputy Chief Engineer (Repair Abroad) shall handover one copy of Repair Order to Parts Control section, for defective aircraft component. Despatch section (Logistics) shall receive defective component alongwith Repair Order for documents preparation, custom clearance and shipment. Deputy General Manager (Logistics) shall update despatch register reference and flight details in PIA Online Stores System (POSS) for shipment tracking. On receipt of aircraft component (repaired abroad) from approved vendor, Stores Quality Inspector shall perform incoming inspection (Refer MOE Chapter 2.2 for details) and issue ‘Certificate of Inspection’ (Serviceable Tag) and copy of either EASA Form 1 or FAA 8130-3 / TCA 24-0078 (with double release). Foreign Receipt section (Logistics) shall generate Receipt Voucher and send aircraft component to respective Stockroom on ‘Stock Return Voucher’ (Refer AMP 2-1 for sample). Deputy Chief Engineer (Repair Abroad) shall record computerised Receipt Voucher for further processing.
2.20.2.4 Component Sent Back to the Customer / Operator Customer aircraft component, established as unserviceable upon installation on aircraft shall be returned through Parts Control section. Defective aircraft component shall be despatched in original packaging, alongwith received documents. Repair Tag shall be attached to defective component, stating reason for non-conformity in column ‘Removal Code’. Although no Repair Order shall be raised, Deputy General Manager (Logistics) Stores shall transmit despatch register reference and flight details to customer.
2.20.2.5 Aircraft on Ground (AOG) Requirements Chief Engineer (concerned) shall initiate AOG requirement on one time basis that routes through Chief Engineer (Maintenance Operation Centre) to Director (Engineering & Maintenance) for approval. Depending on nature, approval for AOG requirements may be granted bypassing normal process. Regularisation for approval shall be pursued from Engineering & Maintenance Committee (EMC) in next subsequent meeting.
2.20.2.6 Warranty Repairs Defective aircraft component, under warranty, are not covered in Permanent Repair Abroad list. Deputy Chief Engineer (planning) concerned shall send ‘Warranty Repair Request’ to Deputy Chief Engineer (Schedule & Check Planning) for initiation of Repair Order, stamped as “Under Warranty Repair – No Payments to be made”. Deputy Chief Engineer (Schedule & Check Planning) shall follow up for all such components.
2.20.2.7 Aircraft / Aircraft Component Maintenance at Vendor’s Facility A situation may arise when an aircraft / aircraft component repair or a major modification may be required to be accomplished at an approved vendor’s facility. Chief Engineer (Maintenance Operation Centre) shall coordinate with all concerned to establish specific requirements in this regard.
2.20.2.8 Beyond Economic Repair During follow-up action, for defective aircraft component declared as “Beyond Economic Repair” (BER) by vendor, Deputy Chief Engineer (Repair Abroad) shall recall aircraft component (valued US$ 10,000/- and above) and despatch the same to concerned shop. Deputy Chief Engineer (production) concerned shall investigate reason of rejection and follow scrapping process as detailed in MOE Chapter 2.19. For defective aircraft component (valued less than US$ 10,000/-), declared by vendor as “Beyond Economic Repair”, Deputy Chief Engineer (Repair Abroad) shall coordinate with concerned shop for such aircraft component. Deputy Chief Engineer (Repair Abroad) may be advised to recall defective aircraft component, for investigation. Deputy Chief Engineer (concerned) production, in coordination with Deputy Chief Engineer (Technical Services Engineering) concerned, shall investigate reason for rejection and follow scrapping process as detailed in MOE Chapter 2.19. If recall of defective aircraft component (valued less then US$ 10,000/-) is not feasible due to financial impact, it shall be decided to scrap such component at vendor’s facility. Deputy Chief Engineer (Repair Abroad) shall provide all required documents to Deputy Chief Engineer (production) concerned, who in consultation with Deputy Chief Engineer (Technical Services Engineering) concerned shall initiate scrapping process by raising ‘Scrap Rejection Certificate’ (Refer AMP 2-1 for sample).
2.21 CONTROL OF COMPUTER MAINTENANCE RECORD SYSTEM 2.21.1 PURPOSE
To define PIA Aircraft Maintenance Management Information System (PAMMIS) used for management of information related to aircraft / aircraft components maintenance computerised recording. ‘PAMMIS’ system organisation, capabilities and procedures are described in “PAMMIS User Manual”.
2.21.2 PROCEDURE 2.21.2.1 General
‘PAMMIS’ is online system, managed on mainframe with data terminals at different locations within the Organisation. Deputy Chief Engineer (HR & Training) shall maintain security against unauthorised access at different levels through issuing passwords for utilization of relevant functions. It also ensures protection against any illicit alterations in the computerised records / database. Backup of ‘PAMMIS’ shall be accomplished on daily and weekly basis. Log backup of databases shall be performed on daily basis. It covers any data deletion, modification and changes. After every seven days of daily backup, an archive backup is created to record all changes in database. Computer backup discs, tapes etc. are stored in different locations from those containing working discs. Entire record / backup shall be stored in a safe way with regard to fire, flood and theft in an environment, ensuring that such record / backup remains in good condition in the IT department building, PIAC Head office, Karachi. Deputy Chief Engineer (HR & Training) shall ensure that in case of any changes in computer programs, previous data shall be available for a period of atleast three years. All required maintenance records as described in MOE Chapter 2.14 are available in hard copy format also and kept by Technical Record section. There is no system of electronic signature being used in PIA Engineering & Maintenance.
2.21.2.2 Database of PAMMIS PIA Aircraft Maintenance Management Information System (PAMMIS) consists of five different modules:
a) Support Functions This module contains master information that is required by all other modules of PAMMIS. Basically, two types of data are available through this module: Tables are maintained for aircraft registration, line station, flight operation, flight sector, ATA codes, etc. which can be used for verification throughout the system to ensure data integrity and available to all users. Aircraft operation data is update of aircraft & component Flight Hours (FH), Flight Cycle (FC) and Landings (Ldg). Information provided by Aircraft Flight Logbook is used by the system to compute times (FH, FC, Ldg) for individual component and sub-assembly of all aircraft types.
b) Aircraft defect and delay (MEL) This module provides data / report on standard parameters for monitoring aircraft status and performance. Engine / APU oil consumption for each aircraft is provided for review on daily basis. Maintenance Log function gives ability to record, review and analyse maintenance log defect and associated defect corrective action. Major outputs of this module include repeated defects, carried forward defects, open defects and defects summary sequenced by ATA chapter.
Delay and Incident Occurrences function allows to record, review and analyze delays and incidents information for planning review purposes. Carried Forward Defect Monitoring and Control Function (MEL) module allows to record, review and analyse all Minimum Equipment List (MEL) items raised due to carried forward defect out of the main base.
c) LRU management / Repair abroad
LRU management / Repair abroad module is designed to track, monitor and control components (Line Replacement Units), providing all pertinent information such as part number, alternate part number, serial number, applicability, ATA chapter, shop life, vendor, turn around time, float, location, component history, serialization, etc.
d) Aircraft maintenance check planning and control This module provides aircraft maintenance check and configuration management information.
e) Aircraft modification This module provides pertinent information on current aircraft modification status with regards to Service Bulletins and Airworthiness Directives.
2.22 CONTROL OF MAN-HOUR PLANNING VERSUS SCHEDULED MAINTENANCE WORK
2.22.1 PURPOSE
To define PIA Engineering & Maintenance policies for developing, monitoring and reviewing the organisational man-hour plan.
2.22.2 PROCEDURE 2.22.2.1 General
Deputy Chief Engineer (production) concerned shall prepare sectional man-hour plan on annual basis for respective section and submit the same to Chief Engineer (concerned). Divisional man-hour plan shall be formulated from the gathered information, considering: ♦ Scheduled aircraft / aircraft component maintenance ♦ Customer aircraft / aircraft component maintenance Workload shall be assessed considering all necessary tasks such as: ♦ Planning ♦ Maintenance records check ♦ Production of Worksheets / Work cards ♦ Accomplishment of maintenance ♦ Inspection ♦ Quality monitoring function
Available man-hours are calculated keeping in view of assessed training needs of personnel and leave rosters (Refer MOE Chapter 2.28 for details). Deputy Chief Engineer (HR, Training & Automation) shall compile ‘Master Man-Hour Plan’ (Refer MOE Chapter 1.7 for details) of scheduled maintenance for the entire Organisation. Such comprehensive plan would take into account all maintenance / support activities performed by personnel under Part – 145 Approval irrespective of equipment on which work is being done. Chief Engineer (concerned) shall continuously monitor man-hour plan and record actual availability of personnel against planned availability, ensuring that at least 50% of actual man-hours are provided through permanent employees. Chief Engineer (HR, Training & Automation), in coordination with all Chief Engineers (concerned), shall review Master Man-Hour Plan on quarterly basis. Chief Engineer (concerned) shall inform Chief Engineer (HR, Training & Automation) for an amendment, when necessary. Divisional man-hour plan for base maintenance shall relate to aircraft hangar visit plan. Aircraft component maintenance man-hour plan would relate to aircraft component planned maintenance and shall evaluate possibility to ensure this workload in respect of available staff. Sectional man-hour plan of Quality monitoring staff would relate to annual Quality Audit Plan and shall be prepared by Deputy Chief Engineer (Quality Audit) for ensuring availability of sufficient staff to carry out their duties properly.
Deputy Chief Engineer (concerned) shall report significant deviation from Master Man-hour Plan, through Chief Engineer (concerned), to Chief Engineer (Quality Assurance) and ultimately to the Accountable Manager for review. Significant deviation means more than 25% shortfall in available man-hours during the calendar month.
To define PIA Engineering & Maintenance policies for minimising rare possibility of an error being repeated in maintenance tasks involving similar maintenance actions on some element / aircraft component of same type fitted to more than one system on the same aircraft during maintenance.
2.23.2 PROCEDURE 2.23.2.1 Generalities
Any task involving some element of similar maintenance on aircraft components of same type fitted to more than one system on same aircraft during a particular maintenance check has possibility of an error being repeated, whenever performed by single person. Critical are such maintenance tasks, if inadequately performed, may lead to unairworthy condition or may have adverse effect on aircraft operating safety. To determine criticality, following maintenance tasks should primarily be reviewed for assessment of impact on safety: ♦ Installation, rigging and adjustment of flight controls ♦ Installation, Bore Scope inspection (BSI), etc. of aircraft engines ♦ Calibration and rigging of components such as engines, landing gears, etc
2.23.2.2 Process To identify Critical Tasks under scheduled maintenance, the Organisation shall review all task cards for each type of aircraft either provided by the manufacturer or developed locally under Airworthiness Directive / modification requiring inspection. Deputy Chief Engineer (Technical Services Engineering) concerned, in coordination with Deputy Chief Engineer (Planning) concerned shall finalize aircraft-wise ‘List of Critical Tasks’ and submit to Deputy Chief Engineer (Maintenance Program & Reliability) for marking cards as “CRITICAL TASK” before handing over to Cardex Control section. Whenever there is amendment in maintenance program or a locally generated Task card is introduced / amended and such change supposedly involves any critical task, Deputy Chief Engineer (Maintenance Program & Reliability) shall inform Deputy Chief Engineer (Technical Services Engineering) concerned and Deputy Chief Engineer (planning) concerned to update the list. Upon receipt of work package for particular maintenance check from Cardex Control section, Deputy Chief Engineer (planning) concerned shall review such package against ‘List of Critical Tasks’ before handing over to maintenance personnel, ensuring that all Task cards involving critical maintenance tasks have been marked. For maintenance check of an aircraft, Deputy Chief Engineer (Maintenance Program & Reliability) shall ensure that critical tasks are scheduled in alternate checks, as far as possible. Alternatively, Deputy Chief Engineer (production) concerned shall ensure that maintenance teams / personnel are grouped in such a way that individual team / person shall be performing maintenance only on one aircraft system at a time.
During line maintenance, critical task being performed by maintenance personnel with independent inspection / supervision by Aircraft Engineer (production) concerned shall be signed off by maintenance personnel for performing task with signing off by Aircraft Engineer (production) concerned for inspection / supervision. Whenever critical maintenance task is performed and checked by one person due to any reason, special precautions must be taken. In such case, Aircraft Engineer (production) concerned shall be only authorised person to perform any critical maintenance task. Aircraft Engineer (production) concerned shall re-inspect the task after completion of all similar tasks. Re-inspection shall be separately signed off on Task / Work card, Aircraft Repair Order (ARO) or Aircraft Technical Logbook. During maintenance check, if critical task arises due to unscheduled maintenance or on basis of maintenance experience, Deputy Chief Engineer (production) concerned shall inform Deputy Chief Engineer (Technical Services Engineering) concerned and Deputy Chief Engineer (planning) concerned for joint evaluation. On the other hand, Task card not involving any critical task but marked as such, shall be notified to Deputy Chief Engineer (Technical Services Engineering) concerned. Critical task identified during unscheduled line maintenance activities shall be logged in Aircraft Technical Logbook with duplicate inspection entry. In all cases, list shall be updated and Deputy Chief Engineer (Technical Services Engineering) concerned, maintaining records of such cases shall inform Deputy Chief Engineer (Maintenance Program & Reliability) for correction. Deputy Chief Engineer (planning) concerned shall mark Aircraft Repair Order (ARO) as ‘CRITICAL TASK’, for critical task arising due to unscheduled maintenance. Deputy Chief Engineer (production) concerned shall ensure that all concerned personnel are trained on critical tasks procedure during recurrent training sessions (Refer MOE Chapter 3.4 for details). Deputy Chief Engineer (production) concerned shall ensure that maintenance personnel, on extended duty (Refer MOE Chapter 2.28 for details), shall not perform any critical task. Aircraft Engineer (production) concerned, being certifying / support staff, shall verify that critical tasks have been performed in compliance with this procedure, before issuing Certificate of Release to Service.
2.24 REFERENCE TO SPECIFIC MAINTENANCE PROCEDURES 2.24.1 PURPOSE
To define PIA Engineering & Maintenance policies for specific maintenance procedures, in accordance with appropriately referenced maintenance data.
2.24.2 PROCEDURE 2.24.2.1 Engine Ground-Run
On-wing engine test run procedures are described in maintenance manuals of different aircraft manufacturers and such procedure is directly used on site without any specific PIA additional procedure. Personnel involved in engine ground run shall be provided with specific training and issued with Authorisation from Chief Engineer (Quality Assurance) for this particular job. A copy of certificate shall be recorded in individual staff file by Technical Assistant to Chief Engineer (Quality Assurance).
2.24.2.2 Aircraft Pressure-Run
Aircraft pressure run procedure shall be accomplished in accordance with applicable maintenance manuals of particular aircraft and such manufacturer procedure is directly used on site without any additional PIA Engineering & Maintenance procedures.
2.24.2.3 Double Check / Duplicate Inspection on Maintenance Task
Double check / Duplicate inspection shall be signed on tasks performed with primary Flight controls, Engine controls, etc. This shall be done where primary mechanical, hydraulic or electrical circuits of controls such as elevators, ailerons, rudder, flaps, etc. are disturbed. Double check / duplicate inspection shall also be performed whenever required by maintenance data during maintenance of aircraft / aircraft components.
2.24.2.4 Aircraft Towing & Taxiing
Technical ground support staff shall primarily perform aircraft towing with assistance from maintenance personnel, under supervision of Aircraft Engineer (production) concerned. Maintenance personnel involved in towing of aircraft shall be provided with special training and issued with towing authorisation after practical demonstration of the process. Chief Engineer (concerned) shall issue towing authorisations for particular aircraft types, valid for a period of two years. A list of authorised personnel shall be sent to Technical Assistant to Chief Engineer (Quality Assurance) for records. Towing training shall include cockpit communication, aircraft braking, relevant aircraft towing procedure, taxiway information, navigation lighting systems and APU starting / shut-down including handling of emergencies. In PIA Engineering & Maintenance, maintenance personnel shall not perform aircraft taxiing. Taxiing shall be made only by flight crew members.
2.24.2.5 Technical Cleaning of Aircraft
Technical cleaning of aircraft on systems such as fuel, clean / used water, hydraulic and pneumatic shall be performed against Aircraft Maintenance Manual requirements and also as a result of inspections carried out during scheduled maintenance. Maintenance
data shall be referred for procedures and materials used. Such cleaning tasks shall be performed only by specialized-trained staff.
2.24.2.6 Jacking Up of Aircraft
Jacking up of aircraft shall be carried out as per Aircraft Maintenance Manuals for the particular aircraft type. Aircraft level limits are observed through given procedures. Appropriate certifying staff shall supervise the job, ensuring service dates and physical condition of jacks’ prior to use.
2.24.2.7 Aircraft Weighing
Aircraft weight and balance check shall be carried out as per requirement of maintenance program, work order or whenever deemed necessary. The check shall be performed in accordance with the applicable maintenance data. Upon completion of the task, generated maintenance records shall be archived by Technical Records section (concerned).
2.24.2.8 Ground and Flight Test Ground and flight test is generally performed upon completion of base check. A flight test will also be performed if a problem cannot be duplicated on ground by means of standard maintenance checks, or if maintenance manual calls for it after a maintenance action. In consultation with Chief Pilot Technical (Flight Operation), test flight plan shall be defined. A test flight plan may also be defined in consultation with customer in case where operator is different from PIA.
2.24.2.9 Extended Range Twin Engine Operations Extended Range Twin Engine Operations (ETOPS) awareness and specialized training is provided to the management and other maintenance personnel. All personnel intended to be given B777 certification authorisations shall be provided ETOPS training on must-basis. Procedures for ETOPS maintenance program shall be followed as per ETOPS manual, controlled by Deputy Chief Engineer (Maintenance Program & Reliability).
2.24.2.10 Maintenance on Fuel Systems and Fuel Tank Safety Fuel tank safety familiarisation training is provided to management and other maintenance personnel. All personnel intended to perform maintenance on aircraft / aircraft components in compliance of Critical Design Configuration and Control Limitations (CDCCL) tasks shall be provided additional specialized training in fuel tank safety as well as associated inspection standards and maintenance procedures issued by manufacturers.
2.24.2.11 Maintenance on Electrical Wiring Interconnection System (EWIS) In order to improve awareness of all personnel associated with aircraft maintenance, trainings on electrical interconnection system (EWIS) are provided for each workgroup according to their job roles. Specialized training shall be provided to maintenance staff directly working on aircraft electrical interconnection system (EWIS) to enhance their competence level. Upon accomplishment of initial training, refreshers shall be conducted through recurrent training session in relevant maintenance / support function areas.
2.25 PROCEDURE TO DETECT AND RECTIFY MAINTENANCE ERRORS 2.25.1 PURPOSE
To describe PIA Engineering & Maintenance policies regarding the means for detecting maintenance errors, identification of contributing factors and measures to avoid any reoccurrence of similar errors during maintenance on aircraft / aircraft components.
2.25.2 PROCEDURE 2.25.2.1 Generalities
Maintenance errors may be defined in number of ways and categorizing types of errors can lead to solutions / remedial actions to prevent reoccurrence of similar errors. Each maintenance error can be categorized to factors, contributing maintenance error such as slip, mistake or violation of procedure, ignorance of maintenance data, etc. Detection of maintenance errors can be accomplished with different means: ♦ Any person in the Organisation, upon detection of maintenance error, shall inform
Aircraft Engineer / Deputy Chief Engineer (production) concerned to communicate such error to Aircraft Engineer (Technical Services Engineering) concerned.
♦ Investigations of flight delays / incidents / repeated defects, post base maintenance failures, unscheduled component removals and post-maintenance test bench failures of components by Technical Services Engineering (concerned).
♦ Spot checks performed during aircraft / aircraft component maintenance. ♦ Internal quality audit findings observed during product audits and forwarded to
Deputy Chief Engineer (Technical Services Engineering) concerned. As policy, management functions must encourage reporting maintenance error by personnel of the Organisation. Chief Engineer (Quality Assurance) shall ensure that no punitive action shall be initiated against person reporting errors. Reporting Forms shall be made available with Deputy Chief Engineer (Technical Services Engineering) and error reporting shall always be considered as a positive action. Aircraft Engineer (Technical Services Engineering) concerned shall initiate ‘Maintenance Error Report’ (Refer AMP 2-3 for sample), mentioning details of maintenance error and proposed action plan. A copy of “Maintenance Error Report”, duly verified by Deputy Chief Engineer (Technical Services Engineering) concerned shall be despatched to Deputy Chief Engineer (Human Factors). Deputy Chief Engineer (Technical Services Engineering) concerned shall retain originals for record, ensuring follow-up for training of maintenance personnel (Refer AMP 2-3 for process flow). Deputy Chief Engineer (Technical Services Engineering) concerned shall prepare a monthly summary of all findings related to maintenance errors for feedback to Chief Engineer (Quality Assurance) and Chief Engineer (production) concerned.
2.25.2.2 Line / Cabin Maintenance Delay, incident and PIREP, particularly repeated defect, shall be investigated for root cause by Deputy Chief Engineer (Technical Services Engineering) concerned in coordination with Deputy Chief Engineer (planning) concerned. Maintenance error shall be categorized and details of errors shall be entered in ‘Maintenance Error Report’.
Deputy Chief Engineer (Technical Services Engineering) concerned shall develop action plan against each maintenance error finding during line / cabin maintenance, which shall include recurrent training session for concerned maintenance personnel to prevent possible reoccurrence of such maintenance error. Action plan may include Technical Service Requirement (TSR), One-time Inspection upon similar aircraft type or equipment. Issuance of Quality Advisory / Technical Notice, revision of Task card, etc shall be suggested to concerned, if required. Action plan shall be followed-up by Deputy Chief Engineer (Technical Services Engineering) concerned until it is accomplished, alongwith filing of Maintenance Error Report and Action Plan for records.
2.25.2.3 Base Maintenance Deputy Chief Engineer (Technical Services Engineering) concerned shall monitor maintenance activities during aircraft base check and aircraft furnishing for any condition that may lead to a maintenance error. Defects reported on final operation / system check and PIREPS from first three post-check scheduled flights shall also be investigated for maintenance errors. Where a maintenance error is found, Aircraft Engineer (Technical Services Engineering) concerned shall prepare Maintenance Error Report with details of occurrence. Deputy Chief Engineer (Technical Services Engineering) concerned shall develop an action plan against each report and follow-up the accomplishment. Records shall be maintained in similar manner by Deputy Chief Engineer (Technical Services Engineering) concerned.
2.25.2.4 Overhaul Shops (Aircraft components including Engine & APU)
Deputy Chief Engineer (Technical Services Engineering) concerned shall investigate all premature component removals and post-maintenance test bench failures (rework conditions) for possible maintenance errors. Where maintenance error is found, Aircraft Engineer (Technical Services Engineering) concerned shall prepare a Maintenance Error Report with details of occurrence. Deputy Chief Engineer (Technical Services Engineering) concerned shall develop an action plan. Follow-up of plan accomplishment, preparation / submission of monthly report and record management shall be carried out in similar manner as for Line and Base Maintenance.
To define PIA Engineering & Maintenance policies regarding process of shift / task handing over during aircraft / aircraft components maintenance.
2.26.2 PROCEDURE
2.26.2.1 Generalities Incharges of both incoming and outgoing shifts shall communicate at handing / taking over, in an effective manner, for completion of continued maintenance activities. Aircraft Engineer (production) concerned shall also participate in the process. In absence of Incharge, senior most Aircraft Engineer available shall act as Incharge of the shift. Handing / taking over takes place at shifts overlap timings. Line / Cabin maintenance activities are being performed round-the-clock in three-shift pattern. Aircraft base checks and aircraft component maintenance areas follow two-shift pattern and personnel are called in night-shift due to any organisational requirement. Shift handing over registers shall be used for recording of comprehensive details about maintenance activities performed during the shift, instructions for coordination with other sections and any leftover maintenance task, etc. Deputy Chief Engineer (production) concerned shall review and signed the register on daily basis to ensure recording of effective communication and if deemed necessary, may issue technical / administrative instructions through same register for maintenance personnel. Handing over register shall be maintained on monthly basis (one register per month) and archived for a period of two years by Deputy Chief Engineer (production) concerned. In case of loss or destruction, these registers may be utilised as input for reconstruction of technical records.
2.26.2.2 Line / Cabin Maintenance Shift Handover As a standard practice, remaining task / subtask in Technical Logbook, Cabin Logbook and continuation sheets of aircraft shall be pursued. Shift handing over register shall be used for other salient tasks, not recorded in logbooks or continuation sheets. Format of register may vary in different sections in Line / Cabin Maintenance division, but should contain following information alongwith acknowledgement signatures of Deputy Chief Engineer (production) concerned: ♦ Aircraft movement, manpower deployment and extended duty / over stay ♦ Brief description of defects, handled during shift on different aircraft ♦ Details / information of significance, that needs to be recorded ♦ Open defects and reasons for carrying forward such defects ♦ Instructions / information to next shift for any leftover maintenance task ♦ Instructions from planning staff for any scheduled / unscheduled maintenance ♦ Requirements from Technical Services Engineering
2.26.2.3 Base Maintenance Shift Handover
Format of handing over registers may vary in different sections of Base Maintenance
division but should contain following information alongwith acknowledgement signature of Deputy Chief Engineer (production) concerned on next working day: ♦ Shift / Group, manpower deployment and extended duty / overstay ♦ Details / information of significance, that needs to be recorded ♦ Instructions for next shift regarding any leftover maintenance task ♦ Instructions from planning staff for any scheduled / unscheduled maintenance ♦ Requirements from Technical Services Engineering
2.26.2.4 Avionics Overhaul Shift Handover Format of handing over register may vary in different sections of Avionics Overhaul division but should contain following information alongwith acknowledgement signatures of Deputy Chief Engineer (production) concerned on next working day: ♦ AOG / critical items status / information ♦ Manpower deployment ♦ Brief description of shift activities ♦ Information to be communicated to other sections by incoming shift
2.26.2.5 Power Plant Overhaul Shift Handover Format of handing over register may vary in different sections of PowerPlant Overhaul division but should contain following information alongwith acknowledgement signature of Deputy Chief Engineer (production) concerned on next working day: ♦ AOG / critical items status / information ♦ Job descriptions as provided by outgoing shifts ♦ Manpower deployment ♦ Brief description of shift activities ♦ Information to be communicated to other sections by incoming shift
2.27 PROCEDURES FOR NOTIFICATION OF MAINTENANCE DATA INACCURACIES AND AMBIGUITIES, TO THE TYPE CERTIFICATE HOLDER
2.27.1 PURPOSE To define PIA Engineering & Maintenance policies regarding management of notification for inaccuracies / ambiguities in maintenance data, observed by maintenance personnel during maintenance on aircraft / aircraft component, to Type Certificate / Supplemental Type Certificate holder / Original Equipment Manufacturer (OEM).
2.27.2 PROCEDURE
2.27.2.1 Generalities Inaccuracy / ambiguity in maintenance data is defined as an inappropriate, incomplete or doubtful maintenance instruction that may be noticed by maintenance personnel during maintenance on aircraft / aircraft components. An inaccuracy / ambiguity, observed in maintenance data must be notified to Type Certificate / Supplemental Type Certificate holder / Original Equipment Manufacturer (OEM). Maintenance data shall cover all type of documents referred in MOE Chapter 2.8. For Task cards, Deputy Chief Engineer (Maintenance Program & Reliability) shall be notified for inaccuracy / ambiguity. In case of Task cards / Work cards / Worksheets, locally developed / derived from manufacturer maintenance data, inaccuracy / ambiguity shall be notified for corrective measure to Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned shall be notified. Deputy Chief Engineer (Quality Audit) shall be informed for remedial action in case of an inaccuracy / ambiguity, observed in organisational procedure.
2.27.2.2 Notification Process Whenever an inaccuracy / ambiguity in maintenance data is found during maintenance on aircraft / aircraft component, ‘Maintenance Data Inaccuracy Report’ (Refer AMP 2-4 for sample) in duplicate shall be raised. Deputy Chief Engineer (production) concerned shall review nature of inaccuracy / ambiguity and coordinate with Deputy Chief Engineer (Technical Services Engineering) concerned for possible modification in maintenance instructions. Deputy Chief Engineer (Technical Services Engineering) concerned shall report such inaccuracy / ambiguity in maintenance data to the manufacturer. For local documents, Deputy Chief Engineer (concerned) shall be notified.
2.27.2.3 Maintenance Instructions Modification Deputy Chief Engineer (production) concerned shall workout maintenance instructions modification on interim basis for completion of maintenance task, until inaccuracy / ambiguity is resolved. Maintenance instructions can be modified only if this will result in equivalent or improved maintenance standards. Modified instruction shall only relate as how to perform a particular maintenance task and shall never be applicable to engineering design of any repair / modification or Critical Design Configuration Control Limitations (CDCCL) items. Aircraft Engineer (production) concerned shall demonstrate safe / appropriate execution of proposed modification in maintenance instructions. Deputy Chief Engineer (Technical Services Engineering) concerned shall verify demonstration / operational check and
send report to Chief Engineer (Airworthiness Management). Modified maintenance instructions shall be submitted to Type Certificate / Supplemental Type Certificate holder / Original Equipment Manufacturer (OEM) for endorsement. Deputy Chief Engineer (Technical Services Engineering) concerned shall incorporate endorsed modified maintenance instructions in affected maintenance data for interim period (Refer MOE Chapter 2.8 for details). All such modified maintenance instructions must be used in following situations only: ♦ Objective of maintenance data to be achieved in more practical / efficient manner ♦ Maintenance cannot be performed by following provided maintenance instructions ♦ Use of alternative tooling / equipment is necessary
2.27.2.4 Incorporation of Amendments Upon receipt of modified maintenance instructions in form of Temporary Revision from Type Certificate holder / Supplemental Type Certificate holder / Original Equipment Manufacturer (OEM), Deputy Chief Engineer (Technical Publications & Records) shall incorporate revision in maintenance data, superseding locally modified maintenance instructions, if incorporated earlier. Deputy Chief Engineer (concerned) shall incorporate correction in case of local documents.
2.27.2.5 Maintenance Data Modifications Records Complete record of inaccuracies / ambiguities in maintenance data shall be maintained by Deputy Chief Engineer (Technical Services Engineering) concerned. Records shall include complete process from notification of inaccuracy / ambiguity to incorporation of amendment in maintenance data with traceability for maintenance instructions identifying any modification.
2.27.2.6 Customer Aircraft In case of maintenance data provided by customer, inaccuracy / ambiguity discovered shall be reported ‘Maintenance Data Inaccuracy Report’ to Deputy Chief Engineer (production) concerned, who shall review and send report to Deputy Chief Engineer (Technical Services Engineering) concerned with copies of relevant maintenance data. Deputy Chief Engineer (Technical Services Engineering) concerned shall inform the customer for inaccuracy / ambiguity, observed in provided maintenance data. Whenever, asked to process inaccuracy / ambiguity on behalf of customer, the Organisation shall follow above-mentioned procedure under a customer work order.
To define PIA Engineering & Maintenance policies regarding planning activities during maintenance on aircraft / aircraft components.
2.28.2 PROCEDURE 2.28.2.1 Generalities
PIA Engineering & Maintenance ensures through generalized and specific processes that all scheduled maintenance shall be planned with regards to availability of required trained personnel, tooling, test equipment, material, maintenance data and facilities. Following information, to ensure effective production planning in the Organisation, shall be furnished to all concerned as per applicability: ♦ Monthly hangar visit plan ♦ Daily aircraft movement schedule ♦ Master man-hour plan ♦ Major Item Change (MIC) sheets ♦ Consolidated list of available tooling / equipment ♦ Aircraft components and materials Status ♦ Critical / AOG part list to overhaul shops
2.28.2.2 Organizing Shifts and Human Performance Limitations PIA Engineering & Maintenance takes into account human performance limitations. For this matter, duties should be scheduled on eight-hourly basis with maximum extension upto 16 hours. Minimum rest between 2 duty cycles shall be limited to 12 hours. Over and above, no maintenance personnel shall perform extended duty of 16 hours on more than 2 occasions in any seven-days time period. Deputy Chief Engineer (production) concerned shall take into account that no critical task shall be performed by the person performing extended duty. Deputy Chief Engineer (production) concerned shall ensure that during maintenance work, shifts and teams are organized and provided with all required resources to ensure completion of maintenance without undue time pressure.
2.28.2.3 Base Maintenance Chief Engineer (Maintenance Operation Centre) shall plan and schedule fortnightly pre-dock meetings to be attended by all concerned. Aircraft base checks shall be discussed and planned two months in advance during such pre-dock meeting. Chief Engineer (Engineering Business Development) shall communicate customer requirements for availability of docks. Inputs such as hangar visit plan, scheduled checks, applicable Airworthiness Directives / mandatory modifications, Major Item Change (MIC) sheet, personnel and material requirements shall be reviewed. Production plan shall be finalized for each check by Chief Engineer (Base Maintenance) and shall be followed up by Deputy Chief Engineer (Planning) concerned. Production plan base check shall encompass resources including
material, manpower, tooling / test equipment, maintenance data, etc. required for a particular base check. Deputy Chief Engineer (Planning) concerned shall monitor timely execution of the maintenance activities as per production plan. Daily production meetings shall be held to review progress on base checks being performed. Progress on scheduled base maintenance shall also be communicated to Chief Engineer (Maintenance Operation Centre) for required actions and information.
2.28.2.4 Line Maintenance Deputy Chief Engineer (planning) concerned shall plan production for assigned aircraft type. Deputy Chief Engineer (planning) concerned shall organize provisioning of all required resources to maintenance personnel during line maintenance activities. Line maintenance activities are primarily based upon aircraft daily movement schedule. Formulating leave rosters and trainings in advance, for each calendar year, ensures manpower availability. Work package for check ‘A’ and Work cards for other planned engine / APU change are received from Technical Records Officer (concerned), at least 72 hours before planned check / task. All tasks shall be carried out under supervision of Shift Incharge, available in each shift.
2.28.2.5 Aircraft Component Overhaul Shops Deputy Chief Engineer (planning) concerned shall develop long-term plan, reviewed every month, based upon Major Item Change (MIC) sheet, removals during base check and inputs from PIA Aircraft Maintenance Management Information System (PAMMIS) for aircraft components (LRUs) stock position. Production plan shall include provisioning of resources to maintenance personnel. Such production plan shall be approved by Chief Engineer (concerned) and followed up by Deputy Chief Engineer (production) concerned. Deputy Chief Engineer (production) concerned shall develop short-term production plan to accommodate critical / AOG items demand. Deputy Chief Engineer (planning) concerned shall provide feedback on production to Deputy Chief Engineer (Rotable Planning). Progress on production plans shall be reviewed at each overhaul shop through weekly meeting.
2.28.2.6 PowerPlant Overhaul Deputy Chief Engineer (Schedule & Check Planning) shall provide scheduled engine / APU removal forecast every month, which includes removals for next three months. Deputy Chief Engineer (Planning) concerned shall develop production plan against these scheduled removals and also cater for removals during base checks. Production Plan shall also include provisioning of all resources to maintenance personnel. Production plan shall be developed on monthly basis and reviewed in weekly meetings. Deputy Chief Engineer (production) concerned shall attend weekly meetings. Deputy Chief Engineer (Technical Services Engineering) Line Maintenance – Aerospace shall perform on-wing monitoring of engines to estimate any unscheduled removal.
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part L2 Edition: 3 Revision: 0 Issue: April’ 08 Page 1 of 2
MAINTENANCE ORGANISATION EXPOSITION
PART L2: ADDITIONAL LINE MAINTENANCE PROCEDURES
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part L2 Edition: 3 Revision: 0 Issue: April’ 08 Page 2 of 2
L 2.1 LINE MAINTENANCE CONTROL OF AIRCRAFT COMPONENTS, TOOLS, EQUIPMENT, ETC.
L2.1.1 PURPOSE
To define PIA Engineering & Maintenance policies for management of components, materials, tooling / equipment specific to line maintenance activities.
L2.1.2 PROCEDURE In general, control of aircraft components, tooling / equipment and maintenance data, for line maintenance activities shall be the same as for other areas of the Organisation. Procedures applicable to Line Maintenance division as well as line stations, if specified in MOE Chapter 5.3, are as follows: ♦ MOE Chapter 2.1 ♦ MOE Chapter 2.2 ♦ MOE Chapter 2.3 ♦ MOE Chapter 2.4 ♦ MOE Chapter 2.5 ♦ MOE Chapter 2.6 ♦ MOE Chapter 2.8 ♦ MOE Chapter 2.19
L2.1.2.1 Additional Processes
Transfer of serviceable aircraft components from maintenance base to any line station shall be performed by Parts Control section under supervision of Deputy Chief Engineer (Rotable Planning). Defective aircraft components, removed at line stations, shall be routed by Deputy Chief Engineer (concerned) production for despatch to the base. As a policy, no unserviceable component shall be despatched to the base on the same aircraft / flight from which it has been removed at any line station. Deputy Chief Engineer (concerned) production, at each line station, shall be responsible for control of tooling / equipment and compliance of above-mentioned procedures at respective line station. Appendix IV to EASA Part-145 requirements specifies conditions for certifying staff at line stations, which are covered by MOE Chapter 3.4.
L 2.2 LINE MAINTENANCE PROCEDURE RELATED TO SERVICING / FUELLING / DE-ICING ETC.
L2.2.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding different procedures used during line maintenance operation, such as: ♦ Aircraft servicing ♦ Aircraft fuelling ♦ Aircraft de-icing
L2.2.2 PROCEDURE
L2.2.2.1 General
Specific maintenance procedures as detailed in MOE Chapter 2.24 shall be applicable to Line Maintenance division as well.
L2.2.2.2 Servicing Procedure Servicing shall be defined as cleaning / lubrication / replenishment of fluids, not involving disassembly. Servicing shall be performed during scheduled tasks in accordance with Aircraft Maintenance Program (Transit / Daily / ‘A’ checks, etc.). Task cards for servicing shall be launched and archived by Technical Records section, in coordination with Aircraft Engineer (Development Engineering / Technical Services Engineering) and Aircraft Engineer (planning) concerned. Deputy Chief Engineer (Development Engineering / Technical Services Engineering) concerned shall ensure update and traceability of the documents. Servicing can also be carried out during unscheduled tasks. Aircraft Engineer (production) concerned, in Line Maintenance division, is responsible to fill in engine oil replenishment record in Aircraft Technical Logbook on each arrival of the aircraft. Appropriate entries in check sheets / Task cards, if raised for particular ground time of aircraft, shall also be filled and signed. Servicing provided to customer aircraft shall be dependent on the nature of contract. However, procedures detailed by customer / operator shall be applicable to third party aircraft in addition to PIA Engineering & Maintenance procedures.
L2.2.2.3 Fuelling Procedure
a) Refueling For refueling an aircraft, Aircraft Engineer (production) concerned shall comply with the following instructions to implement PIA operational procedures for refueling (corporate responsibilities, safety measures, passenger information, etc.): i. Aircraft should be parked in open area, outside hangar, for any type of refueling.
Fuel quantity required for each flight shall be computed and raised on a ‘Fuel Indent Loading Instructions’ by flight operations. Such proforma is then sent to Shift Incharge (Line Maintenance) at base and to Deputy Chief Engineer / Aircraft Engineer (production) concerned at respective line stations.
ii. Aircraft Engineer (production) concerned shall receive two copies of proforma from the shift Incharge and raise refueling request to the refueling organisation.
iii. Prior to refueling, fuel contamination check of source shall be carried out. iv. Aircraft Engineer (production) concerned shall certify fuel uplift slip raised by the
refueling organisation in duplicate. v. One copy of fuel uplift slip and indent proforma, completed by Aircraft Engineer
(concerned) production, shall be attached with log slip detached from Aircraft Technical Logbook at base or line station (green copy). Second copy of fuel up-lift slip and indent proforma shall be kept in Aircraft Technical Logbook for reference of the cockpit crew.
b) De-fueling
De-fueling of aircraft shall be restricted to minimum and is done when necessary for any maintenance task or flight requirement. However, process for de-fueling should be as follows: i. Aircraft Engineer (concerned) production, ensuring that aircraft is parked outside
hangar, shall inform de-fuelling company with written request on fuel requirement slip.
ii. Aircraft should be de-fuelled as per Aircraft Maintenance Manual. iii. Aircraft Engineer (production) concerned shall certify de-fuelling quantity slip raised
by refueling company, ensuring that all precaution are being observed. L2.2.2.4 De-Icing
Due to warm weather conditions at the base, de-icing procedure is not applicable. However, Deputy Chief Engineer (Rotable Planning) shall ensure that the de-icing procedures as per IATA standards are clearly mentioned in each contract with Technical Handling Agent at line station. Line station audits carried out jointly by internal Quality Auditors and Pakistan Civil Aviation authority surveyors shall verify procedures followed by contracted organisation with regards to de-Icing of the aircraft.
L 2.3 LINE MAINTENANCE CONTROL OF DEFECTS AND REPETITIVE DEFECTS
L2.3.1 PURPOSE To define PIA Engineering & Maintenance policies regarding line maintenance control of defects and repetitive defects.
L2.3.2 PROCEDURE L2.3.2.1 General
Procedure is applicable on PIA and customer aircraft. However, for customer aircraft, procedure detailed in MOE chapter 4.2 shall be followed additionally. Line Maintenance division shall perform all aircraft maintenance required, including defect rectification and carry out necessary corrective actions that falls within the scope of Line Maintenance division as and when requested by PIA flight operations, Quality Assurance or the customer / operator. Aircraft Technical Logbook shall remain primary document to record line maintenance carried out on the aircraft. Deputy Chief Engineer (production) concerned shall perform regular spot checks of Aircraft Logbook for PIA Fleet and take immediate corrective measures against any discrepancy found. Aircraft Technical Logbook shall have a page for ‘Attention to Crew’, inserted in the HIL pocket. Notes on the page shall bear signature, date and certification authorisation number of Certifying Staff. Aircraft Engineer (production) concerned, upon releasing aircraft from the station, shall ensure that previous and irrelevant entries are crossed out from ‘Attention to Crew’ page in time, but shall remain legible upon such crossing out. Each Logbook page has block on left hand side for reporting defects, observed during maintenance by Aircraft Engineer (production) concerned and crew-generated reports, logged upon flight / pre-flight observations. Aircraft Logbook shall be used for: ♦ Recording aircraft defects and their rectifications ♦ Crew liaison ♦ Data source for defect analysis (by PIA Engineering & Maintenance)
L2.3.2.2 Defect Deferment and Minimum Equipment List (MEL) Refer to general rules detailed in MOE Chapter 2.15 through 2.20. Aircraft Engineer (production) concerned, holding appropriate certification authorisation, within applicable scope of Minimum Equipment List (MEL), can defer the defect. Aircraft Engineer (production) concerned shall follow MEL instruction for carrying forward a defect and also refer to Despatch Deviation Procedure Guide. Deferment of defects on aircraft shall be notified for the attention of Air Crew and Certifying Staff. This is meant to inform, other line stations or the base, of the non-standard configuration / operation of a system or aircraft component. Information / instructions for determination of measure of unserviceable equipment and systems, which may exist at commencement of a flight while still allowing safe operation of affected aircraft, shall be provided in the form a Minimum Equipment List (MEL). An MEL is issued on the basis of MMEL provided by Type Certificate holder. The
customized MEL shall be sent to the Competent Authority for approval. MEL shall also give a limit (Flight Hours, Flight Cycles, Landings and / or Calendar days), beyond which aircraft shall be grounded and defect is to be rectified on must basis.
L2.3.2.3 Defect Reporting, Recurrent Defects, Repetitive Defects Documents used for defect reporting rectification and certification together with routine inspection documents shall be used for recording, statistical evaluation and information purpose and kept by Technical Records section for further reference. All Pilot Reported (PIREP) defects and their rectifications should further be recorded in PIA Aircraft Maintenance Management Information System (PAMMIS) by Technical Records section, according to individual aircraft, ATA chapter, system and sub-system to facilitate critical study and analysis (Refer MOE Chapter 2.21). All entries on aircraft Technical Logbook shall be made using Ball Point Pen, pressed hard and shall remain legible even after crossing out. Major defect and defect that show recurring cycle (identified as week area) or unusual characteristics shall be picked up by Deputy Chief Engineer (planning) concerned in Line Maintenance for critical study and suitable remedial actions. Deputy Chief Engineer (planning) concerned shall also monitor situation closely until a satisfactory solution is achieved and highlight recurring defects / defects requiring immediate action to all concerned. Track records of such defects shall be maintained by Deputy Chief Engineer (planning) concerned as part of production planning document. Aircraft Engineer (Technical Services Engineering) concerned, shall also monitor repetitive defect and suggest remedial action in form of Technical Services Requirement (TSR) consequently. In addition to this, monthly defect statistics shall be presented by Deputy Chief Engineer (Technical Services Engineering) concerned and where PIREP rate exceeds the Alert Limit, shall notify concerned personnel for remedial action. When the customer / operator reports any failure of system as a recurrent problem, then the Customer’s Quality System management shall be informed of the corrective actions taken by PIA Engineering & Maintenance for rectification of defect at the base (Refer MOE Chapter 4.2).
L2.3.2.4 Release of Aircraft from Transit Station with Defect Covered Under MEL In case, where defect is observed en-route, every possible effort should be made to rectify it. Only, in exceptional cases, where defect cannot be rectified at line station and does not affect safety of aircraft, it may be “Carried Forward (C/F)” in Aircraft Technical Logbook for rectification at the base. Carried forward defect shall be entered in the “Carried Forward Items List” in Aircraft Technical Logbook. One copy (blue) of Log slip shall be placed in C/F (Carried Forward) pouch in Aircraft Technical Logbook (Refer MOE Chapter 2.16).
L2.3.2.5 Release of Aircraft from Maintenance Base with Deferred Defect When aircraft lands at maintenance base with a carried forward defect, all possible efforts must be made to rectify the same. A defect may be carried forward while aircraft is departing from maintenance base, but within repair intervals as mentioned in MEL according to its category. Aircraft Engineer (production) concerned, upon releasing such
aircraft with deferred defect, shall also enter carried forward defect in PIA Aircraft Maintenance Management Information System (PAMMIS) for the information to all concerned and record keeping purposes.
L2.3.2.6 Release of Aircraft from Outstation with Defect Not Covered Under MEL Under normal circumstances, no such release shall be allowed, however in extreme emergency, procedure is as follows:
a) PIA aircraft If an aircraft, at line station, is required to be released with carried forward defect, not covered under the Minimum Equipment List (MEL), Chief Engineer (Quality Assurance) must be informed immediately. Chief Engineer (Quality Assurance) alongwith Director (Engineering & Maintenance) and Director (Flight Operations) shall study the defect and determine impact on safety of aircraft. Chief Engineer (Quality Assurance) shall then communicate such situation to the Competent Authority of aircraft registration. When Chief Engineer (Quality Assurance) reaches to conclusion that the aircraft can be released for flying to maintenance base, the case shall formally be presented to the Competent Authority of aircraft registration for approval. Aircraft shall be released only after obtaining approval from the Competent Authority of aircraft registration.
b) Customer Aircraft In case of customer aircraft, the Competent Authority of operator / customer aircraft registration shall be contacted to obtain an approval for release. This procedure shall only be followed to retrieve the aircraft back to maintenance base, ensuring that flight safety is not compromised.
L2.3.2.7 Technical Delay If there is a delay of more than 15 minutes beyond scheduled departure time, due to technical / maintenance reasons, it shall be considered a “Technical Delay”. All technical delays shall be analysed and the despatch reliability is re-established. All delays of more than 15 minutes must be informed to the Deputy Chief Engineer (production) concerned by Aircraft Engineer (production) concerned on ‘Delay Report’ form (Refer AMP 2-3 for sample). Deputy Chief Engineer (production) concerned shall forward the report to Deputy Chief Engineer (Technical Services Engineering) Technical Services for investigation of the technical delay.
L 2.4 LINE PROCEDURE FOR COMPLETION OF TECHNICAL LOG
L2.4.1 PURPOSE To define PIA Engineering & Maintenance policies regarding completion of Technical Logbook, an official document for recording aircraft defects and their rectification by Line Maintenance personnel.
L2.4.2 PROCEDURE
L2.4.2.1 General Operator documents prescribe requirement for logbook and recommends compulsory existence of Aircraft Technical Logging system to: ♦ Detail information about each flight, ensuring continued flight safety ♦ Current aircraft Certificate of Release to Service ♦ Current maintenance statement giving maintenance status ♦ All outstanding deferred defect that affect operation of aircraft ♦ Any necessary guidance instructions on maintenance support arrangement Aircraft Technical Logbook contains following data: ♦ Defect and its rectification ♦ List and contents of deferred defects under MEL ♦ Components removal / installation details ♦ Notes for the attention of Crew when required ♦ Engine and APU oil filling record ♦ Certificate of Maintenance review (as applicable) ♦ Aircraft release slip
L2.4.2.2 Handling of Logbook and Release to Service
Each maintenance Log slip contains one snag and its rectification with a provision for two component changes. There shall be four copies of aircraft maintenance LOG slip:
Original White Stays in logbook
Copy 1 Blue To identify Carried Forward defect
Copy 2 Green To be removed at maintenance base & line stations
Copy 3 Pink For entry in PAMMIS by Technical Records personnel Flight reported / inspection snags, found during Transit / Turnaround / ‘A’ checks and rectifications, shall be entered in Aircraft Technical Logbook. For cabin defects, Cabin Logbook shall be used. All Major Item Change (MIC) Sheet entries may only be closed after appropriate entry is made in Aircraft Technical Logbook. Aircraft Engineer (production) concerned, being certifying staff holding appropriate certification authorisation, shall issue Certificate of Release to Service for aircraft. Prior to the release to service is signed, certifying staff must ensure that entries made since last release to service are closed, details of rectifications are complete in regard to Part number, serial number, etc. and reference to maintenance data is made where required. Aircraft Engineer (production) concerned is also responsible for the physical condition of
the Technical Logbook folder specified for PIA Aircraft Technical logbooks. Certifying staff shall enter details of check performed with appropriate reference to Task cards / Work cards, if completed during particular check on the release Log slip (Refer MOE Chapter 2.16 for details). For rectification of deferred defects, carried forward items list shall be updated with relevant Log slip item number and certification authorisation number. For completion of Aircraft Technical Logbook on customer aircraft, MOE Chapters 2.16, 4.1 and 4.3 shall be referred.
L 2.5 LINE PROCEDURE FOR POOLED PARTS AND LOAN PARTS L2.5.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding management of pooled and loan aircraft components.
L2.5.2 PROCEDURE
L2.5.2.1 General Under ‘International Airlines Parts Pool Arrangements’, PIA Engineering & Maintenance shall borrow / loan aircraft components at line stations and maintenance base under mutual agreement with other EASA Part-145 Approved / Accepted Maintenance Organisation. Such participation is indicated in Pool / Loan Booklet available at each line station on PIA route map and in Line Maintenance offices at the base. Loaned aircraft component shall be returned within a period of seven days. At line station, Deputy Chief Engineer (production) concerned / Technical Handling Agent shall be allowed to arrange pool / loan aircraft component from an EASA Part-145 Approved / Accepted Maintenance Organisation (Refer MOE Chapter 2.2 for details). Aircraft Engineer (production) concerned either posted at line station or accompanying the aircraft shall be responsible to follow this procedure. If no such personnel are available, Technical Handling Agent shall be responsible for the process as per contract. Before utilizing, pool / loan aircraft component shall be inspected to ensure its integrity, compliance to documentation provided and availability of authorised released certificate (EASA FORM 1) or other acceptable serviceable tag. When installing pool / loan aircraft component, corrective action shall be entered in Aircraft Technical Logbook, listing item as a pool / loan aircraft component and identifying aircraft component provider. Where aircraft is grounded at line stations and components are not available with valid EASA FORM 1, it shall be permissible to install a component without EASA FORM 1, provided a valid Serviceable Tag is available and component is in acceptable physical condition. Such installed component shall be removed within 30 flight hours or when aircraft returns to maintenance base, whichever is earlier.
L2.5.2.2 Handling of Pool / Loan Parts Information of pool / loan item installation on PIA aircraft, at International line station, shall be communicated to Deputy Chief Engineer (Rotable Planning) via telex / e-mail by Technical Handling Agent / Aircraft Engineer (production) concerned. Process detailed in MOE Chapter 2.19 shall be followed, for return of aircraft component to the ‘OWNER’.
L2.5.2.3 Cannibalization An aircraft component is referred to as cannibalized component when removed from an aircraft / aircraft component (NHA – Next Higher Assembly) as ‘Serviceable’ for fitment on another aircraft / aircraft component without performing any maintenance on said component. Aircraft component shall only be cannibalized, when ensured that required component is unavailable with Stockroom (concerned) and Flight Pack section. Cannibalized aircraft component cannot be installed on customer aircraft. However, such component can only be accepted from customer for fitment on its own aircraft / aircraft
component with authorised released certificate (EASA Form 1), issued by customer. Cannibalized aircraft component shall only be installed after ensuring the compatibility through maintenance data. For cannibalization of an aircraft component / sub-assembly, following may be different cases:
a) Cannibalization from Aircraft Aircraft Engineer (concerned) production shall generate ‘Cannibalization Form’ (Refer AMP 2-3 for sample) and hand over a copy to donor section for record. Another copy of the form shall be sent to Deputy Chief Engineer (Rotable Planning) for validation of such cannibalization and further action. Aircraft Engineer, performing cannibalization, must attach ‘Cannibalization Tag’ (Refer AMP 2-1 for sample) to cannibalized item or close to location and shall make entries in Aircraft Technical Logbook of both aircraft.
b) Cannibalization from Aircraft Component An aircraft component / sub-assembly may be cannibalized from serviceable component (NHA – Next Higher Assembly), if available in shop, with prior consent of Deputy Chief Engineer (production) concerned. Aircraft Engineer (concerned) production, requesting cannibalization, shall generate ‘Cannibalization Form’ and attach ‘Cannibalization Tag’ to donor item. Entries shall be made work package / worksheets of donor component and Aircraft Technical Logbook. Cannibalization form shall be handed over to donor section for record and restoration of component serviceability. Deputy Chief Engineer (planning) concerned shall be informed for further action and follow-up.
c) Cannibalization of LRU Sub-assembly from Stockroom In case, where it is imperative to remove aircraft component / sub-assembly (LRU) from another component (NHA – Next Higher Assembly) in stockroom, Incharge Stockroom (concerned) shall attach Cannibalization Tag and received Form with LRU Tracking / Serviceable Tag of donor assembly. Such donor component shall be sent to concerned shop by Incharge Stockroom (concerned), alongwith all documents / tags through Parts Control section, for restoration of component serviceability.
d) Cannibalization at Line Station Before releasing an aircraft at line station, on which cannibalized aircraft component has been installed, Deputy Chief Engineer / Aircraft Engineer (production) concerned shall send information of cannibalized aircraft component including serial number to Deputy Chief Engineer (Planning) concerned with a copy to Deputy Chief Engineer (Rotable Planning) for further action. (Refer AMP 2-3 for process flow).
e) LRU Tracking Procedure (Alternate Process)
Aircraft Engineer (production) concerned shall record cannibalization need in Parts Control register, acquiring blank LRU Tracking Tag for filling cannibalization details in ‘Cannibalization’ portion of LRU Tracking Tag. Cannibalized component details shall be recorded in ‘Serviceable’ portion, whereas defective component details shall be recorded in ‘Unserviceable’ portion. Defective component and LRU Tracking Tag shall be returned to Parts Control section for further processing.
L 2.6 LINE PROCEDURE FOR RETURN OF DEFECTIVE PARTS REMOVED FROM AIRCRAFT
L2.6.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding return of defective aircraft components, removed from an aircraft, during line maintenance activities.
L2.6.2 PROCEDURE
L2.6.2.1 General At the line station, defective aircraft component removal and tagging shall be performed under the responsibility of Aircraft Engineer (production) concerned, either posted at such line station or accompanying the aircraft. If no such personnel are available, Technical Handling Agent shall be responsible for the process as per contract. Procedure for returning defective aircraft component, removed from aircraft, shall be the same as stated in MOE Chapter 2.19. If applicable, defective aircraft component shall be despatched to outside contractor, following the process detailed in MOE Chapter 2.20.
L2.6.2.2 Flight Pack Aircraft Flight Pack shall consist of aircraft components, material and tooling required for rectification of defects at line stations. Such items shall be stored in containers, securely placed in aircraft cargo hold. Selection of contents for Flight Pack shall be based on Minimum Equipment List (MEL) for aircraft and the organisational in-service experience. For ready reference, Flight Pack Items List shall be kept at a designated location in the aircraft cockpit.
L2.6.2.3 Flight Pack Procedure All maintenance personnel, utilizing any item from the Flight Pack, shall act in accordance with the following set of instructions: In rectification column of Aircraft Technical Logbook, Aircraft Engineer (production) concerned shall make a clear entry by stating that particular aircraft component / material has been used from Flight Pack for defect rectification. Aircraft component / material, used from Flight Pack at line station, should be crossed out from Flight Pack Item List. Flight number, sector, date, location, signature and certification authorisation number must be mentioned against deletion. Aircraft Engineer (production) concerned shall ensure that defective aircraft component is returned to maintenance base by normal stores shipment. It is ensured that affected aircraft / flight are not used for shipment of such defective aircraft component. On arrival of aircraft at maintenance base, Flight Pack section under supervision of Deputy Chief Engineer (Rotable Planning) shall review Aircraft Technical Logbook and Flight Pack Item list. If any item is found consumed, same shall be drawn from respective Stockroom (Refer MOE Chapter 2.3) and replenished accordingly.
L2.6.2.4 Amendments in Flight Pack List
Amendment for the content of Flight Pack Items list shall be initiated by Deputy Chief Engineer (Line Maintenance) concerned in consultation with Deputy Chief Engineer
(Rotable Planning) using form ‘Request for Addition / Deletion of Aircraft Parts in Flight Pack’ (Refer AMP 2-1 for sample). Proposed changes shall be verified by Deputy Chief Engineer (Technical Services Engineering) concerned, prior to submission to Chief Engineer (Quality Assurance) with suggestions / recommendations, if any. Chief Engineer (Quality Assurance) shall approve such amendment and copy shall be sent to the Competent Authority of aircraft registration, for information. Approved amendment shall be notified to Chief Engineer (Maintenance Operation Centre) for incorporation of updates in Flight Pack Items list for particular aircraft type / registration. Deputy Chief Engineer (Rotable Planning) shall ensure that revised Flight Pack Items lists are available with appropriate Flight Packs.
L 2.7 LINE PROCEDURE CONTROL OF CRITICAL TASKS L2.7.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding control of the critical tasks during line maintenance activities.
L2.7.2 PROCEDURE MOE Chapter 2.23 states requirements regarding control of critical tasks. During line maintenance, maintenance personnel in the Organisation shall follow same procedure.
3.1 QUALITY AUDIT OF ORGANISATION PROCEDURES 3.1.1 PURPOSE
To define PIA Engineering & Maintenance policies for monitoring compliance with the Part-145 requirements and organisational procedures through internal Quality Audits in the Organisation.
3.1.2 PROCEDURE
3.1.2.1 Generalities
PIA Engineering & Maintenance through their Quality Assurance division shall perform quality audits and feedback functions in a manner so as to ensure airworthiness of aircraft / aircraft components and good maintenance practices by adhering to Part-145 requirements and organisational procedures. Engineering Quality Assurance division shall, at all times, comply with the requirements stated in the Part-145 requirements under Part 145.A.65. Independence of Quality Assurance division is ensured through audits being performed by the authorised internal Quality Auditors not responsible for any function being audited. Deputy Chief Engineer (Quality Audit) shall prepare ‘Quality Audit Plan’ (Refer AMP 3-1 for sample) on annual basis, covering all the Part-145 requirements and organizational procedures. Audit plan shall be approved by Chief Engineer (Quality Assurance). Audit plan shall also contain a number of surveillance / un-scheduled audits covering the scope of Approval on sample basis and following areas:
♦ Quality audits of organisational procedures on scheduled / un-scheduled basis,
alongwith review of Maintenance Organisation Exposition (MOE) and Associate Maintenance Procedures (AMP).
♦ Quality audits of aircraft / aircraft components covering each product line once every 12 months.
♦ In case, maintenance activities are performed round-the-clock (three-shifts pattern), at least 25% of audits shall be carried out during evening / night shifts.
Authorized Aircraft Engineers (Quality Audit) shall perform audits in accordance with Quality Audit Plan. Deputy Chief Engineer (Quality Audit) shall review the Audit plan every six months for accomplishment and revision accordingly.
3.1.2.2 Principles of Quality Audits Purpose of Quality Audit is to establish information on which PIA Engineering & Maintenance can improve its performance. Principles of Quality Audits are not limited to but driven from the Part-145 requirements alongwith audit guidelines provided by the ISO 19011 standard. Audit process is divided into following steps:
a) Preparation
Pre-audit meeting for each audit shall be administered through attendance of all participating auditors (Refer AMP 3-1 for details). Deputy Chief Engineer (Quality Audit) shall define objective, scope and criteria for the audit alongwith nomination of Lead Auditor / Group Lead / Auditors. Previous NCRs of the particular division shall also be reviewed. Initial intimation with the request for confirmation of availability on particular
dates, shall be sent to Chief Engineer (concerned) for finalization of audit program / schedule. Lead Auditor / Group Lead shall prepare checklists as per applicability matrix of organisational procedures driven along side the Audit Plan. Upon confirmation, finalized detailed audit program / schedule shall be sent to Chief Engineer (concerned).
b) Audit Execution
Lead Auditor shall conduct the opening meeting with Auditee management. Audit shall be performed on sample basis by conducting interviews, making observation and checking records in accordance with predefined scope and criteria. Audit findings shall be recorded with agreement of Auditee on the evidences seen during the audit. Group Lead shall finalize Non-Compliance Report (AMP 3-1 for sample) against each audit finding. Acknowledgement signature of Auditee shall be acquired prior to closing meeting. In case of any conflict during audit activities, Group Lead shall immediately report to nominated Lead Auditor for resolution. Chief Engineer (Quality Assurance) and Deputy Chief Engineer (Quality Audit) shall be informed accordingly. Lead Auditor shall conduct closing meeting with Auditee management to conclude audit activity. Lists of findings and Non-Compliance Reports shall be handed over to Chief Engineer (concerned).
c) Post Audit Activity
Auditee shall propose corrective actions, against each Non-Compliance Report. Such corrective action shall be submitted to Quality Auditor within seven working days from date of closing meeting. Group Lead shall evaluate corrective action for removal of finding / root cause and implementation within the specified target closure date. Non-Compliance Report shall be returned to Auditee with comments, if further details of corrective action or documentary evidence are required for acceptance. Audit follow-up and verifications on corrective actions shall be performed in consultation with Deputy Chief Engineer (Quality Audit). Detailed Audit report for each audit shall be prepared by Deputy Chief Engineer (Quality Audit) for perusal of Director (Engineering & Maintenance) and the Accountable Manager.
3.1.2.3 Finding Levels Non Compliance Report (NCR), raised against observed finding, during audit shall be marked as ‘Level 1 / Level 2 / Level 3 Finding’ in accordance with the EASA guidelines. For Level 1 finding an immediate corrective action is must prior to resumption of particular activity, found in non-compliance state. For Level 2, auditee shall be provided with 60 days for the implementation of corrective actions. Level 3 findings shall be observations or suggestions for improvement.
3.1.2.4 Audit Records All records related to Quality Audits shall be archived in hard copies at Quality Audit section for a period of at least two years after closure of each audit.
To define PIA Engineering & Maintenance policies regarding internal Quality Audits of aircraft and aircraft components in the Organisation.
3.2.2 PROCEDURE
3.2.2.1 General
Aircraft / aircraft components Quality Audit shall be focused on verifying compliance of organizational procedures, competence of maintenance personnel, availability / use of appropriate maintenance data / tooling and completion of maintenance records. Aircraft Engineer (Quality Audit) shall perform sample audits of at least one product on each product-line per year to ensure quality products resulting from effective compliance of maintenance procedures. Annual Quality Audit Plan (Refer AMP 3-1 for sample) shall also cover product audits on aircraft and aircraft components. Records of such product audits shall be secured and archived in hard copies for a period of at least two years after closure of particular audit. Audit process shall be same as for Organisation procedures audit as described in this manual and shall not require any subcontracted resources.
3.2.2.2 Aircraft Quality Audits
Deputy Chief Engineer (Quality Audit) shall develop annual product audit plan. Such plan shall encompass Quality Audits of each type of aircraft covered in Organisation’s approved scope of work for each maintenance check being performed in the Organisation. Quality Audits of aircraft shall cover following areas alongwith sample-based verification of maintenance carried out on specific aircraft during a particular check: ♦ Aircraft cabin for emergency equipment, adequate appearance and satisfactory
operation of emergency systems ♦ Aircraft exterior for condition of airframe / engines / APU and evident leakages
(hydraulic, fuel, water, etc) ♦ Aircraft cockpit for emergency equipment availability, condition and labelling ♦ Availability of aircraft documents, related to maintenance activities ♦ Sufficiency of procedures resulting in good maintenance practices ♦ Availability and use of appropriate maintenance data ♦ Availability and use of recommended / approved tools and equipment ♦ Completion of maintenance records in an effective and timely manner ♦ Assessment for competence of personnel involved in maintenance activities ♦ Awareness of human factors, performance and limitations in aircraft maintenance
3.2.2.3 Aircraft Component Quality Audits
Quality Audit plan shall define schedule of audits for aircraft components, encompassing each product-line from the categories (C1 to C20) as per Organisation’s approved scope of work as defined in this manual. Quality Audits of aircraft components shall cover following areas alongwith sample-
based verification of maintenance carried out on specific component during particular scheduled / un-scheduled maintenance: ♦ Aircraft component’s physical condition ♦ Condition / serviceability status of work bench / work area ♦ Sufficiency of procedures resulting in good maintenance practices ♦ Availability and use of appropriate maintenance data ♦ Availability and use of recommended / approved tools and equipment ♦ Completion of maintenance records in an effective and timely manner ♦ Assessment for competence of personnel involved in maintenance activities ♦ Understanding of human factors, performance and limitations in aircraft component
maintenance 3.2.2.4 Unscheduled Aircraft and Aircraft Component Audits
Unscheduled aircraft and aircraft component audits may also be performed on the basis of significant findings of previous product / procedure audits, parameters such as high delay rate, more reworks, premature component removals, incidents / accidents and requirements from the Competent Authority / Accountable Manager. During verifications against corrective actions, Aircraft Engineer (Quality Audit) may perform an unscheduled product audits (Refer AMP 3-1 for details). Non-Compliance Report shall be raised against a finding during unscheduled audit. Audit process shall be same as for scheduled audit but shall not require the opening / closing meeting processes. Records of unscheduled audits shall be secured and archived in hard copies for a period of at least two years after closure of particular audit.
To define PIA Engineering & Maintenance policies regarding remedial (corrective) action against non-compliances generated during internal Quality Audit, root cause analysis and Management Reviews.
3.3.2 PROCEDURE
3.3.2.1 Corrective Actions
Deputy Chief Engineer (concerned), being Auditee, shall be responsible to propose and implement corrective action against each Non-Compliance Report. Where required resources are beyond authority of Deputy Chief Engineer (concerned), level shall be raised to Chief Engineer (concerned) and upto Director (Engineering & Maintenance). Proposed corrective action shall define actions to eliminate non-compliance and prevention of recurrence. Corrective action plan against Level 1 findings must be submitted to Quality Auditor within Twenty-four (24) hours. However, corrective action plans against Level 2 findings shall be submitted within Seven (07) working days. Corrective action plan for level 3 findings is not mandatory, however Auditee must reply to the observations within Seven (07) working days for records of Quality Audit Section. In case of any Level 1 finding, an immediate corrective action is the must prior to resumption of any particular activity. Non-compliance closure time limit for Level 1 and Level 2 findings shall not exceed seven (07) and sixty (60) calendar days, respectively. Extension in closure time limit shall only be allowed in extreme / justified cases. Request for such extension shall be submitted by Auditee, to Chief Engineer (Quality Assurance) after getting consent from the office of Director (Engineering & Maintenance). Quality Auditor shall only accept the proposed corrective action when satisfied that such corrective action shall result in removal of root cause of finding and target closure date for finding, specified in the Non-Compliance Report is being followed. Quality Auditor may ask for further details of corrective action(s) or samples of documents referred in the corrective action(s) from Auditee, before acceptance. In case of any Level 1 finding, Quality Auditor shall process acceptance of submitted corrective action plan within two (02) days. Whereas, for Level 2 finding, processing time for acceptance shall be four (04) days after receipt of corrective action plan. A copy of accepted Non-Compliance Report shall be sent to the concerned Auditee for record and follow-up accordingly. Upon acceptance of corrective action plan, Quality Auditor may subject closure of Non-Compliance Report to verification of implemented corrective action. Verification against Level 1 finding shall be performed immediately after implementation of corrective action. In case of Level 2 findings, verification of implemented corrective action shall be planned within 30 days past the closure 60 days period. Quality Auditor shall record the verification plan and intimate the Auditee for such verification.
3.3.2.2 Root Cause Analysis Whenever any finding is observed due to some action / activity of area beyond the scope
of Auditee division or the finding demands corrective action implementation in areas other than Audited section as well, Deputy Chief Engineer (Quality Audit), in coordination with representatives from all concerned / related sections shall perform Root Cause Analysis for such finding (Refer AMP 3-1 for details). An effective corrective action shall be finalised by Deputy Chief Engineer (Quality Audit) with consensus from one or more concerned / related sections. Chief Engineer (Quality Assurance) shall issue Quality Alert / Advisory (Refer MOE Chapter 3.13 for details) for corrective measures within the Organisation. Policy matters shall be forwarded to Director (Engineering & maintenance) for issuance of Engineering Instructions in this regards or to be taken as action item in Engineering Coordination meeting.
3.3.2.3 Audit reports
After conclusion of an audit, Deputy Chief Engineer (Quality Audit) shall submit an Audit Report to the Accountable Manager through Chief Engineer (Quality Assurance). Each audit report shall contain list of audit findings and summary of audit activities. Copy of Audit report shall also be sent to Director (Engineering & maintenance) for review and further necessary actions accordingly.
3.3.2.4 Management Reviews Regular meetings between Deputy Chief Engineer (Quality Audit) and Group Lead / Auditors shall be held to review progress on finalization of findings, corrective actions and verifications. Both qualitative and quantitative analyses for each audit shall be carried out for presentations during Management Reviews. Findings and progress on corrective actions shall be discussed in Management Review held, under the chair of Accountable Manager, every six month. Where Management review is chaired by Director (Engineering & maintenance) the minutes shall be provided to the Accountable Manager for his perusal. Root Causes and their possible corrective measures shall also be presented in management reviews. All nominated management personnel alongwith deputies and Quality Audit personnel shall attend such meetings. Management review meeting shall also encompass progress on Human Factors training programs and Ramp Inspections / Spot Checks. Management Review proceedings shall be recorded and minutes of the meeting shall be distributed to participants. Decisions made by the management shall be documented and Chief Engineer (Quality Assurance), on behalf of the Accountable Manager, shall pursue the required actions at different levels in the Organisation. Minutes shall be archived, at Quality Audit section, for a period of at least two years from the date of issuance of such minutes.
3.4 CERTIFYING STAFF AND CATEGORY B1 AND B2 SUPPORT STAFF QUALIFICATION AND TRAINING PROCEDURES
3.4.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding trainings and qualifications. This procedure also defines issuance, revalidation, extension and withdrawal of the certification authorisations for certifying staff related to the EASA Part-145 Approval.
3.4.2 PROCEDURE 3.4.2.1 General Procedure for Certifying Staff Qualification and Training
Certification authorisation shall be issued by Chief Engineer (Quality Assurance), clearly defining Scope of such authorisation alongwith limitations (if any). Following shall be verified prior to issuance of certification authorisation: i. Nominee is holding the Pakistan CAA issued Aircraft Maintenance Engineer (AME)
License or Aircraft Engineer’s Inspection Authorization (AEIA) Class-I Company Approval as per ICAO Annexure-1. In addition to qualification requirements, such nominee has completed initial Human Factors and Aviation Legislation training from an organisation acceptable to the Competent Authority.
ii. Type training at a level corresponding to Part – 66 Appendix III, for required scope, has been provided to the nominees.
iii. Minimum experience requirements of aircraft maintenance for initial issue shall be 5 years for line maintenance and 8 years for base maintenance.
iv. For initial issue / renewal / extension / revalidation of certification authorisation, nominee must be involved in at least six months of actual relevant aircraft / aircraft component maintenance experience in consecutive two years on required scope.
v. Competence assessment related to certification authorisation scope by Deputy Chief Engineer (Technical Services Engineering) concerned.
vi. Required Continuation training has been provided in the last two years period on organisational procedures, Human Factor and Aviation Legislation.
3.4.2.2 Basic and Type Trainings
Trainings for all personnel in the Organisation shall be managed through annual training plan, approved by Chief Engineer (HR, Training & Automation). Deputy Chief Engineer (HR, Training & Automation) shall enquire for any input from different areas for development of annual training plan. Such plan shall include list of trainees, anticipated training dates, trainings curricula, etc. (Refer AMP 3-2 for details). Trainings shall be subcontracted to PIA Training Centre and syllabi for training shall be approved by the Pakistan CAA. Classification of trainings shall be in accordance with the ICAO Annexure-1 and recommendations of Original Equipment Manufacturer (OEM). Type trainings at a level corresponding to the Specification 104, level III shall be based on Appendix IV of the Part-145 regarding special conditions for certifying staff. In general, induction training is arranged at vendor’s facility upon induction of new aircraft / aircraft component. In addition to these type trainings on aircraft / aircraft components, maintenance and associated equipment trainings shall also be conducted. ‘Basic’ trainings, as per the ICAO Annexure-1, are acceptable to the Pakistan CAA for application of Aircraft Maintenance Engineer (AME) Licence in LWTR for applicable
category. ‘Type’ trainings, for aircraft maintenance, are acceptable to the Pakistan CAA for AME Licence Type Ratings (applicable categories) and Aircraft Engineer’s Inspection Authorization (AEIA) Class-I Company Approval. Organisational procedures and human factors training shall be provided to certifying staff and support staff involved in aircraft / aircraft component maintenance. In the Organisation, acquiring Aircraft Maintenance Engineer’s (AME) Licence / Aircraft Engineer’s Inspection Authorization (AEIA) Class-I Company Approval alone, does not authorise maintenance personnel for certification, unless issued with a certification authorisation by Chief Engineer (Quality Assurance). Certification authorisation must state a clear definition / identification for scope of authorisation and its limitations.
3.4.2.3 Experience Record ‘Experience Record book’ (Refer AMP 3-2 for sample) introduced by the Pakistan CAA under reference CAA / 2228 / AW shall be used by maintenance personnel, working on aircraft / aircraft component, to endorse work experience. This conforms to requirement for proper experience verification, laid down by the Pakistan CAA for qualification examination (AME Licence / Company Approval). Such relevant experience of at least six months shall also be submitted for initial issue of certification authorisation. ‘Certifying Staff Experience Record Book’ (Refer AMP 3-2 for sample) shall be used by certifying staff to establish concurrency of relevant experience on scope of certification authorisation and must be submitted at renewal / extension / revalidation in original for the verification purposes.
3.4.2.4 Continuation Training PIA Engineering & Maintenance shall ensure that certifying staff shall be provided with regular trainings on the Part-145 requirements, organisational procedures, aviation legislation, human factors and relevant technological updates. Each certifying staff shall be provided with continuation training in every two-year time. Duration of training shall depend upon specific requirements for each type / category. Essential topics to be covered in continuation training are as follows: i. EASA Part-145 requirements ii. Relevant technology updates (aircraft / aircraft components) iii. Maintenance Organisation Exposition (relevant organisational procedures) iv. Aviation Legislation and Human factor training as per Part-66 Deputy Chief Engineer (HR, Training & Automation) shall prepare an annual programme for certifying staff continuation training. Chief Engineer (HR, Training & Automation) shall approve the programme and monitor progress of continuation trainings. Training programme shall include following information for each certifying staff: ♦ Name, Staff / Authorisation No., location, etc. of all certifying staff to be trained
(Group-wise nomination is preferred, according to scope of authorisation) ♦ Anticipated training dates Contents / syllabi of such trainings shall be based on the following: ♦ Amendments / Changes in the regulations from the Authorities
♦ Changes in organisational procedures, feedback on procedural trainings ♦ Human factor issues, incident reports and audit findings (internal / external) ♦ Airworthiness Directives, Service Bulletins, Service Letters, etc ♦ Quality Alerts / Advisories and Technical Notices ♦ Relevant technology updates through technical bulletins / seminars Continuation training shall be accomplished through an amalgamation of classroom sessions and dissemination of information through recurrent training and issuance of technical publications such as Quality Alerts / Advisories, Technical Notices, Human Factors Bulletins, etc. Training material for the Part-145 requirements, organisational procedures and Quality Alerts / Advisories shall be formulated by Deputy Chief Engineer (Quality Audit). Chief Engineer (Quality Assurance) shall approve syllabus and nominate personnel to impart such trainings. Deputy Chief Engineer (HR, Training & Automation) shall archive all training records. Relevant technology updates such as Airworthiness Directives / Service Bulletins / other modifications and Technical Notices shall be discussed during “Recurrent Training” sessions, held in every section on scheduled basis. Such trainings shall be imparted as per scope of certification authorisations for a particular group of certifying staff. Deputy Chief Engineer (production) concerned, in close liaison with Deputy Chief Engineer (Technical Services Engineering) concerned, shall perform training need analysis for other maintenance / support staff and plan such trainings against sectional manpower. Shift / leave rosters shall also be reviewed so that no staff is overlooked, while planning these sessions. Plan shall be reviewed after six months to address deviations (if any) and accommodate personnel, who could not be scheduled for such training previously. Deputy Chief Engineer (production) concerned shall submit nominal roll of recurrent training attendees to Deputy Chief Engineer (HR, Training & Automation) on monthly basis. Such records shall be used for verification of continuation training during issue / extension / revalidation of certification authorisation. All sectional Incharges shall keep copies of training records, being an auditable document.
3.4.2.5 Feedback System for Continuation Training A feedback system shall be established to collect observations from certifying staff on adequacy of methods, contents and implementation of training in concluding session of continuation training. Feedback, alongwith audit findings, shall be taken as an input for review of training curricula / durations. Review shall be carried out on yearly basis. Continuation training shall also be utilised to get feedback on adequacy of organisational procedures and their implementation in actual maintenance environment. All feedback, obtained from such training, shall be forwarded to Chief Engineer (HR, Training & Automation) on monthly basis. Anticipated procedural changes shall be forwarded to Chief Engineer (Quality Assurance) office.
3.4.2.6 Issuance of Certification Authorisation Deputy Chief Engineer (production) concerned shall raise the request for certification authorisation to maintenance personnel on ‘Assessment Form’ (Refer AMP 3-2 for sample). It shall be ensured that nominee is involved in at least six months of actual
relevant aircraft / aircraft component maintenance experience in last consecutive two years on required scope of certification authorisation. Same shall be verified by concerned Technical Services section through ‘Experience Record Book’ being maintained by maintenance personnel. Request for certification authorisation shall provide particulars of maintenance staff and scope / limitations (if any). Such form shall be submitted to Deputy Chief Engineer (HR, Training & Automation) for verification of initial / continuation trainings and onward despatch to Deputy Chief Engineer (Technical Services Engineering) concerned. Upon receipt of verified form, Deputy Chief Engineer (Technical Services Engineering) concerned shall assess the candidate against required scope of authorisation and forward completed form and ‘TSE Experience Records Book certificate’ to Technical Assistant to Chief Engineer (Quality Assurance). For candidate, who could not qualify such verification / assessment at any stage, Deputy Chief Engineer (concerned) shall immediately return ‘Assessment Form’ to the Initiator with appropriate remarks / findings, keeping a copy for records. Each signatory shall retain / archive a copy of ‘Assessment Form’ prior to its despatch to next section during assessment process. Technical Assistant to Chief Engineer (Quality Assurance) shall forward the case to Chief Engineer (Quality Assurance) for approval. Chief Engineer (Quality Assurance) shall issue certification authorisation (Refer 3-2 for sample), defining the scope / limitations of authorisation (if any). Upon issuance of certification authorisation, original ‘Assessment Form’ with appropriate remarks, shall be archived by Technical Assistant to Chief Engineer (Quality Assurance) in individual’s record file. A copy of certification authorisation shall be recorded in certifying staff record file (Refer MOE Chapter 3.5 for details). Following information shall be given on each individual authorisation: ♦ Name of the certifying staff (Aircraft Engineer) ♦ Scope of authorisation ♦ Limitations (if any)
Certifying staff shall also be issued with authorisation stamp bearing the certification authorisation number. It is the prime responsibility of stamp holder to make all possible efforts for security against any loss or misuse of such stamp. Certifying staff, upon query, shall present certification authorisation to the Competent Authority within 24 hours. Validity of certification authorisation, issued to individual, shall be clearly mentioned on the authorisation. In general, certification authorisation shall be issued for a period of two years to all certifying staff.
3.4.2.7 Revalidation of Certification Authorisation Revalidation of certification authorisation shall be performed every two years from date of issue, unless otherwise mentioned on authorisation. In order to rationalize revalidation process, authorisations for Line / Base Maintenance certifying staff, are linked with Aircraft Maintenance Engineer (AME) Licences being renewed on two-year basis by the Pakistan CAA. Revalidation request shall be initiated by Deputy Chief Engineer (production) concerned,
provided following requirements have been fulfilled during last two-year period: i. Certifying staff (concerned) has been involved in utilising relevant authorisation for
a period of at least six months, covering entire scope of issued authorisation ii. No significant discrepancy is reported against the individual Certifying staff shall utilize ‘Certifying Staff Experience Record Book’ to demonstrate concurrency of relevant experience on scope of certification authorisation and submit original record at revalidation to Deputy Chief Engineer (Technical Services Engineering) concerned for verification. Revalidation of certification authorisation shall be processed in a similar manner to that of initial issue and shall be limited to previous scope of the authorisation.
3.4.2.8 Extension in Scope of Certification Authorisation Extension in the scope of certification authorisation shall be requested by Deputy Chief Engineer (production) concerned, on ‘Assessment Form, ’for certifying staff enhancing technical qualification and fulfilling other applicable requirements. Request for extension, providing particulars of certifying staff and scope / limitations (if any), shall be submitted to Deputy Chief Engineer (HR, Training & Automation) for verification of continuation trainings and onward despatch to Deputy Chief Engineer (Technical Services Engineering) concerned. Upon receipt of verification, Deputy Chief Engineer (Technical Services Engineering) concerned shall assess certifying staff against new scope of authorisation and forward completed form to Technical Assistant to Chief Engineer (Quality Assurance). For candidate, who could not qualify such verification / assessment at any stage, Deputy Chief Engineer (concerned) shall immediately return ‘Assessment Form’ to the Initiator with appropriate remarks / findings, keeping a copy for records. Each signatory shall retain / archive a copy of ‘Assessment Form’ prior to its despatch to next section during assessment process. Technical Assistant to Chief Engineer (Quality Assurance) shall forward the case to Chief Engineer (Quality Assurance) for approval. Chief Engineer (Quality Assurance) shall issue a revised certification authorisation to certifying staff, defining total scope / limitations (if any). Upon issuance of the revised certification authorisation, original ‘Assessment Form’ with appropriate remarks, shall be archived by Technical Assistant to Chief Engineer (Quality Assurance).
3.4.2.9 Limitation, Suspension and Revocation of Certification Authorisation Whenever any condition for revalidation of certification authorisation is not met, or for any reason, on rationale after due investigation, such authorisation can be limited / suspended / revoked by the Chief Engineer (Quality Assurance). Any of the following conditions may lead to limitation / suspension / revocation of certification authorisation: ♦ Certification has been performed for an aircraft / aircraft component beyond the
scope / limitation of authorisation. ♦ Upon exclusion of an aircraft type from scope of work, approved by the Competent
Authority. Certification Authorisation bearing authorisation scope for only the type being excluded should be revoked.
♦ Continuation training has not been provided to the Certifying Staff during last two consecutive years.
♦ Certifying Staff has not been found utilising the issued authorisation for at least six months in the last two consecutive years. Failing in competence assessment may also be a reason.
In any of above cases, Chief Engineer (Quality Assurance) shall decide for limitation / suspension / revocation. Technical Assistant to Chief Engineer (Quality Assurance) shall notify for decision to concerned individual, through Deputy Chief Engineer (production) concerned. A copy of this notification shall be placed in individual’s record file. In case of limitation, revised certification authorisation shall be issued, upon return of previous one. If certification authorisation is suspended / revoked, certifying staff must return issued authorisation to Technical Assistant to Chief Engineer (Quality Assurance) for amendment of certifying staff record. Re-issuance of suspended / revoked authorisation shall be processed in a similar manner as for the initial issuance of certification authorisation.
3.4.2.10 Withdrawal of Certification Authorisation Certifying staff resigning from service or leaving Organisation, certification authorisation shall be withdrawn. Upon such withdrawal, certifying staff shall be asked to return the issued certification authorisation alongwith the authorisation stamp for clearance from Technical Assistant to Chief Engineer (Quality Assurance). Aircraft Engineer holding certification authorisation, on promotion to the cadre of Deputy Chief Engineer, shall also return his authorisation alongwith issued authorisation stamp to Technical Assistant to Chief Engineer (Quality Assurance). An acknowledgement received from this office shall be submitted by the individual to the Deputy General Manager (HR) Engineering for confirmation of his new designation. Upon transfer to any other section / station, certification authorisation shall be withdrawn. Revised authorisation may be issued to certifying staff (concerned), if required. Chief Engineer (concerned) shall inform Chief Engineer (Quality Assurance) for transfer, promotion, resignation, retirement, etc. of certifying staff at the earliest but not later than three working days. Technical Assistant to Chief Engineer (Quality Assurance) shall amend certifying staff record (Refer MOE Chapter 3.5 for details) for certification authorisation withdrawn and archive all returned authorisations, acknowledgements and stamps.
3.4.2.11 Specific Procedure for Certifying Staff Qualification on Aircraft < 5700 kg Since intended scope of work of PIA Engineering & Maintenance does not include any aircraft with MTOW less than 5700 kg, no such procedure / requirement is applicable.
3.4.2.12 Specific procedure for Certifying Staff Qualifications on Aircraft > 5700 kg Upon receiving initial training (basic / type trainings) and obtaining applicable aircraft / aircraft component maintenance experience, maintenance staff shall be eligible to apply for AME Licence / AEIA Class-I Company Approval examination, on prescribed form to
either the Pakistan CAA / Engineering Quality Assurance, through proper channel. Curricula of initial (basic) trainings cover following subjects: ♦ Mathematics, Physics, Metallurgy, Electricity, Non-Destructive Testing, etc ♦ Basic aerodynamics, structures, thermodynamics, digital technology, etc ♦ Introduction to aircraft systems ♦ Air legislation and Human factors Qualifications shall be Aircraft Maintenance Engineer’s (AME) Licence issued by the Pakistan CAA or Aircraft Engineer’s Inspection Authorization (AEIA) Class-I Company Approval issued by Chief Engineer (Quality Assurance). Aircraft Maintenance Engineer’s (AME) Licence shall be the prerequisite for promotion of maintenance personnel to the cadre of Aircraft Engineer in PIA Engineering & Maintenance. Endorsement of the Aircraft Type certification shall be issued by the Pakistan CAA on B737-300, A310-300, B777-200 / -300. Aircraft Maintenance Engineer’s (AME) Licence is valid for a period of two years and shall be renewed by the Pakistan CAA subject to compliance with conditions that licence holder has been engaged in maintenance related activities of particular type for a period of at least six months during last two years. Application for renewal of Aircraft Maintenance Engineer’s (AME) Licence shall be submitted to Technical Assistant to Chief Engineer (Quality Assurance) for verification and onward submission of application alongwith Aircraft Maintenance Engineer’s (AME) Licence (booklet) to the Pakistan CAA. Renewal application for licence shall be received two months in advance from date of expiry of particular licence.
3.4.2.13 Specific Procedure regarding certifying staff of Aircraft Components
Aircraft Engineer’s Inspection Authorisation (AEIA Class-I) Company Approval shall be issued by Chief Engineer (Quality Assurance) for aircraft components in overhaul shops. Company Approval shall be the prerequisite for promotion of maintenance personnel to the cadre of Aircraft Engineer in PIA Engineering & Maintenance. Maintenance personnel, involved in aircraft component maintenance, shall be provided complete applicable initial training (basic / type trainings) and experience requirement for particular Company Approval category (Refer AMP 3-2 for details). Company Approvals categories and training / experience requirements are referred in General Engineering Manual (GEM). Selected personnel shall complete ‘Basic and Type’ trainings, in respect of initial issue of certification authorisation as per MOE 3.4.2, described earlier and as per requirement for each Company Approval category. Curricula of these trainings shall cover following, depending on category of approval: ♦ Basic mathematics, physics, metallurgy, electricity, non-destructive testing, etc ♦ Basic aerodynamics, structures, thermodynamics, digital technology, etc ♦ Air legislations and Human factor ♦ Introduction to aircraft systems / components, related to scope Maintenance personnel shall gain practical experience, defined for Company Approval category, on particular equipment. Deputy Chief Engineer (production) concerned shall manage for provision of trainings / practical experience.
3.4.2.14 Comparison of PIA Licensing system with Part – 66:
Maintenance staff working in Line / Base Maintenance, upon fulfilment of minimum requirements, shall acquire Aircraft Maintenance Engineer’s (AME) Licence as described in the Pakistan CAA Airworthiness Notices No. 34 / 2000 and 35 / 2000. Following is the brief comparison of PIA licensing system and Part – 66:
Part – 66 Categorization PAKISTAN CAA Categorization Explanation and Limitations
Cat A: Line maintenance certifying mechanic No provision The Pakistan CAA does not qualify certifying
staff in this Part – 66 Category.
Cat A, Airframe Scope limited to Airframe, defined in AMP 3-2. Cat B1: Line Maintenance certifying technicians –
Mechanical Cat C, Engines Scope limited to Engine, defined in AMP 3-2.
Cat X, Electrical Scope limited to Electrical, defined in AMP 3-2.
Cat X, AFCS Instruments Scope limited to Instruments / AFCS, defined in AMP 3-2
Cat B2: Line Maintenance certifying technicians -
Avionics Cat R, Radio Scope limited to Radio / Radar as defined in the
AMP 3-2.
Cat C: Base Maintenance certifying engineers Not defined separately See Note 1 below
Note 1: Although not defined separately, certifying staff shall be authorised by the
Pakistan CAA for issuance of Certificate of Maintenance Review (C of MR). ♦ Aerospace: Qualified in both A & C categories for aircraft type. ♦ Avionics: Qualified in both X categories (Electrical & AFCS Instruments) for
aircraft type. ♦ Radio: Qualified in both Radio and Radar categories for aircraft type.
3.5 CERTIFYING STAFF AND CATEGORY B1 AND B2 SUPPORT STAFF RECORDS
3.5.1 PURPOSE
To describe PIA Engineering & Maintenance policies, regarding control for records of certifying staff.
3.5.2 PROCEDURE
3.5.2.1 General
Control of ‘List of Certifying Staff’ (Refer MOE Chapter 1.6 for details) and management of records for all technical qualifications and Authorisations issued in the Organisation is prime responsibility of Technical Assistant to Chief Engineer (Quality Assurance). A separate file shall be maintained for all certifying staff and authorised personnel including those with limited scope of authorisations.
3.5.2.2 Record Files
Record files shall be traceable by individuals’ staff numbers. Following minimum information of each certifying staff shall be recorded to complete the file: ♦ Name ♦ Date of birth ♦ Experience ♦ Aircraft maintenance license / Class-I company approval relevant to authorisation ♦ All relevant trainings completed ♦ Scope of Certification Authorisation with limitations, if any ♦ Date of issue of first Authorisation ♦ If appropriate – expiry date of Authorisation ♦ Identification Number of Authorisation
Upon receipt of a change in any of the above information for a certifying staff, the file of the particular individual shall be updated accordingly. An authorised access to records shall be maintained for a minimum number of personnel to ensure that records cannot be altered in an illicit manner or accessible to an unauthorised person. Copies of certificates (basic / type) and continuation training record shall be maintained by Deputy Chief Engineer (HR, Training & Automation). Technical Assistant to Chief Engineer (Quality Assurance) shall archive the Assessment forms alongwith other records (Refer MOE 3.4 for details). Record shall be kept for a minimum of three years after certifying staff has ceased employment with PIA Engineering & Maintenance or Certification Authorisation has been withdrawn / revoked. Certifying staff, upon request, shall be given a secured access to their own record. A copy of such record shall be provided to individual, upon request, while leaving the Organisation. Technical Assistant to Chief Engineer (Quality Assurance) shall ensure that free access to such records has been provided to the Competent Authority, during audits of record system or competence assessment process for a particular certifying staff.
3.6.1 PURPOSE To define PIA Engineering & Maintenance policies regarding the selection / training / qualification of Quality Audit personnel and management of audit authorisations.
3.6.2 PROCEDURE
3.6.2.1 General
Chief Engineer (Quality Assurance) shall authorise Aircraft Engineers (Quality Audit), upon fulfilling training requirements, to perform independent Quality Audits as per annual Quality Audit Plan (Refer MOE Chapter 3.1). Deputy Chief Engineer (Quality Audit) shall supervise Aircraft Engineers (Quality Audit) for performing procedure / product audits. Deputy Chief Engineer (Quality Audit) shall nominated auditors, keeping in view the effective handling of audits workload within due schedule (Refer AMP 3-1 for details).
3.6.2.2 Selection of Quality Auditors Function of audits in PIA Engineering & Maintenance shall not be subcontracted to any other organisation. Quality Auditors shall be selected among Aircraft Engineers within the Organisation, possessing appropriate academic / technical knowledge, commitment and aptitude. In order to ensure independence, Quality Auditors shall not perform any type of Certification during their stay in Quality Audit section. Selection shall be made on approved criteria. Following shall be the attributes, defined by the Organisation, for Quality Audit personnel:
Deputy Chief Engineer (Quality Audit)
Aircraft Engineer (Quality Audit)
Educational Level Science Graduate X Engineering / Science Graduate X
Experience Aviation Experience X X Consulting / Management X
Specific Knowledge Quality Standards X X Aviation Legislation X X Organisational processes X X Aircraft Technical (Type) X X
Additional Skills Presentation X X Training X X Auditing X X Computing / Networking X X Communication X X Negotiating X
3.6.2.3 Training of Quality Auditors
Aircraft Engineer (Quality Audit) shall be trained and qualified prior to perform an audit. Trainings shall be based on knowledge of Aviation Legislation, applicable regulations,
organisational procedures, audit processes and techniques. Basic training shall include comprehension of Maintenance Organisation Exposition (MOE) / Associate Maintenance Procedures (AMP). Such trainings shall enable Aircraft Engineer (Quality Audit) to monitor compliance of Part-145 requirements, identifying non-compliances in an effective, impartial and timely manner. For reasons of integrity and objectivity, Aircraft Engineer (Quality Audit) shall be given opportunities to enhance technical qualification at par with other maintenance personnel in the Organisation. Upon fulfilling applicable requirements, Aircraft Engineer (Quality Audit) shall be eligible to acquire technical qualification (AME Licence / AEIA Class - I Company Approval), thus keeping abreast with other Aircraft Engineers. To facilitate aircraft / aircraft components product audits, technical trainings shall be provided to Aircraft Engineer (Quality Audit) on priority basis. Continuation / Recurrent training, with respect to Part-145 requirements, organisational procedures and aviation legislation, shall be provided to each Aircraft Engineer (Quality Audit) upon receipt of an amendment in the requirements or procedures. In view of application of human factors / performance issues, Aircraft Engineer (Quality Audit) must receive human factors initial / continuation training. Such training shall be of sufficient duration in each two-year period in relation to relevant Quality Audit findings and other internal / external sources of information available to the Organisation on human errors in maintenance.
3.6.2.4 Issuance of Audit Authorisation
Deputy Chief Engineer (Quality Audit) shall prepare a case for audit authorisation, nominating personnel upon successful completion of initial training and required number of audits as Observer. After assessment, Chief Engineer (Quality Assurance) shall issue audit authorisation to Aircraft Engineer (Quality Audit). Aircraft Engineer (Quality Audit) shall also be issued with an authorisation stamp bearing a unique audit authorisation number. It is prime responsibility of stamp holder to make all possible efforts for security against any loss or misuse of such stamp. Aircraft Engineer (Quality Audit), upon query, shall present such Authorisation to the Competent Authority within 24 hours. Audit authorisation, issued to individual, shall be valid for a period of two years from the date of issue.
3.6.2.5 Revalidation of Audit Authorisation To maintain audit authorisation, Aircraft Engineer (Quality Audit) shall perform audits on regular basis. Lead Auditor shall perform audits in the capacity of Lead Auditor / Group Lead alongwith the follow up. Audit authorisation shall be revalidated every two years from date of issue. Request for revalidation shall be made by Deputy Chief Engineer (Quality Audit), upon assessment of competence and continued utilization of audit authorisation.
3.6.2.6 Revocation of Audit Authorisation
Whenever condition for revalidation of audit authorisation is not met or for any reason on rationale after due investigations, such Authorisation shall be suspended / revoked by Chief Engineer (Quality Assurance) and concerned Quality Auditor shall be notified for
such suspension / revocation, in writing. A copy of such notification shall be placed in individual’s record file.
3.6.2.7 Withdrawal of Audit Authorisation Resignation / retirement from service of the Organisation, transfer to other location for new assignment, issued audit authorisation shall be withdrawn. Upon such withdrawal, the individual shall return Authorisation alongwith issued stamp to prior to the clearance from Deputy Chief Engineer (Quality Audit).
3.6.2.8 List of Quality Audit Personnel Performing Audits Deputy Chief Engineer (Quality Audit) shall control and maintain record files and Audit Logbooks for Quality Auditors with following information: ♦ Name ♦ Date of Birth ♦ Academic Qualifications ♦ Technical Qualifications ♦ Trainings (subject, dates, duration) and certificate copies ♦ Lead Auditor status (Y/N) ♦ Number of Audits performed
To define PIA Engineering & Maintenance policies regarding training and qualification of Inspectors in the Organisation. Inspectors shall be the following personnel: ♦ Aircraft Engineer (QA) Maintenance ♦ Store Quality Inspectors (incoming stores inspection)
Aircraft Engineer holding valid AME Licence / AEIA Class – I Company Approval, formerly working in aircraft / aircraft maintenance areas, are eligible to become Aircraft Engineer (QA) Maintenance. Such personnel shall be assigned task of quality assurance inspections and spot check during aircraft / aircraft components maintenance activities due to their previous experience and necessary technical knowledge of processes, products and working methods applied in the assigned areas. Selection of personnel shall be based on qualifications, skills / aptitude, analytical approach and specific knowledge of aviation legislation, quality standards, maintenance processes, various computer applications, etc. Additional organisational procedures, aviation legislation and human factors training shall be provided to such personnel. Ramp inspections of PIA Owned Aircraft shall be performed as planned by Deputy Chief Engineer (QA) Maintenance. The selection of Aircraft for Ramp Inspection shall be based on the Flight Number / Sector / destination, planning shall be such that complete schedule is encompassed. The ideology of Ramp Inspections shall be driven from the EASA ‘Safety Assessment of Foreign Aircraft’ (SAFA) regulation. Spot Checks are performed to monitor organisational procedures implementation in day-to-day maintenance activities on aircraft / aircraft components (Refer AMP 3-1 for details). Deputy Chief Engineer (QA) Maintenance shall plan such activities and nominate Aircraft Engineer (QA) Maintenance to perform Spot Checks. ‘Discrepancy Report / Corrective Action Request’ (Refer AMP 3-1 for sample) shall be raised against any finding during spot check process. Such request shall be handed over to concerned section for appropriate corrective action. Deputy Chief Engineer (concerned) shall ensure that an appropriate, timely corrective action against the finding has been taken and finding has been eliminated in an effective manner. Such action shall be recorded and submitted to Deputy Chief Engineer (QA) Maintenance within 07 days period. Deputy Chief Engineer (QA) Maintenance shall ensure that all records related to Spot Checks / Ramp Inspections shall be archived for a period of at least two years after closure of particular finding.
3.7.2.2 Store Quality Inspector (Incoming Stores Inspection) Selection for Store Quality Inspectors in the Organisation shall be based on technical training, competence, experience and ability to perform inspection functions. Five years aircraft / aircraft component maintenance experience shall be considered as minimum
mandatory requirement. Stores Quality Inspectors shall be made familiar with regulatory requirements, applicable organisational procedures and aircraft components / material acceptance criteria (EASA Form 1, FAA 8130-3 / TCA 24-0078 with double release or Certificate of Conformity). Comprehensive initial training shall be provided to technical staff and assessment shall be performed by Technical Assistant to Chief Engineer (Quality Assurance). Such personnel shall be designated as Stores Quality Inspectors and ‘Inspection Permit’ (Class – II) shall be issued by Chief Engineer (Quality Assurance). Such permit shall authorise Store Quality Inspector to issue Serviceable Tag (Certificate of Inspection) for incoming stores. Continuation training shall be provided to Stores Quality Inspectors in every two-year period, planned by Deputy Chief Engineer (HR, Training & Automation). Continuation training shall be accomplished through amalgamation of classroom session and dissemination of information through issuance of technical publications such as Quality Alerts / Advisories, Technical Notices, Human Factor Bulletins, etc. Essential topics to be covered in continuation training are as follows:
i. Amendments in EASA Part-145 ii. Changes in organisational procedures iii. Aviation legislation and Human factor issues Deputy Chief Engineer (HR, Training & Automation) shall archive all training records for such personnel. Record of Store Quality Inspectors’ qualifications and authorisations shall be archived by Technical Assistant to Chief Engineer (Quality Assurance).
3.8.1 PURPOSE To define PIA Engineering & Maintenance policies regarding selection, training and competence assessment of aircraft / aircraft component Mechanics (including Officers Engineering, Senior Technicians and Technicians).
3.8.2 PROCEDURE
3.8.2.1 Generalities Mechanics are maintenance personnel involved in maintenance activities of following: ♦ Airframe, engines and other related systems ♦ Avionics and radio systems ♦ Sheet metal and composites ♦ Cabin / aircraft interiors ♦ Fuel systems, hydraulics, pneumatics, emergency systems Mechanics are not authorised to issue Certificate of Release to Service. Though, it is ensured that they are able to perform maintenance tasks to any standard specified in maintenance data under supervision of Certifying Staff.
3.8.2.2 Recruitment of Technician
Mechanics shall be recruited against vacancies raised in the Organisation, according to prescribed criteria, from any of the following sources: i. Three years apprenticeship from PIA Training Centre ii. Diploma in Associate Engineering (DAE) from technical institutions iii. Other aviation maintenance organisations iv. Specialised skills Following shall be the basis for recruitment: ♦ Age (minimum 18 years) ♦ Educational qualification (minimum 12 years with science subjects for apprentices /
diploma in relevant field for technicians recruited directly). ♦ General Technical knowledge (assessed through examination and interview)
3.8.2.3 Basic Training
Apprenticeship training is provided at PIA Training Centre in Aerospace / Avionics trades for three years. Classroom training is supplemented by practical training at PIA facilities. Successful candidates may be recruited / absorbed as Technicians. However, such apprenticeship training shall not contribute to prerequisites of Aircraft Maintenance Engineer Licence (AME) Licence / Aircraft Engineer Inspection Authorisation (AEIA) Class – I Company Approval examinations. Upon recruitment, Technicians shall undergo On Job Training (OJT) under supervision of qualified staff. Training need shall be analysed for all inductees in the Organisation by Deputy Chief Engineer (HR, Training & Automation). Successful completion of initial / basic training and the competence assessment by Deputy Chief Engineer (production)
will enable mechanics to perform maintenance activities under supervision of certifying staff. All Mechanics shall receive Human factor and organisational procedures training. Such trainings shall be of sufficient duration in relation to specific job roles in the Organisation, relevant quality audit findings and other internal / external sources of information available to the Organisation on human errors in maintenance.
3.8.2.4 Type Training On management’s recommendation, mechanics in maintenance shall attend relevant training for aircraft / aircraft components, conducted at PIA Training Centre. Additional specialized trainings shall be recommended by Deputy Chief Engineer (production) concerned on the basis of training need analysis.
3.8.2.5 Training Plan Deputy Chief Engineer (concerned) shall prepare annual training plan for maintenance personnel in the section. Plan shall cater for training on organisational procedures, technical skills and human factors. Such plan shall then be forwarded to Deputy Chief Engineer (HR, Training & Automation) for finalization. Finalized plan shall be received by Deputy Chief Engineer (concerned) for man-hour planning.
3.8.2.6 Records List of Technicians / Senior Technicians shall be maintained by Deputy Chief Engineer (HR, Training & Automation), in co-ordination with Deputy Chief Engineer (concerned) for following trades / specialties: ♦ Airframe, Engine, Radio, Electrical and Instrument systems of aircraft ♦ Aircraft components ♦ Sheet metal, machining process, cabin maintenance, painting process
3.8.2.7 Approved Inspectors (Aircraft Component Maintenance) Approved Inspector, performing inspection on aircraft components at piece-part level during component maintenance, shall be issued with ‘Inspection Permit’ (Class – II) by Chief Engineer (Quality Assurance). Such permit shall authorise Approved Inspector to issue ‘Aircraft Part Inspection Tag’ (Refer AMP 2-1 for sample) for aircraft component found serviceable and appropriate for Next Higher Assembly (NHA). Such personnel shall be trained on systems within their scope of authorisation and organisational procedures. Records of such Approved Inspectors shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance).
3.8.2.8 Technicians on Contract Technicians may be hired on short-term contracts, if need arises. Before induction of technicians on short-term contract, their qualification and capability shall be assessed through assessment of technical qualification and written examination / interview. Upon completion of organisational procedures and human factors training, such Technicians shall be allowed to work under supervision of permanent authorised personnel.
3.9 AIRCRAFT OR AIRCRAFT COMPONENT MAINTENANCE TASKS EXEMPTION PROCESS CONTROL
3.9.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding exemptions related to maintenance tasks on aircraft / aircraft components.
3.9.2 PROCEDURE
3.9.2.1 General Aircraft / aircraft component maintenance task exemption process control is understood as method where time extensions from maintenance schedule and / or deviation from manufacturer instructions become necessary. Such time extension may be required due to lack of material, manpower, aircraft availability, etc. and exemption shall be acquired from the Competent Authority. Process of exemption for deviation from an aircraft technical standard or maintenance procedure shall be applied when maintenance personnel are unable to comply with a particular requirement or to comply through method, different from that prescribed in the relevant maintenance data. In this context, it shall refer to deviating from approved maintenance standard. Existence of a procedure for obtaining an exemption from the Competent Authority, as prescribed by this chapter, is not a reason for applying for any change of maintenance instructions without prior notice of the manufacturer’s instructions. Furthermore, this exemption procedure does not allow modification of engineering design as well.
3.9.2.2 Maintenance Task Exemption Process Aircraft / aircraft component shall be released to service after completion of required maintenance / defect rectification according to maintenance data (Aircraft Maintenance Schedule, Service Bulletins, etc.) and applicable mandatory requirements. Before submitting application for such exemption, Deputy Chief Engineer (production) concerned shall ensure that all efforts to resolve the problem have been made and despatch of aircraft is difficult due to certain justified constraints. Constraints may be due to impracticality of performing maintenance task due to lack of a tool, spare or other same nature constraint (no exemption is possible to mandatory requirements). Request for maintenance task exemption shall be generated by Deputy Chief Engineer (production) concerned on prescribed form for initial validation of Deputy Chief Engineer (Technical Services Engineering) concerned. When request is generated to postpone routine task card as per maintenance schedule, compensation action shall be taken in place of postponed action to ensure effectiveness of the affected aircraft system. For exemption related to deviation from any maintenance instruction, validation of modified instruction shall be obtained from the manufacturer. Chief Engineer (Quality Assurance) shall assess and if found justified, request shall be submitted to the Competent Authority for approval. Prior to submission, following shall be verified: ♦ Significance of deviation and justification, provided
♦ Completeness of the request ♦ Attached documents Upon receipt of approval from Competent Authority, Chief Engineer (Quality Assurance) shall intimate Chief Engineer (concerned), ensuring that the exemption is exercised in accordance with the scope / limitation of approval. Certifying Staff shall be responsible to record any such exemption and approval reference in particular Certificate of Release to Service.
3.9.2.3 Maintenance Task Exemption Process made on behalf of a customer When an exemption for any maintenance task deviation is required on customer aircraft, customer organisation shall be contacted to obtain such exemption from the Authority of registration of aircraft.
3.10 CONCESSION CONTROL FOR DEVIATION FROM ORGANISATIONS’ PROCEDURES
3.10.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding concession control for deviations from the organisational procedures.
3.10.2 PROCEDURE
3.10.2.1 General
Deviation from organisational procedure is defined as process / task, not covered by any procedure or beyond any limit as described, in the Maintenance Organisation Exposition (MOE) / Associate Maintenance Procedures (AMP). Prior concession must be obtained for any such deviation from the organisational procedures. Permanent deviation from existing procedures shall initiate an introduction / amendment of the subject in organisational procedures. Amendment in Maintenance Organisation Exposition (MOE) and Associate Maintenance Procedures (AMP) shall be processed as per MOE Chapter 1.11. Concession shall be granted by Chief Engineer (Quality Assurance) against temporary deviation from other administrative procedures with an appropriate approval. Temporary deviations must be documented, clearly stating the reason and must be duly signed by the Initiator. The intent of the original instruction must be maintained.
3.10.2.2 Concession Control Deputy Chief Engineer (concerned) shall send a written request for concession against deviation to Deputy Chief Engineer (Quality Audit). In case of an urgent need, request may be made in advance via e-mail / telephone. However, it then becomes mandatory for the Initiator, to regularize such concession within two working days. Deputy Chief Engineer (Quality Audit) shall assess deviation (identification, justification and reference to explanatory documentation). If deviation found justified, request shall be forwarded to Chief Engineer (Quality Assurance) with recommendations. Deviation shall be notified to the Competent Authority with request for concession alongwith all pertinent information. Concession granted by the Competent Authority shall be formalised by Chief Engineer (Quality Assurance). Feedback shall be sent to the Initiator and granted concession inn original shall be archived by Technical Assistant to Chief Engineer (Quality Assurance). With the request to the Competent Authority, compensation measure shall be provided. Compensation measure is action taken to ensure that non-application of initial instruction of Maintenance Organisation Exposition shall not be subject of a problem besides. When request is made for concession against deviation from Maintenance Organisation Exposition and Associate procedures, Chief Engineer (Quality Assurance) shall control the alternate action or procedure, required by the Competent Authority.
3.11 QUALIFICATION PROCEDURE FOR SPECIALISED ACTIVITIES SUCH AS NDT, WELDING ETC
3.11.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding management of training, qualification and authorisations for specialised services (NDT, Welding, etc.) personnel.
3.11.2 PROCEDURE 3.11.2.1 General
Following are the Non Destructive Testing (NDT) techniques, being utilized within the Organisation: ♦ Eddy Current Testing (ET) ♦ Ultra Sonic Testing (UT) ♦ Radiographic Testing (RT) ♦ Magnetic Particle Testing (MT) ♦ Penetrant Testing (PT) PIA Engineering & Maintenance shall not perform Non Destructive Testing (NDT) as a particular task on customer aircraft / aircraft component unless such Non Destructive Testing (NDT) is required by maintenance schedule of the Customer. Non Destructive Testing (NDT) shall only be carried out on aircraft / aircraft components, maintained by the Organisation. Where necessary, these Non Destructive Testing (NDT) tasks may be contracted only to the EASA Part – 145 Approved Maintenance Organisations.
3.11.2.2 Qualification and Approval of NDT Personnel Qualification of NDT personnel is based on standard EN 4179 and qualification levels of NDT personnel shall be limited to: i. Level 1 – Operative (Technician / Officer Engineering) ii. Level 2 – Supervisor (Aircraft Engineer) Penetrant Testing (PT) may be carried out or checked by Certifying Staff holding a Category B1 Authorisation and alongwith appropriate Non Destructive Testing (NDT) Approval. Chief Engineer (Quality Assurance) shall duly approve detailed procedure of training, qualification and Authorisation, based on European NDT Standard of EN 4179, described in a document (Refer AMP 3-2 for Process Flow).
3.11.2.3 Training Requirements Candidates of Level 1 / 2 shall complete adequate training to become familiar with principles / practices of applicable test techniques and organisational procedures. Deputy Chief Engineer (HR, Training & Automation) shall manage all trainings, for qualification / re-qualification as per organisational procedures. Classroom training shall be provided in-house, supplemented by practical training. NDT Personnel shall be trained for issuance of certification of Level 1 & Level 2. Certificates provided, upon successful completion of training shall be recorded. Competence assessment of NDT Personnel shall be ensured to perform the specialised tasks. Such evaluation shall be made on the basis of a written examination and results
shall be recorded in individual files. Non Destructive Testing (NDT) shall be performed in accordance with documents e.g. Non Destructive Testing (NDT) Manuals, Standard Practices Manuals, Service Letters, etc. Personnel not performing Non Destructive Testing (NDT) for a continued period of more than six months must be re-qualified on that particular technique. Revalidation of NDT Authorisation shall be based on assessment. Re-qualification shall be required every three years and validation of NDT Authorisation shall be based on annual vision test performed at PIA Medical Centre.
3.11.2.4 Welding Personnel Welders’ Authorisations are issued to welding personnel by the local Civil Aviation Authority, CAA (Pak). Candidates shall be qualified, fulfilling necessary training and experience requirements, laid down by CAA (Pak) in Airworthiness Notice No. 63/2000. Validation of Welder’s Authorisation shall be based on annual vision test performed at PIA Medical Centre.
3.11.2.5 Records All qualification / Authorisation record (individual files) shall be maintained and controlled by Technical Assistant to Chief Engineer (Quality Systems). List of Authorised personnel shall be maintained and controlled by Technical Assistant to Chief Engineer (Quality Assurance) under Reference # E&M/CE(QA)/CSL–NDT.
3.11.2.6 Contractual Staff (Specialised Tasks) NDT personnel performing specialised tasks may be employed on contract. Criteria for granting an Authorisation for Non Destructive Testing (NDT) / welding to contracted personnel shall remain same as those for PIA Engineering & Maintenance personnel as described above. Prior to employment, qualifications / competence shall be assessed for such personnel. Copies of technical qualifications and written examination / interviews shall be archived. Personnel, employed on contract, shall also be trained on organisational procedures.
3.12 CONTROL OF MANUFACTURERS’ AND OTHER MAINTENANCE WORKING TEAMS
3.12.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding major repair / modification being performed by working team of Original Equipment Manufacturer (OEM) / approved maintenance organisation, at PIA Engineering & Maintenance facilities.
3.12.2 PROCEDURE
3.12.2.1 General
For any major repair, including modifications on aircraft / aircraft component, Chief Engineer (Maintenance Operation Centre) shall contact customer support division of the particular organisation. A comprehensive agreement shall be established between PIA Engineering & Maintenance and Original Equipment Manufacturer (OEM) / maintenance organisation, mentioning details of required repair / modification.
3.12.2.2 Handling of In-house Maintenance Considering major repair / modification as ‘in-house maintenance’, upon endorsement from Director (Engineering & Maintenance), Repair / Work Order shall be sent to Original Equipment Manufacturer (OEM) / approved maintenance organisation from Chief Engineer (Maintenance Operation centre) office. If required, Work Package / Modification Signature Sheet (Refer AMP 2-3 for sample) shall be formulated trade-wise by Deputy Chief Engineer (Engineering) / (Technical Services Engineering) concerned, using maintenance data. Deputy Chief Engineer (Technical Publication & Records) shall make necessary arrangements for provisioning of applicable maintenance data. Chief Engineer (production) concerned shall ensure necessary arrangements regarding access to adequate facilities, availability of appropriate logistics support and provisioning of skilled workforce to working team for particular task. Working team shall be provided restricted access to documentation, stores and records. However, for further information, they may contact Deputy Chief Engineer (production) concerned. Deputy Chief Engineer (production) concerned shall coordinate with working team for effective accomplishment of maintenance task and completion of maintenance records. All tasks shall be recorded on Task cards / Worksheets by concerned team and records shall be controlled as per organisational procedures. Deputy Chief Engineer (Technical Services Engineering) concerned shall verify maintenance according to the Work Order. Upon completion of such repair / modification / maintenance task, a report shall be generated by the working team in the form of “Certificate of Compliance” and Certifying Staff shall issue a Certificate of Release to Service / EASA Form 1for particular task. Chief Engineer (Quality Assurance) shall ensure that working team is authorised to issue Certificate of Release to service / EASA Form 1. Otherwise, appropriate Certifying Staff from the Organisation shall be nominated to issue Certificate of Release to service / EASA Form 1 for particular aircraft / aircraft component after working team has signed the work completion.
3.13 HUMAN FACTORS TRAINING PROCEDURE 3.13.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding the human factors training for all personnel related to the Part – 145 Approval.
3.13.2 PROCEDURE
3.13.2.1 Generalities Human factors study relates to optimization of relationship between human beings and their activities, by systematic application of human sciences. Such application shall be integrated within the framework of comprehensive procedures and proper consideration of human performances. Human performance is defined as capabilities / limitations of an individual which might have an impact on the safety, airworthiness and efficacy during maintenance activities. In addition to required knowledge and competence for particular task, all maintenance personnel shall be trained to understand how human factors and performances may influence their assigned activities. Consequently, training need and duration for initial human factors training shall be analyzed for each individual to capture and reduce human related maintenance errors in the Organisation. All personnel in the Organisation must receive human factors continuation training in each two year period.
3.13.2.2 Human Factors Initial Training
In respect to perception of human factors applications and human performance, Chief Engineer (HR, Training & Automation) shall perform training need analysis regarding initial Human Factors training for all human resource, in coordination with Deputy Chief Engineer (Human Factors). Personnel being recruited shall be assess for training need to meet Part-145 human factors training standard. Deputy Chief Engineer (HR, Training & Automation) shall develop comprehensive training plan to ensure that all employees receive initial human factors training relevant to their functions within the Organisation. Initial human factors training shall cover all topics of training syllabus, approved by the Competent Authority, as a dedicated course. Human factors training shall be aimed to reduce human errors and discourage procedural violations. Deputy Chief Engineer (Human Factors), in consultation with Chief Engineer (Quality Assurance), shall finalize syllabi according to job roles. Contents and duration of initial human factor training shall be based on the particular nature of work for each function within the Organisation. Deputy Chief Engineer (HR, Training & Automation) shall arrange initial human factors training sessions in coordination with Deputy Chief Engineer (Human Factors). Nominees for each session shall be grouped according to nature of work and availability of personnel. PIA Training Centre resources shall be utilised for training sessions. Upon completion of each session, certificates shall be issued to all attendees. Deputy Chief Engineer (HR, Training & Automation) shall archive the copies of certificates with training records of each individual.
3.13.2.3 Human Factors Continuation Training Human factors continuation training shall be managed with intent that personnel remain current on human factors and feedback on human factors issues is collected through
such trainings. In order to identify and categorize human factor issues, Deputy Chief Engineer (Human Factors) shall receive all information on human errors in maintenance through following documents (Refer AMP 2-3 for details): ♦ Maintenance Error Reports (Refer MOE 2.25 for details) ♦ Accident / Incident / Defect Reports (Refer MOE 2.18 & L2.3 for details) ♦ Quality Audit Reports (Refer MOE 3.3 for details) ♦ Corrective Action Requests raised during Spot Checks / Ramp Inspections ♦ Human factors surveys and HF Disclosure forms (Refer AMP 2-3 for sample) Deputy Chief Engineer (Human Factors) shall analyse received information regarding discovered errors / findings and finalize contents / duration of continuation trainings, in consultation with Chief Engineer (Quality Assurance). In addition to requirement for certifying staff, human factors continuation training shall be provided through in-house recurrent training sessions to all other personnel. Recurrent training shall be conducted to impart knowledge of human factor issues and discovered maintenance errors and practical problems within the Organisation.
Continuation training shall be of interactive nature and Deputy Chief Engineer (Human Factors) shall compile feedback collected during training. Issues related to facilities, equipment, human resource, etc. shall be identified by Deputy Chief Engineer (Human Factors) in consultation with Chief Engineer (Quality Assurance). Recommendations for corrective / preventive actions shall then be submitted to the Accountable Manager. Deputy Chief Engineer (Human Factors) shall manage human factors recurrent training, through nominated Human Factors trainers of respective divisions. Curriculum shall be finalised prior to each training session. Records for trainings shall be received by Deputy Chief Engineer (Human Factors) for archiving. In addition to recurrent training, the Organisation shall use following means to enhance awareness among all personnel in the Organisation:
a) Quality Alerts / Advisories Quality Alert is issued against deviation from a regulation or procedure, directly affecting safety of personnel, equipment or facilities. Such deviation may be observed during aircraft / aircraft component maintenance, quality audit, spot check or ramp inspection. Personnel at all levels are equally responsible for reporting of any deviation and similarly strict adherence of issued instructions is mandatory for all concerned. Quality Advisory is issued when there is neither any standard nor a procedure available on the subject and issue is considered as critical to draw attention of personnel for safety and quality improvement within the Organisation. Contents of Quality Advisory shall be formulated into organisational standard / procedure. Deviation, from regulation or procedure, shall be reported to Deputy Chief Engineer (Technical Services Engineering) concerned for review of significance and submission of detailed report alongwith recommendations for Quality Alert to Chief Engineer (Quality Assurance). Whenever, standard or procedure is unavailable, Deputy Chief Engineer (Technical Services Engineering) concerned shall recommend for the Quality Advisory. Technical Assistant to Chief Engineer (Quality Assurance) shall prepare initial draft for Quality Alert / Advisory for review / finalization by Chief Engineer (Quality Assurance).
Quality Alert / Advisory shall be issued as per distribution list, maintained by Technical Assistant to Chief Engineer (Quality Assurance). Quality Alert / Advisory instructions shall be disseminated through re-current trainings. Deputy Chief Engineer (production) concerned, through spot checks, shall ensure that personnel at sectional level are complying with the issued instructions. Deputy Chief Engineer (Quality Audit) shall review Quality Advisory for incorporation in organisational procedures with feedback for Technical Assistant to Chief Engineer (Quality Assurance). Quality Advisory shall be withdrawn, upon inclusion of instructions and approval of amendment in Maintenance Organisation Exposition by the Competent Authority. Quality Advisory shall then be stamped as “WITHDRAWN”. Quality Advisory may refer to some technical information that is already provided in maintenance data. Such information can never supersede contents of maintenance data. Technical Assistant to Chief Engineer (Quality Assurance) shall review, on regular basis, all Quality Alerts / Advisories for revision / cancellation. Records of all issued Quality Alerts and Quality Advisories shall be archived in separate files by Technical Assistant to Chief Engineer (Quality Assurance). An index, for each category shall be maintained to demonstrate Quality Alert / Advisory Number, subject and issue date. Status of document shall also be mentioned for withdrawal in case of Quality Advisories. However, stamped copy shall remain archived with the records for future reference.
b) Human Factors Bulletins Human factors bulletin is published to focus on maintenance errors consequential to human factors, malpractices and organisational culture. Main objective of bulletin is to pass on information regarding experiences, recorded and categorised as human errors, within the Organisation as well as from other aircraft maintenance organisations. Human factors bulletin, published by Deputy Chief Engineer (Human Factors) on monthly basis, is distributed to Certifying Staff in particular and other maintenance personnel in general. Bulletins and relevant correspondence are archived by Deputy Chief Engineer (Human Factors) for records.
3.14 COMPETENCE ASSESSMENT OF PERSONNEL 3.14.1 PURPOSE
To describe PIA Engineering & Maintenance policies for the competence assessment of management personnel, Certifying Staff and Quality Assurance personnel.
3.14.2 PROCEDURE 3.14.2.1 Generalities
Performance appraisal for all personnel with respect to their duties and responsibilities shall be carried out on yearly basis. However, the competence assessment of Certifying Staff and Quality Assurance personnel with respect to specific functions / tasks shall be carried out during process of issuance / revalidation of relevant Authorisations. The competence assessment shall be performed on following principles: ♦ Knowledge of organisational procedures laid down in Maintenance Organisation
Exposition (MOE), Associate Maintenance Procedures (AMP) and other applicable documents
♦ Awareness of regulations / requirements, issued by the International Civil Aviations Organisation (ICAO), European Aviation Safety Agency (EASA), Federal Aviation Administration (FAA), Pakistan Civil Aviation Authority (CAA-Pak) and ability to fulfil their obligations for compliance in the Organisation
♦ Comprehension of human performance limitations and human factors leading to maintenance errors during aircraft / aircraft component maintenance
3.14.2.2 Assessment of Management Personnel
Credentials of individual shall be submitted for initial assessment to Competent Authority prior to approval as management personnel. Performance appraisal of management personnel shall establish competency on following, in addition to above general items: ♦ Comprehension on technical issues, with competence to resolve all procedural and
technical complications falling under his responsibilities ♦ Managerial skills including leadership qualities and ability to motivate teams, whilst
practicing good human factor principles ♦ Understanding the application of modern quality concepts in the Organisation ♦ Ability to ensure that all required maintenance is performed as per maintenance
data and when inability to perform / complete a particular task is evident, problem shall be reported to Chief Engineer (Quality Assurance) for appropriate action.
♦ Comprehension of Supervisor also performing maintenance tasks, that such task must not be undertaken when incompatible with any management responsibility.
3.14.2.3 Assessment of Certifying Staff
Deputy Chief Engineer (Technical Services Engineering) concerned shall perform competence assessment for each individual for relevant intended certifying duties, prior to issuance, extension or revalidation of Certification Authorisations. Following shall be the criteria for such assessment: ♦ Ability to perform certification, comprehension for Certification Authorisation scope
and compliance of organisational procedures pertaining to use of maintenance data, tooling and completion of maintenance records.
♦ Ability to interpret and comply, with clarity, instructions laid down in maintenance data to level where maintenance staff need to be guided for a particular task.
♦ Comprehension of relevant aviation technology and knowledge of responsibilities to keep abreast with new technological developments
♦ Aptitude to determine whether an aircraft / aircraft component is ready for release to service or not and understanding customers’ procedures whilst issuing the applicable release certificate (CRS / EASA Form 1, whichever is applicable).
Assessment may not be against complete spectrum of work but shall be over a period demonstrating that staff is adequately exposed to the intended work.
3.14.2.4 Assessment of Quality Assurance Personnel It shall be ensured that Aircraft Engineers in Engineering Quality Assurance shall have similar technical qualifications and status to those working in maintenance areas for reasons of integrity and objectivity. Quality Assurance personnel shall be assessed for competence upon selection and issuance / revalidation of relevant authorisations by Chief Engineer (Quality Assurance). Deputy Chief Engineer (Quality Audit) shall perform competence assessment of Quality Audit personnel. Aircraft Engineer (Quality Audit) shall be able to monitor compliance with Part-145 requirements, identifying non-compliance in an effective / timely manner. During assessment, in addition to items listed in generalities, it shall be determined that Quality Assurance personnel possess skills / aptitude, analytical approach and specific knowledge of aviation legislation, quality standards, maintenance processes, various computer applications, etc.
3.14.2.5 Assessment of Planners, mechanics and Specialised services Staff Competence of all personnel in aircraft / aircraft component maintenance, planning, libraries and other engineering services areas shall be assessed by ’on the job’ evaluation. Deputy Chief Engineer (production) concerned shall ensure that job descriptions against each job role within the section have been developed and personnel are provided with initial and recurrent training for continued competence. Organisational procedures training for particular role in the Organisation shall also be provided to all personnel (Refer MOE 1.11 for details). An individual shall be permitted for unsupervised work after successfully achieving required level of competence. Record of such trainings and competence assessments shall be archived by Deputy Chief Engineer (production) concerned. Assessment of competence shall be performed to establish that: ♦ Ability of planning staff to interpret maintenance requirement into maintenance task
and understanding that they are not authorised to deviate from maintenance data. ♦ Maintenance staff ability to perform maintenance task to any standard specified in
maintenance data and inform supervisors of any mistake requiring rectification. ♦ Specialised services staff shall be able to perform specialised maintenance activity
to standard specified in maintenance data and understanding that they shall inform and await instructions from their supervisor in case where completion of such activity is not possible in accordance with maintenance data.
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part 4 Edition: 3 Revision: 0 Issue: April’ 08 Page 1 of 2
MAINTENANCE ORGANISATION EXPOSITION
PART 4: CONTRACTED OPERATORS
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part 4 Edition: 3 Revision: 0 Issue: April’ 08 Page 2 of 2
To define PIA Engineering & Maintenance policies regarding maintenance and release to service the aircraft / aircraft components on behalf of the contracting operators.
4.1.2 PROCEDURE
4.1.2.1 General PIA Engineering & Maintenance shall maintain and release to service aircraft / aircraft components on behalf of contracting operators. In such contracts, the Organisation shall clearly define limitations for any maintenance task performed for contracting operator, especially for pre-flight inspections, airworthiness of aircraft and serviceability of both operational and emergency equipment.
4.1.2.2 Maintenance Contracts Deputy Chief Engineer (Sales) concerned, in supervision of Chief Engineer (Engineering Business Development), shall manage contracts with the contracting operators for all technical aspects. Contracts shall be formulated in accordance with EASA Part-145 documentation, containing following information: ♦ List of requested maintenance tasks ♦ Applicable maintenance data ♦ Concerned aircraft and / or part identification ♦ Records requested by the Operator ♦ Specific procedure with the Operator (responsibility for provisioning of maintenance
data, components / material, work order, maintenance program, defect rectification, CRS, review of SBs and all requirements mentioned in EU-OPS documentation.)
Contracted maintenance tasks shall never exceed EASA Part-145 approved scope of work and capability (Refer MOE Chapter 1.9 for details). Technical elements of each contract shall be made readily available to the Competent Authority personnel, when deemed necessary.
4.1.2.3 List of Contracting Operators Deputy Chief Engineer (Sales) concerned shall maintain list of contracting operators, providing following information, for each Operator: ♦ Name of the Operator ♦ Location and address ♦ Type of Equipment under contract ♦ Level of work to be performed ♦ Period of contract ♦ Specification of each contract Deputy Chief Engineer (Sales) concerned shall also maintain individual files of each operator for the purpose of records. Records shall be archived for atleast two years after maturity period of the contract.
4.2 OPERATOR PROCEDURES AND PAPERWORK 4.2.1 PURPOSE
To define PIA Engineering & Maintenance policies regarding documentation and procedures to be followed for maintenance performed on the operators’ aircraft / aircraft components.
4.2.2 PROCEDURE
4.2.2.1 General PIA Engineering & Maintenance shall perform maintenance on the aircraft / aircraft components in accordance with operator’s Aircraft Maintenance Program. All such maintenance tasks shall be performed conforming to maintenance data, available or provided by the operator, whichever is referred in the contract. All organisational procedures, defined in this manual must be complied with during accomplishment of maintenance tasks for the contracted operators.
4.2.2.2 Documentation Deputy Chief Engineer (Sales) concerned shall generate Outside Party Work Order (Refer AMP 2-4 for sample), whenever a request for maintenance on aircraft / aircraft component is received from the operator / customer. Such Work Order shall provide details of maintenance tasks to be performed and reference of applicable maintenance data to be utilised for such maintenance. Deputy Chief Engineer (Sales) concerned shall coordinate with Deputy Chief Engineer (Technical Publication & Records) for verification of status regarding maintenance data. Upon confirmation, operator shall be requested to handover aircraft / aircraft component for required maintenance. Certifying staff, holding appropriate certification authorisation, shall issue the aircraft Certificate of Release to Service on Aircraft Technical Logbook or EASA Form 1 for aircraft component, in accordance with operator Work / Repair Order and organisational procedures. For base maintenance activities, task completion and release certificates are recorded on the Organisational recording document such as Task / Work cards, etc. For line maintenance activities, contracted operator may request to use their recording system such as operator’s Aircraft Technical Logbook.
4.3.1 PURPOSE To define PIA Engineering & Maintenance policies for record completion and retention of records on behalf of the operators.
4.3.2 PROCEDURE
4.3.2.1 General PIA Engineering & Maintenance shall complete all maintenance records as specified in MOE Chapter 2.17 and retain copies of such records, on behalf of the customers / operators. If contracted operator ceases operating aircraft, a copy of such records shall be transferred to the next operator.
4.3.2.2 Records Completion Deputy Chief Engineer (Technical Publication & Records) must retain a copy of issued Certificate of Release to Service, providing original to the operator with an update of operator’s Logbooks. Issued authorised release certificate for aircraft component (EASA Form 1) shall be transmitted to the customer / operator and the copies shall be retained. Documents mentioned in MOE Chapter 2.17 shall be provided to the customer / operator and shall include following: i. Status of Airworthiness Directives applicable to aircraft / aircraft components,
including accomplishment date ii. Details of current modifications / repairs with substantiating data to support
compliance with Airworthiness requirements, including:
♦ Compliance program ♦ Master drawings list, production drawings, installation instructions, etc. ♦ Engineering reports (static strength, fatigue, damage tolerance, etc.) ♦ Ground and flight - test results ♦ Weight and balance change data ♦ Maintenance / Repair manual supplements ♦ Maintenance program changes / instructions for continued Airworthiness. ♦ Aircraft flight manual supplement
4.3.2.3 Records Retention
PIA Engineering & Maintenance shall keep all data related to: ♦ Aircraft / aircraft component serial No ♦ Aircraft / aircraft component life (hours, cycles, landings, whichever is applicable.) ♦ Status of all life-limited parts Records of the customer aircraft / aircraft components shall be archived separately from other records. However, procedures as detailed in MOE Chapter 2.14 shall remain applicable. Copies of all detailed maintenance records and associated maintenance data (if any) shall be retained by Technical Records section for atleast three years from
releasing date of particular aircraft / aircraft component. All such records shall be secured against fire, flood and theft. Records keeping area shall have restricted / authorised access for security reasons. Upon cease of maintenance activities, Deputy Chief Engineer (Technical Publication & Records) shall despatch retained maintenance records to last operator / customer of aircraft / aircraft component, through Deputy Chief Engineer (Sales) concerned. If the operator / customer is not traceable, the Competent Authority shall be informed and their judgment shall be considered as final regarding management of such records. For records kept in a computer database (Refer MOE Chapter 2.21), the Organisation shall have at least one backup system, which should be updated on daily basis. In case of loss of a record, it shall either be searched at probable locations or retrieved from backup. If not possible, Chief Engineer (Quality Assurance) shall nominate a team for investigation of the loss. Conclusively, loss statement shall be issued by Chief Engineer (Quality Assurance). Such record shall be recovered in consultation with the concerned customer / operator and record shall be submitted to the Competent Authority for their acceptance.
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part 5 Edition: 3 Revision: 0 Issue: April’ 08 Page 1 of 2
MAINTENANCE ORGANISATION EXPOSITION
PART 5: APPENDICES
PIA ENGINEERING & MAINTENANCE Part- 145
Maintenance Organisation Exposition
MOE Part 5 Edition: 3 Revision: 0 Issue: April’ 08 Page 2 of 2
5.1.1 PURPOSE To define PIA Engineering & Maintenance policies regarding management of list of documents / forms used within the Organisation and sample of forms in Maintenance Organisation Exposition (MOE) / Associate Maintenance Procedures (AMP).
5.1.2 PROCEDURE
5.1.2.1 General Documents / forms are used in the Organisation during support maintenance / support activities and issuance of Certificate of release to service / authorised release certificate for aircraft / aircraft components.
5.1.2.2 Forms Management Need for document / form shall be generated by Deputy Chief Engineer (concerned). Such requisition, alongwith proper justification and design / format, shall be submitted to Deputy Chief Engineer (Quality Audit) for assessment of document / form. Finalised document / form, compliant with EASA Part-145 requirements, shall be despatched to Deputy Chief Engineer (Maintenance Program & Reliability), for allocation of unique form number and onward submission to Chief Engineer (Quality Assurance) for approval. Upon approval, Deputy Chief Engineer (concerned) being initiator shall record the original file and inform Deputy Chief Engineer (Quality Audit) for inclusion of approved document / form in relevant Associate Maintenance Procedures (AMP) in forthcoming revision. Deputy Chief Engineer (Maintenance Program & Reliability) shall make arrangements for printing and accordingly inform all concerned for availability of new form in the allocated Stockroom. Deputy Chief Engineer (concerned) shall communicate for new document / form within the section, with instructions to dispose obsolete ones. Personnel shall be trained, if required for use of revised document / form through recurrent training.
5.1.3 LIST OF DOCUMENTS / FORMS Following table is an overview of technical forms being used in the Organisation. Basic form number is mentioned for each form, listed in alphabetical order, whereas, revision number and sample is provided with relevant Associate Maintenance Procedure (AMP).
121 ESL/001/2002 Work Sheet (1) for Electronics Std. Lab AMP 2-2
122 ESL/002/2002 Work Sheet (2) for Electronics Std. Lab AMP 2-2
5.1.4 LIST OF APPENDICES TO MOE 5.1 1. List of Certifying Staff (Sample) 2. Manual Status Letter 3. Request for change in CCL / Capability Enhancement 4. MOE Amendment Request Form 5. Aircraft Certificate of Release to Service 6. Component authorised Release Certificate (EASA Form 1 Issue 2)
Enclosed herewith, please find Edition No.___, Revision No. ___, Issue date: ___________ of the MOE / AMP. Please read instructions below and act accordingly, upon insertion of revised pages.
1. Remove / discard obsolete pages and replace old ‘Manual status Letter’ with this letter. 2. Put signature, date and official stamp on this letter and place before the Title page. 3. Send a signed copy of new ‘Manual Status letter to:
Deputy Chief Engineer (Quality Audit), PIA Engineering & Maintenance, Karachi.
Above changes (Edition: ___, Revision: ___, Issue: ________), upon grant of Approval by the Competent Authority, shall be incorporated in PIA Engineering & Maintenance MOE / AMP. Chief Engineer (Quality Assurance) Competent Authority Acceptance Date: Date:
5.2.1 PURPOSE To define PIA Engineering & Maintenance policies for subcontracting maintenance tasks to non EASA Part-145 Approved / Accepted organisation and administration of list of subcontractors. However, presently PIA Engineering & Maintenance is not subcontracting maintenance services to any Non EASA Part-145 Approved / Accepted organisation, for aircraft / aircraft components under EASA Part – 145 Approval.
5.2.2 PROCEDURE
5.2.2.1 General Any non EASA Part-145 Approved / Accepted maintenance organisation, for aircraft / aircraft components maintenance under EASA Part-145 Approval, shall be permitted by PIA Engineering & Maintenance. Such organisation shall apply for prior authorisation from Chief Engineer (Quality Assurance). Deputy Chief Engineer (Quality Audit) shall perform an initial audit of potential subcontracted organisation to assess compliance with EASA Part-145 requirements. If the organisation is found with acceptable level of compliance, the authorisation shall be issued by Chief Engineer (Quality Assurance).
5.2.2.2 List of Subcontracted Organisations List of non EASA Part-145 Approved / Accepted organisations, providing maintenance services within intended scope of work under EASA Part-145 Approval, shall be managed by General Manager (Procurement & Logistics). Any amendment in list shall be submitted to Chief Engineer (Quality Assurance) for approval. List of subcontracted organisations shall contain following details: ♦ Name of organisation ♦ Reference number of individual file of organisation ♦ Any approval such as ISO 9001:2000, AS9000, etc. (if any) ♦ Addresses and locations of organisation ♦ Contact numbers of organisation ♦ Approval / Authorisation number of organisation ♦ Nature and scope of work subcontracted to organisation
5.3 LIST OF LINE MAINTENANCE LOCATIONS AS PER 145.A.75(d)
5.3.1 PURPOSE To define PIA Engineering & Maintenance policies regarding administration for list of line stations approved under EASA Part-145 Approval. However, presently no line station except Karachi line maintenance is approved as per intended scope of work for PIA Engineering & Maintenance.
5.3.2 PROCEDURE
5.3.2.1 General Line station shall be location, other than maintenance base, where line maintenance activity is performed on an aircraft / aircraft component under EASA Part-145 Approval. Such line maintenance location shall be capable of supporting any minor maintenance, approved by the Competent Authority (Refer MOE Chapter 1.8).
5.3.2.2 List of Line Stations List of line stations, performing maintenance on PIA aircraft and as well as customer aircraft, shall be controlled by Deputy Chief Engineer (Line Stations). Such list shall provide information for level of maintenance with limitations on different aircraft types. List of line stations shall be reviewed on operational requirements within intended scope of work under EASA Part-145 Approval. An amendment in the list shall be submitted, through Chief Engineer (Line Maintenance) to Chief Engineer (Quality Assurance) for approval. List of line stations shall contain following details: ♦ Addresses and locations of line station ♦ Contact numbers of organisation / personnel at line station ♦ Type of aircraft, level of maintenance with limitations (if any)
5.4 LIST OF CONTRACTED ORGANISATIONS AS PER 145.A.70(a)16
5.4.1 PURPOSE To define PIA Engineering & Maintenance policies regarding administration of lists for the contracted organisations.
5.4.2 PROCEDURE
5.4.2.1 General Contracted organisation shall be an EASA Part-145 Approved / Accepted Maintenance Organisation performing maintenance on aircraft / aircraft components under EASA Part-145 Approval, whenever requested by PIA Engineering & Maintenance (Refer MOE Chapter 2.1).
5.4.2.2 List of Contracted Organisations General Manager (Procurement & Logistics) shall maintain ‘Approved Vendor Lists’, under reference # GM(P&L)/003&004/AVL and GM(P&L)/006/AVL for all contracted maintenance organisations, as per contracts managed by Chief Engineer (Maintenance Operation Centre) on behalf of PIA Engineering & Maintenance. Lists shall be provided in the Organisation as per distribution lists. Any revision in the lists shall be submitted to Chief Engineer (Quality Assurance) for approval. Lists of contracted organisations shall contain following details: ♦ Name of organisation ♦ Reference number of individual file for organisation ♦ Addresses and locations of organisation ♦ Contact numbers of organisation ♦ EASA Part-145 Approval number of organisation ♦ Nature and scope of work contracted to organisation
5.4.2.3 Record Files of Contracted Organisations Deputy Chief Engineer (Repair Abroad) shall maintain files for contracted organisations, providing aircraft / aircraft component maintenance services. Files for contracted organisations, providing pooled / loaned aircraft components and aircraft maintenance at different line stations shall be managed by Deputy Chief Engineer (Rotable Planning). All records shall be archived for a period of minimum two years after maturity / termination of the contract / agreement with the contracted organisation.
