Aeroweld RSM rev 10.1 electronicaero-weld.com/PDF/Aeroweld_RSM_REV_10 Electronic.pdf · Aeroweld RSM Rev 10 i REVISION LOG AND TRANSMITTAL ... 3.3.11 Welder 3-7 10 9/14/12 ... 10.4

UNCONTROLLED WHEN COPIED OR PRINTED CONTROLLED FORMS LOCATED AT: http://www.aero-weld.com/forms.htm

AEROWELD, INC 433 Breesport

San Antonio, Texas 78216

ELECTRONIC REPAIR STATION MANUAL

Including:

QUALITY CONTROL SYSTEM

ELECTRONIC MANUAL: This manual is maintained and revised to be up to date and valid while posted on this internet based link. Aeroweld authorizes no other electronic copies. Users are prohibited from saving or copying this electronic file onto computers or other storage devices. Printed copies of this file are uncontrolled and the user must validate the revision. Please contact Aeroweld at 210-590-7888 with any questions concerning this manual.


AEROWELD, INC 433 Breesport

San Antonio, Texas 78216

REPAIR STATION MANUAL

Including:

QUALITY CONTROL SYSTEM

FAA Certificated Repair Station

W2XR853X

Manual Number:

Assigned To:


AEROWELD, INC Issue: 10 Date: 9/14/12

Aeroweld RSM Rev 10 i

REVISION LOG AND TRANSMITTAL Manual Number: _________ Revision Number: 10 Revision Date: 9/14/12

Page Number Instructions Page Number Instructions all insert

Follow the instructions in the table above to incorporate this revision into your manual. For pages not included previously, you will be instructed to “add” the page. When you “remove” pages, those pages are to be discarded. After you have completed inserting this revision into your manual, sign and date this page in the space provided below. Make a copy of this page and insert it in front of the previous Revision Log and Transmittal pages in your manual. This will provide a chronological revision history. Return the original signed copy of this page to the Chief Inspector.



Aeroweld RSM Rev 10 ii

_________________________________ _____________ HIGHLIGHTS OF CHANGE Revision 9 Complete Rewrite 10 All pages reprinted for convenience. Changes made to the following pages:

2-1 Electronic Manuals Wording Clarified 2-2 Electronic Manuals Wording Clarified 3-10 Employee summary data requirements explained 4-1 Policy on rental equipment defined 5-1 Capabilities List – yearly review explained Section 9 – Contract Maintenance Explained 10-11 New Maintenance Defect form and web site listed 10.14 Self disclosure discussed. A-1 Housing Facilities Updated



Aeroweld RSM Rev 10 iii

TABLE OF CONTENTS

And LIST OF EFFECTIVE PAGES

Title Page Rev Date COVER PAGE n/a REVISION LOG AND TRANSMITTAL i 10 9/14/12 HIGHLIGHTS OF CHANGE ii 10 9/14/12 TABLE OF CONTENTS/LIST OF EFFECTIVE PAGES iii 10 9/14/12 iv 10 9/14/12 v 10 9/14/12 PREFACE vi 10 9/14/12

SECTION 1: GENERAL POLICY AND PROCEDURE 1-1 10 9/14/12

1.1 Introduction 1-1 10 9/14/12 1.2 Definitions and Acronyms 1-1 10 9/14/12 1.3 Changes to the Repair Station 1-2 10 9/14/12 1.4 Capabilities List 1-2 10 9/14/12

SECTION 2: MANUAL REVISION AND CONTROL 2-1 10 9/14/12 2-2 10 9/14/12 SECTION 3: ORGANIZATION AND PERSONNEL 3-1 10 9/14/12

3.1 General 3-1 10 9/14/12 3.2 Organizational Structure 3-1 10 9/14/12 3.3 Personnel Duties and Responsibilities 3-2 10 9/14/12 3.3.1 Accountable Manager 3-2 10 9/14/12 3.3.2 President 3-2 10 9/14/12 3.3.3 Director Quality 3-2 10 9/14/12 3-3 10 9/14/12 3.3.4 Quality Assurance Manager 3-4 10 9/14/12 3.3.5 Chief Inspector 3-5 10 9/14/12 3.3.6 Maintenance Manager 3-6 10 9/14/12 3.3.7 NDT Manager 3-6 10 9/14/12 3.3.8 NDT Level III 3-7 10 9/14/12 3.3.9 NDT Level II Technician 3-7 10 9/14/12 3.3.10 NDT Level I Technician 3-7 10 9/14/12 3.3.11 Welder 3-7 10 9/14/12 3.3.12 Technician 3-8 10 9/14/12 3.3.13 Machinist 3-8 10 9/14/12



Aeroweld RSM Rev 10 iv

3.4 Personnel Qualifications 3-9 10 9/14/12 3.4.1 Supervisors 3-9 10 9/14/12 3.4.2 Repairmen 3-9 10 9/14/12 3.4.3 Inspection Personnel 3-9 10 9/14/12 3.5 Personnel Records and Roster 3-10 10 9/14/12 3.5.1 Inspection Personnel Roster 3-10 10 9/14/12 3.5.2 Supervisor Personnel Records 3-10 10 9/14/12

3-11 10 9/14/12 SECTION 4: HOUSING AND FACILITIES 4-1 10 9/14/12 SECTION 5: CAPABILITIES LIST 5-1 10 9/14/12

5.1 Capabilities List Self Evaluation 5-1 10 9/14/12

SECTION 6: TRAINING 6-1 10 9/14/12

SECTION 7: OFF PREMISES MAINTENANCE 7-1 10 9/14/12

7.1 Performance of Maintenance at a Location 7-1 10 9/14/12 Other than the Repair Station 7.2 Performance of Maintenance at A Location 7-1 10 9/14/12 Outside The United States 7.3 Performance of Maintenance at A One Time of 7-2 10 9/14/12 Special Circumstance Location

SECTION 8: AIR CARRIER MAINTENANCE 8.1 Airworthiness Release For Air Carrier Work 8-1 10 9/14/12 8.2 Required Inspection Item RII 8-1 10 9/14/12 8.3 Mechanical Reliability Reports 8-2 10 9/14/12

SECTION 9: CONTRACT SERVICES 9-1 10 9/14/12 SECTION 10: QUALITY CONTROL SYSTEM 10-1 10 9/14/12

10.1 Introduction 10-1 10 9/14/12 10.2 Revisions to the Quality Control System 10-1 10 9/14/12 10.3 Initiating Work Orders 10-2 10 9/14/12 10.4 Continuity of Inspection Responsibility 10-3 10 9/14/12 10.5 Receiving Inspection 10-4 10 9/14/12 10.5.1 Materials, Equipment, and Tools 10-5 10 9/14/12 10.6 Preliminary Inspection 10-5 10 9/14/12 10.7 Hidden Damage Inspection 10-6 10 9/14/12 10.8 Part Identification and Tracking 10-7 10 9/14/12 10.9 In-Process Inspection 10-7 10 9/14/12 10.10 Final Inspection and Return to Service 10-8 10 9/14/12 10.10.1 Major Repairs and Alterations 10-8 10 9/14/12 10-9 10 9/14/12 10.11 Record keeping System and Procedures 10-10 10 9/14/12



Aeroweld RSM Rev 10 v

10.12 Reports of Failures, Malfunctions, or Defects 10-11 10 9/14/12 10.13 Scrap Parts Program 10-11 10 9/14/12 10.14 Correcting Repair Station Deficiencies 10-12 10 9/14/12 10.15 Technical Data 10-12 10 9/14/12 10.16 Tools and Equipment 10-13 10 9/14/12 10.17 Equivalent and Fabricated Special Tools 10-14 10 9/14/12 10.18 Calibration Policy and Procedures 10-14 10 9/14/12 10.19 Calibration Reference Standards 10-15 10 9/14/12 10-16 10 9/14/12

APPENDIX A: DESCRIPTION OF HOUSING AND FACILITIES A-1 10 9/14/12 A-2 10 9/14/12 APPENDIX B: APPROVED CONTRACT MAINTENANCE LIST B-1 10 9/14/12 APPENDIX C: CAPABILITIES LIST C-1 10 9/14/12 C-2 10 9/14/12



Aeroweld RSM Rev 10 vi

PREFACE

This manual was developed by Aeroweld, Inc., Inc. to meet current requirements of 14 CFR Part 145. It is intended to satisfy the requirements for a “Repair Station Manual” and “Quality Control Manual.” It describes the facilities, equipment, personnel, policy and procedures used in the operation of this repair station. Forms are contained in Forms Manual FM-01. Housing and facility changes that require FAA acceptance are described in Appendix A of this manual. Maintenance functions contracted to an outside source must be approved by the FAA are listed in Appendix B of this manual.

NOTE

All forms mentioned in this manual are contained in the forms manual FM-01.



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SECTION 1: GENERAL POLICY AND PROCEDURE

1.1 Introduction

To operate as a certificated repair station, the person or organization must have a valid Repair Station Certificate issued in accordance with 14 CFR Part 145. Aeroweld, Inc., Inc. has met these certification requirements and been issued ratings by the FAA under certificate number W2XR853X. All work will be performed in accordance with 14 CFR Part 43 and the limitations prescribed in our Operations Specification and Capabilities List found in Appendix C to this manual. This repair station will not perform any service for which it is not rated, and will not perform any service for which it is rated if it requires technical data, equipment, materials, facilities or trained personnel that are not available. Policy and procedures pertaining to specific requirements are described in this manual will be followed. A copy will be accessible for use by repair station personnel at all times.

1.2 Definitions and Acronyms The following definitions for terms and acronyms shall apply when referenced in this manual. Accountable Manager - the person designated by the certificated repair station who is responsible for and has the authority over all repair station operations conducted under Part 145, including ensuring that repair station personnel follow the regulations and serving as the primary contact with the Federal Aviation Administration (FAA). article - an aircraft, airframe, aircraft engine, propeller, appliance, or component part. contract maintenance – maintenance functions performed by person(s) or organizations under an agreement with the repair station. This contract may be written, verbal, or implied. CHDO - the certificate holding district office of the FAA with oversight responsibility of the repair station. EPA – Environmental Protection Agency FAA - Federal Aviation Administration FSDO – Flight Standards District Office RII - Required Item Inspection



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RSM – Repair Station Manual. For the purposes of this manual, the RSM is includes the repair station manual, quality control manual, and training program combined.



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1.3 Changes to the Repair Station If Aeroweld, Inc., Inc. intends to change the location of its’ facilities or makes changes to existing housing or facilities that could have a significant effect on the repair station’s ability to perform work, those changes will be submitted as a revision to Appendix A of this manual. The revised Appendix A must be accepted by the FAA prior to these changes becoming effective. The Accountable Manager is responsible for ensuring this is accomplished. In the event that Aeroweld, Inc., Inc. sells or transfers its assets, an amended repair station certificate is required. The Accountable Manager is responsible for reporting these changes to the FAA. The new owner is responsible for preparing and transmitting to the FAA, the application for such an amendment, and may not operate the Repair Station until these changes have been accepted by the FAA. This repair station certificate does not have any fixed duration. It is effective until it is surrendered, suspended, or revoked. If our certificate is suspended or revoked, or if we elect to surrender it, the Accountable Manager will be responsible for returning it to the FAA.

1.4 Capabilities List

Aeroweld, Inc., Inc. uses a Capabilities List to identify articles maintained by the repair station under the limited ratings.



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SECTION 2: MANUAL REVISION AND CONTROL

Aeroweld will use both an electronic version of the RSM and a hard copy version as required. Aeroweld provides enough computer work stations so all personnel required to use the RSM have access to the manual while performing work for the repair station. Aeroweld personnel working off-site will be issued an internet link to the electronic manual, as necessary.

Revisions to this RSM may be initiated by the Chief Inspector and must be approved by the Accountable Manager. Each revision will be identified using sequential numbering and a date representing when the revision was initiated. A vertical bar (change bar) is placed in the margin adjacent to revised text to make changes easier to recognize by users. Existing change bars will be removed at the next revision to the page. The Table of Contents and List of Effective Pages are combined into one set of pages that help locate subject text and provide a means of verifying the current revision status of each page. Changes made to the RSM are approved by the Accountable Manager and documented by his/her signature on at the bottom of the last page of the Table of Contents and List of Effective Pages.

Aeroweld electronic manuals will be constructed and maintained consistent with the recommendations of FAA Advisory Circular AC 120-78 (as revised). Only the Quality Assurance Manager or his/her designee shall have write capabilities to the Aeroweld manual system. Electronic versions will be published in Adobe Acrobat® PDF format, and will be password protected to prevent changes. Receipt of instruction and familiarization on electronic manuals or revisions thereof shall be reflected by completion and return of Aeroweld Revision Notice/Acknowledgment (AW-33).

The Chief Inspector also will notify the CHDO when the RSM has been revised by letter or email. Aeroweld will provide the CHDO a paper or electronic copy or Compact Disc (CD) of the revised RSM as requested. The FAA CHDO will notify Aeroweld in writing whether it accepts or rejects the revised RSM. The Chief Inspector will retain a copy of the CHDO’s acceptance/rejection document for at least 2 years.

Aeroweld will begin using the revised RSM as soon as it is issued. However, in the event the Federal Aviation Administration (FAA) subsequently notifies Aeroweld that a revision is not acceptable, the Director of Quality and the Manager of Quality Control will determine whether any repair station work is or was affected by the unacceptable revised procedure(s). The Chief Inspector will coordinate any rework required with the customer. If an article has already been approved for return to service, the Chief Inspector will notify the Accountable Manager and the customer, and work with the customer to develop an effective strategy to correct the deficiency.

The Chief Inspector is responsible to ensure that revisions are issued for each copy of the RSM. The Revision Log and Transmittal Page are designed to provide a record of each revision and include instructions for entering the changes into the manual. When a revision



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Manual Revision and Control (cont.)

has been issued, a Revision Log/Transmittal Page is created for the revision. Instructions published on this page are followed by the manual holder when inserting the revision into their RSM. When this process is complete, the page is signed and dated at the bottom by person assigned to the manual.

A copy of this page will be made and inserted into the manual to provide a record of revision. As subsequent revisions to the manual occur, each Revision Log/Transmittal Page is copied and added to the manual in front of the previous record, creating a revision history. The original signed Revision Log/Transmittal Page is returned to the Chief Inspector.

The original signed Revision Log/Transmittal Page is returned to the Chief Inspector to provide a record for monitoring and controlling the revision status of each RSM. A distribution log of manuals will be maintained by the Chief Inspector listing all assigned copies of the manual by number and assignment. The original Revision Log/Transmittal Pages will be kept on file with the distribution log and made available to the FAA upon request.

NOTE: Electronic versions of this manual are completely reissued at each revision, the last “date inserted” and “initials” may remain blank on electronic copies of this document.

Each supervisor and inspector listed on the repair station roster and the FAA CHDO shall be assigned a copy of this RSM. A current copy of this manual will also be accessible for use by all repair station personnel. To prevent access to information that is not maintained current, no employee may make a copy of the manual or pages from the manual, without clearly identifying them as uncontrolled copies.

The RSM will be maintained current at all times. The individual to whom the manual copy is assigned is responsible for updating their manual, even if the task is delegated. If the Chief Inspector does not receive the signed Revision Log/Transmittal Page within 2 weeks of the revision distribution, he/she will contact the individual responsible for that manual.

If the manual has been completely revised, old manuals shall be destroyed.


AEROWELD, INC. Issue: 10 Date: 9/14/12

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SECTION 3: ORGANIZATION AND PERSONNEL

3.1 General

This section contains policy and procedures that relate to personnel issues of the repair station. It includes a description of key positions in the repair station but may not describe other positions that do not directly affect the quality control system.

Employees will be hired based on their skills, knowledge, and experience. Initial qualifications will be evaluated through a review of employment history, training records, and certifications. Job assignments will be made based on the employee’s qualifications. Qualifications for specific positions are defined later in this section.

3.2 Organizational Structure

This organization chart identifies (by title only) each position with authority to act on behalf of the repair station. Only positions that relate to the operation of the repair station are included.

CEO Accountable

Manager

President

Director of Quality Director of Training

Responsible Level III

Quality Assurance Manager

Chief Inspector NDT Manager

Administration

Level III Technician Level II Technician Level I Technician

Maintenance Manager

Welder Machinist Technician



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3.3 Personnel Duties and Responsibilities

3.3.1 Accountable Manager

The Accountable Manager is the person designated by the repair station with responsibility and authority over all repair station operations. All duties of the Accountable Manager may be delegated to any qualified assistant, as they deem necessary. However, such delegation does not relieve the Accountable Manager of the overall responsibilities. The Accountable Manager is responsible for: • Providing adequate equipment, materials and competent, qualified personnel, as

necessary, pertinent to the operation of the repair station, in order that it may comply with all applicable Federal Aviation Regulation and manufacturer’s recommendations.

• Ensuring that all repair station housing, facilities, and equipment are properly maintained.

• Directing, planning, and laying out details of inspection standards, methods, and procedures used by the repair station in complying with all applicable Federal Aviation Regulations and manufacturers' recommendations.

• Ensuring that repair station personnel are trained in accordance with the Personnel Training Program listed in Section 6.

• Maintaining a current roster of all management, supervisory, and inspection personnel. • Coordinating revisions to the Repair Station Manual to insure that changes initiated by

the Chief Inspector are properly reviewed and incorporated into the manual. In the absence of the Accountable Manager, the Director Quality acts on his or her behalf.

3.3.2 President The President reports to the Accountable Manager and is responsible for operations. He is the executive responsible for all operations and management of Aeroweld additionally; he has approval authority for all job quotes. The President is responsible for and has the authority over all repair station operations that are conducted under part 145. His duties include ensuring that repair station personnel follow the regulations. In the absence of the President, the Director Quality acts on his or her behalf.



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3.3.3 Director Quality The Director Quality is responsible to the Accountable Manager or the President for the overall state of the company’s Quality and Inspection system and also serves as the primary contact with the Federal Aviation Administration (FAA). He shall be the final authority in returning to service airframes, engines, propellers, appliances and the component parts thereof. He is also responsible for utilizing organizational resources in order to meet company goals and tasks. The individual provides job quotes and schedules technicians accordingly. He has return to service authority.

Additional duties include but are not limited to the following:

• Ascertain that all inspections are properly performed and that the proper inspection records, reports and forms used by the Repair Station are properly executed prior to releasing the product for return to service.

• Accomplish the final acceptance of all incoming material, including new parts, supplies and the airworthiness of articles on which work has been performed outside the Repair Station by contract.

• Ensures that preliminary, hidden damage, in-progress, and final inspections of all articles processed by the repair station are recorded as outlined in this manual.

• Oversee the proper tagging and identification of all parts and components as outlined in this manual.

• Provide for continuity of inspection responsibility, assuring completion of required inspection when personnel shift or assignment changes occur.

• Ensure rejected and unserviceable parts are handled in such a way as to prevent their reuse as serviceable parts.

• Ensure that all inspections are properly performed on all completed work before it is approved for return to service, and that the proper inspection and maintenance records, reports, and forms required for such release are properly executed.

• Maintain files of completed work orders and inspection forms in such a manner that the file pertaining to a specific repaired item can be located for review.

In the absence of the Director of Quality, the NDT Manager acts on his or her behalf.



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3.3.4 Quality Assurance Manager This individual reports to the Director Quality and has unimpeded access to the CEO. In addition, he is responsible for directing, planning, and laying out the details of inspection standards, methods, and procedures used by the repair station in complying with all applicable Code of Federal Regulations (CFR) and manufacturer’s specifications and recommendations. The Quality Assurance Manager is authorized by the Accountable Manager to make applications for Repair Station Certification and/or rating, FAA Form 8310-3, as it pertains to the original application for certification and rating, change in rating, and changes in location or housing facilities and other forms and initiate correspondence with the FAA in regard to the certification or operation of the Repair Station. It is the duty of the Quality Assurance Manager to: • Assist the Director Quality and provide direction to all personnel assigned as

nondestructive testing technicians. • Maintain and keep a current file of pertinent CFR’s, Specifications, and Airworthiness

Directives • Determine that all technical data on all articles inspected by the Repair Station are

secured and kept current with the latest revisions. In addition, assure that all military technical orders used in the overhaul and repair of components have been evaluated and approved by the FAA.

• Assure that periodic checks are made on all inspection tools and the calibration of precision test equipment used by the repair station is current. Further, assure that a current record of those inspections and test is maintained.

• Determine that no defective, unserviceable, or unairworthy parts are installed in any component or articles released by the Repair Station.

• Submit reports to the FAA within 96 hours of discovering any failure, malfunction or defects of unairworthy condition in accordance with CFR 145.221.

• The proper execution of Malfunction and Defects Report, Form 8010-4 or Service Difficulty Report, Form 8070-1, when required.

• Assure the proper execution of FAA form 337, and / or a maintenance release when it is required.

• Report to the FAA Flight Standards District Office (FSDO) any known violations of CFR’s that the Repair Station is responsible for. Reporting shall be in a manner consistent with AC 120-56, Voluntary Disclosure Report.

• Responsible for the drug and alcohol program. • Providing adequate training, equipment, materials, and competent personnel pertinent

to the operations of the repair station in order that it may comply with all applicable



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CFR, manufacturer’s recommendations, company and quality standards and requirements.

• Assuring that all personnel who perform aircraft maintenance or preventive maintenance functions on Part 121 programs are relieved from duty for at least 24 consecutive hours during any seven day period or the equivalent thereof within any one calendar month.

In the absence of the Quality Assurance Manager, the NDT Manager acts on his or her behalf.

3.3.5 Chief Inspector

The Chief Inspector is responsible to the Director Quality for the overall operation of the inspection department and, as such will have authority in the returning to service. In addition, the inspector is responsible for directing, planning and laying out the details of inspection standards, methods and procedures used by the repair station complying with all applicable CFR’s, manufacturer’s specifications and recommendations.

It is the Chief Inspector’s duty to:

• Ascertain that all inspections are properly performed on all completed work and that the

proper inspection records, reports and forms used by the repair station, are properly executed prior to releasing the product for return to service.

• Maintain and keep current a file of pertinent CFR’s, specifications, type certification data sheets, and airworthiness directives.

• Shall be responsible to keep a record of test and calibration equipment. • Shall see that test equipment is maintained and calibrated according to the standards

specified in this manual. • Determine that no defective, unserviceable, or unairworthy parts are installed in any

component or articles released by the repair station. • Submit reports of unairworthy condition in accordance with CFR 145.221 • Assure the proper execution of FAA Form 8130-3 when required, and/or a maintenance

release. • Accomplish the final acceptance of all incoming material, including new parts,

supplies and the airworthiness of articles on which work has been performed outside the repair station by contract.

• Conduct the receiving, preliminary, hidden damage, in progress, and final inspection of all articles processed by the repair station and record results as outlined in this manual.

• Oversee the proper tagging and identification of all parts and components as outlined in this manual.

• Provide for continuity of inspection responsibility, assuring completion of required inspection when personnel shift or assignment change.



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• See that rejected and unserviceable parts are handled in such a way as to prevent their reuse as serviceable parts.

• Ascertain that all inspections are properly performed on all completed work before it is approved for return to service, and that the proper inspection and maintenance records, reports, and forms required for such release are properly executed.

• Maintain files of completed work orders and inspection forms in such a manner that the file pertaining to a specific item repaired can be readily located for review.

• Responsible for the roster of certificated inspection personal authorized to sign a maintenance release for return to service.

• Audit the work order package to ensure all sign offs are correctly executed and all items accounted for prior to releasing the aircraft.

• Assigns trips outside the United States and notifies the CHDO. • Maintains and distributes the Electronic Manual in accordance with Section IX of this

manual. • Issue badges to new employees. NOTE: The Chief Inspector may delegate all duties assigned to any qualified assistant as necessary, however, such delegation does not relieve the Chief Inspector of the overall responsibilities. In the absence of the Chief Inspector, the NDT Manager acts on his or her behalf.

3.3.6 Maintenance Manager

The welding department manager is responsible for directing and maintaining all welding and other operations of Aeroweld as instructed by the Accountable Manager or President.

Additional duties include but are not limited to the following:

• Directing all personnel assigned to the production department. • Provide adequate training, equipment, materials and competent personnel pertinent to

the operations of the repair station in an order that it will comply with all applicable CFR and manufacturer’s recommendations.

• Ensure that all welding operations are properly performed and that the proper records, reports, and forms used by the repair station are properly executed.

• Ensure that preliminary, hidden damage, in-progress and final inspections of all articled processed by the repair station are recorded as outlined in this manual

• Responsible for reviewing welding documents submitted to Aeroweld and to provide support to parties involved.

• This individual is also responsible for the procurement and proper housing of materials and supply for the maintenance shop.



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• Ensure that all maintenance and if necessary, calibration of equipment contained in the welding shop are maintained in accordance with manufacturer’s recommendations.

In the absence of the Maintenance Manager, the Director Quality acts on his or her behalf.

3.3.7 NDT Manager

The NDT Manager is responsible to the Director Quality for the overall operations of the NDT Department. The Manager of NDT shall have the final authority in the NDT acceptance of airframe, engines, propellers, appliances and the component parts thereof. Additional duties include but are not limited to the following:

• Assist, supervise and direct all personnel assigned to the NDT Department. • Ascertain that NDT inspections are properly performed on all completed work and that

inspections records, reports and forms used by the Repair Station are properly executed prior to releasing the product for return to service.

• Ensure that periodic checks and calibration of all department equipment is performed. • Perform additional duties as required by the Director Quality.

In the absence of the NDT Manager, the Director Quality acts on his or her behalf.

3.3.8 NDT Level III

An NDT Level III is responsible for the training, qualification and certification of NDT Level I and Level II Technicians. This position has return to service authority. Perform additional duties as required by the NDT Manager.

3.3.9 NDT Level II Technician

An NDT Level II is a certificated repairman and as such has return to service authority. Perform additional duties as required by the NDT Manager.

3.3.10 NDT Level I Technician



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An NDT Level I Technician may receive guidance or supervision from a certified Level 2 or 3 when necessary. When authorized by the Responsible Level 3 may perform interpretations and evaluations of specific products(s) or product form(s) for acceptance or rejection in accordance with approved work instructions and have return to service only for those specific items authorized by the Level 3. Perform additional duties as required by the NDT Manager

3.3.11 Welder

A welder performs welding under the direction of the Maintenance Manager. A welder does not have return to service authority. Perform additional duties as required by the Maintenance Manager.

3.3.12 Technician

A technician performs any function that he is qualified for. The technician may hold an FAA Airframe, Power Plant, or Repairman certification. The Technician does not have return to service authority. Perform additional duties as required by the Maintenance Manager.

3.3.13 Machinist

A Machinist performs machining operations under the direction of the Maintenance Manager. A Machinist does not have return to service authority. Perform additional duties as required by the Maintenance Manager.



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3.4 Personnel Qualifications

3.4.1 Supervisors

Supervisors will be technically qualified and have a working knowledge of the overall job functions of the repair station. He/She will be certificated under 14 CFR Part 65 appropriate to the work assigned. The Accountable Manager is responsible for verifying this before assignment of a supervisor and must also meet these qualification requirements.

3.4.2 Repairmen

Repairman certificated under 14 CFR Part 65 for this repair station may perform, supervise and approve aircraft for return to service work for the repair station under the ratings and limitations of their certificate. He/she may not supervise or return to service any work functions that are not specified on the certificate. To be qualified for any ratings under a repairman certificate, a candidate must have a minimum of 18 months of practical experience in the procedures, practices, inspection methods, materials, tools, and equipment generally used in the duties of the specific job. He/She must be familiar with and understand the policy and procedures of this manual and meet all other requirements of 14 CFR Part 65.101. The Accountable Manager and the Director of Quality will determine when AEROWELD requires a repairman. The Accountable Manager and the Director of Quality will review the qualifications of all individuals AEROWELD recommends for repairmen to ensure they meet the requirement of 14 CFR Part 65.101 for the job function they are occupying. The Accountable Manager will recommend individuals as repairmen. The Director of Quality will ensure all individuals who receive repairman certificates have their training record updated to reflect the certificate. If an employee leaves AEROWELD or no longer performs the job requiring the repairman certificate, the Director of Quality will ensure the individual’s repairman certificate is surrendered to the FAA in accordance with 14 CFR Part 65 and the individual’s training record annotated as such.

3.4.3 Inspection Personnel

The Director of Quality selects inspection personnel based on an individual’s qualifications and training. To be an inspector, an individual must be an employee of the repair station and have:



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• Completed company training covering the applicable Federal Aviation Regulations and

current RSM procedures in accordance with Training Program Manual TP-01. • The ability to read, write, speak, and understand the English language. • A thorough understanding of the inspection methods, techniques, and equipment used

to determine the airworthiness of the article, including visual inspection aids.

Before assignment as an inspector with the authority to approve an article for return to service, the Accountable Manager will determine that all of the above requirements have been met. This will be documented and maintained in the inspector’s personnel records. Recurrent training will be conducted in accordance with the Training Program to ensure that proficiency is maintained (reference Training Program Manual TP-01).

3.5 Personnel Records and Roster

The repair station will maintain a roster of all management, supervisory and inspection personnel, including identification of individuals responsible for approving articles for return to service and RII authorizations. The Accountable Manager is responsible for ensuring that this roster is kept current and will revise the roster within five days after any change in personnel or work assignments that could affect the accuracy of the roster, and will notify the CHDO in the same timeframe.

This roster may be maintained either on paper or electronic format, as long as it contains all of the information listed above. The roster will be kept in the Accountable Manager’s office and available for review by the FAA and repair station employees at any time.

The repair station will also maintain employment summaries for each person whose name appears on the roster. The summary will include the employee’s position, certificates held, experience, address, and at least the last three places of employment and description of responsibilities at those locations. Employment summaries will be maintained by the Accountable Manager in his/her office.

3.5.1 Inspection Personnel Roster

The Inspection personnel roster will contain the following information:

• Legal name, present title, and scope of current position; • total years of experience and the type of work performed; • employment history, including name of previous employer and length of employment

by month and year; • a sample of the signature and initials used on work documents • scope of present employment and



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• Type and certificate number of any certificate held, along with any ratings or limitations.

3.5.2 Supervisor Personnel Records

The Supervisor personnel roster will contain the following information: • Legal name, present title, and scope of current position; • total years of experience and the type of work performed; • employment history, including name of previous employer and length of employment

by month and year; • a sample of the signature and initials used on work documents • scope of present employment and • Type and certificate number of any certificate held, along with any ratings or

limitations.



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SECTION 4: HOUSING AND FACILITIES

Aeroweld, Inc. (Aeroweld), FAA Certified Repair Station No. W2XR853X is located at 433 Breesport San Antonio, Texas 78216. Our offices and nondestructive testing instruments, welding and related equipment are stored and maintained at this location. The Accountable Manager is responsible for the efficient layout of the repair station and for ensuring the facilities and equipment are adequate to perform all work under the repair station certificate. The Chief Inspector shall be responsible for all tools / equipment that is rented, leased, or borrowed. He shall ensure that the tools / equipment meet the customer’s requirements and if calibration is required he shall verify that the instrument has a proper calibration label and verify the label with the calibration certificate. In general, Aeroweld uses only company owned equipment. In some instances, an expensive and infrequently used piece of equipment may be rented. When special tools or equipment is required, the Quality Department will obtain the necessary tools or equipment. All tools and equipment, even if not owned or controlled by Aeroweld, will be received and processed through Aeroweld’s receiving inspection process. This includes proper labeling and identification and, if required, verification of calibration. The calibration records must indicate that the equipment is calibrated to the standards established by the article manufacturer, the equipment manufacturer, or standards traceable to the National Institute for Standards and Technology (NIST) or equivalent. The building is of steel frame with concrete block walls construction on a concrete slab and is approximately 5000 square feet. The building has a 120/240 volt electrical supply system with central heat and air conditioning. The shop area has a 150 psig compressed air system. Equipment consists of welding machines, mill, shear, break, lathe, drill press, Heat Treat Oven and non destructive test sets. Whenever a significant change is anticipated to the location, housing, or facilities that might have a significant impact on the ability of the repair station to accomplish its work, the Chief Inspector will develop a revision to Appendix A. The Accountable Manager must approve this revision before a copy is sent to the FAA CHDO for acceptance. The FAA must approve these changes prior to their implementation. After FAA approval, standard manual revision procedures will be followed.



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SECTION 5: CAPABILITIES LIST

The capability list shall those items Aeroweld may inspect using X-Ray under Aeroweld, Inc. Limited Ratings. It is controlled by revision number and date. The Accountable Manager of this repair station maintains a current Capability List.

The Capability List is available for review to all personnel of this repair station. During receiving/inspection, the receiving inspector shall refer to the capabilities list to verify that the services requested are listed. If the services requested are not on the list, the Accountable Manager is notified immediately. The customer will be contacted and the services requested revised to be in compliance with the Capability List, or the work will be declined.

5.1 Capabilities List Self Evaluation

The regulations permit Aeroweld to revise its capability list after conducting a self-evaluation of the repair station’s capability. The Director of Quality is responsible for determining if an article is within the scope of Aeroweld’s authority before adding an article to the capability list.

Aeroweld will conduct a self-evaluation to determine if it has adequate housing, facilities, equipment, tools, material, technical data, processes, and trained personnel to perform work on an article under CFR Part 145. This review will be conducted by the Director of Quality when new capabilities are sought, but not less than once a year. The purpose of the yearly review will be to insure that all of the equipment, documentation, training, and personnel necessary to support the existing listed capabilities are still in place. The Director of Quality will use the Capability List Self Evaluation Form (AW-20) to determine that Aeroweld has the facilities, equipment, data, and trained personnel necessary to perform the work.

The Director of Quality will review the results of the evaluation with the Accountable Manager. If deficiencies are found, they must be corrected and the correction validated before the capability list may be revised. If approved, the Director of Quality or designee will revise the capability list. He will also review the capabilities list at that time and delete any items that no longer meet the minimum requirements of the self evaluation.

The Chief Inspector will submit the revised capability list with a cover letter to the CHDO within five (5) working days of the addition. Upon receipt of the revision, the CHDO is requested to indicate review and acceptance by completion of the “FAA CHDO Acceptance Section” of the List of Effective Pages and returning to Aeroweld. Changes made per that revision will be indicated by change bars located in the left hand margin.



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Records/documentation in support of revisions to the Aeroweld capability listing including but not limited to Aeroweld form AW-20 and any correspondence with the CHDO will be maintained by the Chief Inspector for two (2) years. Records may be purged after the two (2) year required period.



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SECTION 6: TRAINING

Training of Repair Station personnel will be accomplished in accordance with the Repair Station Approved Training Program. This program is set forth in a stand-alone document titled, “Training Program Manual, TP-01.” The Quality Assurance Manager has the overall responsibility for seeing this program is fully implemented. He will also review the effectiveness of the program every 120 days, and initiate changes if found necessary.



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SECTION 7: OFF PREMISES MAINTENANCE

7.1 Performance of Maintenance at a Location Other Than the Repair Station

The NDT / Maintenance Manager will be responsible for assigning the personnel required to complete the job, and the supervision necessary to perform the work in a satisfactory manner. The Chief Inspector will insure that all required forms and work is completed as required by this manual. He will also assign a qualified Inspector who will be responsible for approving/returning the aircraft to service. In addition, the responsible Manager will ensure that the article undergoing maintenance will be protected from damage and from the elements, and that all Repair Station personnel will work in a safe environment. He will also be responsible for providing work forms, tools, technical data, and any other necessary equipment to accomplish the required work, as well as insuring that a copy of the RSM is available for use.. He will establish an effective communication system between the field site and the Repair Station. All personnel assigned to the field site will accomplish the specific function of work in the same manner as if it were performed at the Repair Station, unless deviations are approved by the Chief Inspector, and in accordance with all applicable Federal Aviation Regulations.

7.2 Performance of Maintenance at a Location Outside The United States Aeroweld Inspections may provide specialized service for its customers at a location outside the United States on a temporary basis. An occasion may arise in which an Aeroweld customer has an aircraft located in a foreign country that requires specialized services; Aeroweld will provide services for which it is rated, provided the following occurs:

• The Aeroweld customer inquires about the possibility of work being performed • A Contract or Work Order is executed between Aeroweld and the customer

describing the work to be performed.



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• The CHDO will be notified of operations to be performed in a foreign country by the Chief Inspector by phone conversation and followed by a formal letter of request e-mailed or faxed for approval.

• Work is performed in accordance with procedures in this section. • Services provided in a foreign country will be conducted on a temporary basis,

and will terminate upon completion of the services as defined in the contract.

Regardless of where maintenance services are to be performed, an evaluation will be made of the work to be performed by the Chief Inspector, or his designee, in determining the scope of work to be performed, required personnel, and material required to accomplish the job. The Chief Inspector may delegate his duties to the technician outside of the United States, if physical tasks normally performed by the Chief Inspector are required.

7.3 Performance of Maintenance At A One Time or Special Circumstance Location Should Aeroweld need to perform services at a location not previously approved under this RSM, the Chief Inspector will contact the CHDO to obtain permission. This contact will be either in writing or via e-mail. The response of the CHDO will be retained for a minimum of two years after the work is performed.



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SECTION 8: AIR CARRIER MAINTENANCE

Aeroweld may perform maintenance, preventive maintenance, alterations, and inspections for air carriers conducting operations under CFR Parts 121, 125, 129, and 135, and for other customers. Before work is accepted, the Chief Inspector will verify that Aeroweld is authorized and has the proper manuals, tools, test equipment, and qualified personnel to accomplish the work. If there is any special training required, including training by the customer (as would be the case for an RII), the Chief Inspector will notify the Accountable Manager. For training provided by the customer, the Manager of Training will work with the customer to ensure any Aeroweld personnel requiring training receive the training before beginning work. The Chief Inspector will be the principal contact for the Air Carrier. He will review all purchase orders and purchase order amendments for complete and correct instructions. The Chief Inspector will keep a file of the Air Carrier’s procedures, including all necessary technical data.

8.1 Airworthiness Release For Air Carrier Work

All work performed under the continues airworthiness requirement of CFR 121, 125, 129, and 135 will have an airworthiness release or appropriate entry in the aircraft log prepared in accordance with the certificate holders manual for the work performed.

Aeroweld will maintain adequate personnel for the performance of work which it contracts.

Prior to starting any work, Aeroweld will have in its possession, a current copy of the applicable section of the maintenance manual for the work that is to be performed.

Each person performing maintenance or preventative maintenance, working a Part 121 aircraft under the provisions of continuous airworthiness requirement will be relieved from duty for 24 consecutive hours during any seven day period or its equivalent, in any one calendar month.

A list of supervisory and inspection personnel is maintained at Aeroweld listing the authorized personnel in responsible for the maintenance and inspections and who hold an appropriate FAA Mechanic’s or Repairman’s Certificate.



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8.2 Required Inspection Item RII

A Required Inspection Item (RII) is any maintenance operation, repair or alteration which, if improperly performed could result in a failure, malfunction or defect, endangering the safe operation of the Aircraft if not performed properly or if improper parts or materials are used will be given a required inspection.

When work is performed for an air carrier under the continued airworthiness requirements of CFR Parts 121, 125, 129, and 135, and is and is a Required Inspection Item the person with the final acceptance shall be qualified as an RII Inspector by the owner/operator.

The owner/operator shall furnish to Aeroweld, Inc. a list of Required Inspection Items and the Chief Inspector or his designee, will review the experience level, training records, and qualifications of inspection personnel who will perform the RII inspections and submit their names of qualified personnel to the air carrier for their approval. As a minimum each RII qualified personnel shall hold a valid FAA A&P certificate or appropriate Repairman’s Certificate.

8.3 MECHANICAL RELIABILITY REPORTS

When work is being accomplished for an air carrier and a defect as described under the Malfunction or Defect Report is found, the air carrier will be notified in order that a Mechanical Reliability Report may be issued by the air carrier. The certificate holder of the aircraft is responsible for reporting the Mechanical Reliability Report per CFR 121.703.



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SECTION 9: CONTRACT SERVICES

Aeroweld only contracts minor services necessary as part of a larger effort. This includes items such as having an item sandblasted so that Aeroweld may perform an inspection on the bare item. If the item must be returned painted, that service would also be contracted. None of the primary services Aeroweld provides are contracted. The Quality Assurance Manager is responsible for the contract maintenance program. Aeroweld may contract maintenance to certificated and non-certificated facilities provided:

a. The maintenance function is approved by the CHDO; b. Aeroweld provides a listing of maintenance functions to be contracted to each outside facility in a format acceptable to the CHDO; c. Aeroweld remains directly in charge of the work performed by the non-certificated person; d. Aeroweld verifies by test and/or inspection, that the work has been performed satisfactorily by the non-certificated person and that the article is airworthy before approving it for return to service; e. The non-certificated person follows a quality control system equivalent to the system followed by the certificated repair station;

In accordance with the requirements of 14 CFR §145.223(c), Aeroweld will not approve for return to service any article on which a maintenance function was performed by a noncertificated person if the non-certificated person does not permit the FAA to make the inspection described in 14 CFR §145.223(b). In accordance with the requirements of 14 CFR §145.217(c), Aeroweld will not provide only approval for return to service of a complete type-certificated product following contract maintenance, preventive maintenance, or alterations.



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SECTION 10: QUALITY CONTROL SYSTEM

NOTE

All forms mentioned in this manual are contained in the forms manual FM-01.

10.1 Introduction

This section defines quality control policies and procedures used by Aeroweld, Inc., Inc. The purpose of the quality control (QC) system is to ensure the airworthiness of the articles on which the repair station maintains or services.

Other required elements of the quality control system pertain to currency of technical data and calibration of test equipment. Policy and procedures regarding technical data, equipment and tools can be found in this section. This section describes the following:

• the system and procedures for inspection of incoming raw materials. • the system and procedures for preliminary inspection of parts to be plated. • the system and procedures to inspect for hidden damage. • the system and procedures for performing final inspection. • the system and procedures for correcting repair station deficiencies.

In addition, Appendix D of the RSM contains samples of all necessary standard forms and an explanation of how to complete those forms.

Aeroweld services are offered at our location and at the location of the customer’s aircraft. The Quality system has been designed to insure that work performed at any location meets the same requirements and standards. Services and locations are as follows:

• Non Destructive Testing (NDT) In shop and On Aircraft • Welding - In shop and On Aircraft • Machining – In shop only • Heat Treat – In shop only

Different procedures and forms are required depending on the type of work being performed and the location. Those differences are noted in the following sections.



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10.2 Revisions to the Quality Control System

Revisions to the Quality Control System will be accomplished in accordance with standard manual revision procedures found in Section 1. One required element of the quality control system described in 14 CFR 145.211 is the establishment and maintenance of inspection personnel proficiency. This information is published in Section 3 of this manual.

10.3 Initiating Work Orders

Upon receipt of a work request for maintenance on an airframe, engine accessory, propeller, or a product requiring a specialized service covered by the Repair Station certificate, the NDT Manager or his designee will issue a Repair Station Work Order Form AW 18 to authorize that work to be accomplished. The work order number is the sequential number on the work order form. The number will then be the basic reference for the product’s maintenance record. The work order will specify the work to be accomplished.

The work order will be supplemented as necessary with detailed inspection instructions along with applicable forms to assure proper inspection and repair of the item involved. Those forms will be identified by the work order number. A copy of the printed and numbered work order form may be retained in the Chief Inspector’s office for reference. However, the official copy will be maintained in archives for a maximum of 2 years.

Upon completion of a work order the Chief Inspector or his designee closes out the work order.

It will be the responsibility of the Chief Inspector to ensure that proper supplemental instructions are furnished to ensure proper progressive servicing, inspection and testing of the product involved.

NDT Technicians / Inspectors will annotate work accomplished on Aeroweld NDT Report forms (AW-1) and use their signature to sign off work. NDT Technicians and Inspectors will be responsible for the quality and completeness of all work performed. All work must comply with FAA and Aeroweld standards. NDT Technicians / Inspectors will ensure all appropriate documents reflect the current job status and the sign offs are complete and correct. NDT Technicians / Inspectors will use their signature to signify acceptance of inspections and discrepancies.

A list of NDT Technicians / Inspectors is maintained on file in the Chief Inspectors office.



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A copy of work orders and supplement forms can be found in Section VI of this manual.

Work orders will be shown to be complete when Aeroweld forms are signed by authorized individuals.

10.4 Continuity of Inspection Responsibility

The continuous progress of inspections includes a receiving inspection, preliminary inspection, hidden damage inspection, and all other required inspections that must be accomplished through the various stages of work applicable manufacturers' recommendation or other acceptable or approved methods and procedures.

A turnover Log will be provided, when necessary, at each job site in which a status is maintained for information to the succeeding inspector. Its purpose is to assure a continuing responsibility for in-progress work inspections.

All forms used to document work performed on aircraft or components have been designed to show the signature of the NDT technician, welder, technician or inspector who performs the inspection.

Continuity of inspections between shift changes for Aeroweld Inspections issued and controlled work documents is by partial work buy-off of the applicable work document. Work documents for customers of Aeroweld will be maintained in accordance with the customer’s manual requirements (if different from Aeroweld Inspections).

After maintaining an airframe, powerplant, propeller, or accessory for which this repair station is rated, that article will be checked by a qualified inspector prior to being approved for return to service. Certification that the part is airworthy with respect to work performed will be documented on appropriate work order or aircraft maintenance records.

Samples of work forms, inspection forms and instructions for completing them are contained in the Forms Manual FM-01. At the completion of maintenance, the Chief Inspector or his designee will audit the work order package to ensure all sign-offs are correctly executed and all items are accounted for prior to releasing the aircraft.



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10.5 Receiving Inspection

All components, hardware, or raw material received by Aeroweld require as a minimum, a visual inspection. All material shall have the Purchase Order Number placed on the box or on the material as appropriate. Example: PO XXXX. All material shall have traceability to the manufacturer.

The Chief Inspector is responsible to see that all incoming hardware, parts, components, materials, equipment and other products processed for use by the Repair Station are subject to a receiving inspection to insure conformance to Aeroweld purchase orders, and/or applicable technical specifications and meet acceptable quality standards.

The receiving inspection is used to verify parts, processes, and work that was performed conforms to the order requirements, and that the paperwork received (material certifications, calibration certifications, etc.) verifies the authenticity of the item, the work performed and/or traceability to a known standard. Items received are also inspected for contamination, damage incurred during shipping and the proper state preservation. When damage has occurred to the shipping container or the material within the container the customer shall be notified and the container quarantined in the bond area until the issue is resolved. Pictures of the damage shall accompany the notification to the customer via e-mail.

Materials identified as having a specific shelf life shall be identified with Aeroweld Form AW-9 Shelf Life label and placed in the proper storage area until they are needed. The stock of similar materials should be rotated so the older, unexpired shelf life items may be used first.

All aircraft related parts brought into the facility will have a completed parts identification tag(s) attached. Should a part be delivered to the facility without a tag attached the employee making the discovery will be responsible for completing and attaching an Aeroweld Parts Identification Tag, AW-3.

Any items that fail to conform to the technical data will be identified with a Rejected Parts Tag Form AW-2, and segregated in a bond area, if practical, until the item can be returned to the vendor for replacement or scrapped. All items that pass shall be routed by the inspector to the appropriate incoming shelf for inspection / repair. All aircraft related items sent out to contractors for subsequent operations such as plating, bead blasting, etc shall be returned to Aeroweld with the information that was



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required on the original PO for service. All paperwork shall remain with the part and a copy retained by Aeroweld for two years.

At no time shall any items be released until the Chief Inspector or his designee has approved the material to the pertinent technical data.

The receiving inspection will be recorded on Aeroweld Receiving Inspection Form AW-34. Traceability of materials received in lots, such as weld wire, Penetrant and Magnetic particle shall have the batch number attached to the container and the original certification retained maintained by the Chief Inspector.

10.5.1 Materials, Equipment, and Tools

The Chief Inspector or his designee will check all incoming materials, equipment, and tools to ensure that they conform to purchase orders, conform to acceptable technical standards, and are properly identified. Shelf-life items will be identified and the manufacturer’s expiration date will be clearly marked on the part, material, and/or container, along with the Received Date, Purchase Order Number, and Expiration Date using from AW-4. Incoming materials will also be inspected for shipping damage, corrosion, rust or other deterioration. Any material or component failing to meet the incoming inspection will be clearly labeled with a discrepancy tag stating the reason for rejection. The Chief Inspector will decide how to correct any discrepancies or how to dispose of an item.

10.6 Preliminary Inspection

The Chief Inspector will perform this inspection. The inspection will be performed before the Repair Station begins work on the article. The inspection will be appropriate for the article being serviced and may include visual, operational, and limited disassembly if necessary to allow thorough inspection.



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Aeroweld from AW-19 is used to record the inspection results. This from will be completed before any services are performed on the article being inspected. If discrepancies are discovered, they will be recorded on the form along with the recommended actions to correct these discrepancies. The Chief Inspector is responsible to insure that any required current technical data is available before inspection If the part is serial numbered and life limited, the Chief Inspector will determine the item’s total time, as well as the time since overhaul.

The Chief Inspector will also perform a Suspect or Unapproved parts inspection for all articles received. In addition, the Chief Inspector is also responsible to determine if defects found on the article must be reported a failures or defects to the FAA.

The completed Preliminary Inspection form is to be added to the work order file. If recommended actions are listed on the form that were not actions requested by the customer, the part will be moved to the repair station bonded area and the customer contacted by the Chief Inspector. The customer will be informed of the additional actions necessary to the article. If the customer agrees with the recommended actions, these actions will be added as part of the work order scope.

If the customer does not agree with the recommended action, the Chief Inspector will be responsible to determine if the part can be restored to an airworthy condition without the recommended actions being taken. If the part can be satisfactorily restored without the recommended actions, the Chief Inspector will complete the Preliminary Inspection form (AW-19), noting in the Recommendation section which work the customer declined to have performed. If the Chief Inspector determines that the article cannot be restored to airworthy condition without the recommended work being performed, he will have the article returned to the customer and the Repair Station will decline the work.

If the article is released for servicing within Aeroweld, a completely filled out Part Identification tag (AW-3) will be attached to the part. If the part is returned to the customer, it will be packed, marked, and tagged as received.

The NDT / Maintenance Manager will insure, prior to beginning any work for an air carrier under the continuous airworthiness requirements of CFR Parts 121, 125, 129, or 135, that the current necessary information and specifications are included or referenced in the work instructions accompanying the article through the inspection process. This will insure that the work is performed in accordance with the owner/operator instructions.

10.7 Hidden Damage Inspection Any airframe, powerplant, accessory or associated part that has been involved in an accident will be subject to a thorough and searching inspection for Hidden Damage. These inspections will be performed in areas adjacent to the damaged area and/or in the



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case of deterioration, a thorough review of similar materials or equipment in a particular system or structural area. The Chief Inspector has overall responsibility for this inspection.

The scope of this inspection will be governed by the type of unit involved with special consideration to previously recorded operating history, malfunction or defect reports, service bulletins and A.D. notes applicable to the unit(s) involved.

The NDT technician or inspector is responsible for listing of all discrepancies noted during this inspection of the aircraft, engine or appliance which will be documented on either an Aeroweld NDT Report form (AW-1) or owner/operator approved documentation forms. All of these forms become part of the Work Order file.

The Chief Inspector will notify the owner/operator of the results of the inspection and will either authorize the repair of the noted damage or will defer the repair in accordance with the Air Carriers approved procedures as outlined in their maintenance manual.

10.8 Part Identification and Tracking Some NDT processes performed by Aeroweld require complete cleaning of the part. This may remove existing identification. The cleaning process may also prevent the attachment of tags or labels to the individual parts. The procedures defined in this section insure that identification and control of parts is maintained throughout the process. Throughout the inspection process, some form of identification will remain with the part. This may be accomplished by keeping the Work Order form near the part, or by the Work Order number being listed on a tag on the part. At all times is must be possible to easily identify the Work Order to which the part belongs.

10.9 In-Process Inspection

The Chief Inspector will review the applicable technical data, customer instructions, or when adequate inspection cannot be performed at a later stage, and make a determination of the requirement for In-Process Inspection(s). When In-Process Inspections are found to be required, form AW-36 will be used to document the requirement. The Chief Inspector or his designee will perform the inspection. If multiple inspections are required, one copy of the form will be used for each inspection. If the inspections must be performed in a certain order, the Chief Inspector will indicate on the form.



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If the work is found unsatisfactory, it will be written up on form AW-36, along with the corrective action taken. If rework is required the customer’s paperwork will be reviewed by the Chief inspector to determine if rework is allowed. If rework is allowed then Aeroweld will proceed with the rework. If rework is not allowed then the customer will be consulted for further action. All results shall be documented on AW-36. If the work being performed is NDT, form AW-1 may be used to record the results of in-process inspections. The NDT Manager will be responsible for determining when in-process inspections are necessary. This form will also be used to record any NDT defects noted as well as corrective action. All paperwork created to document in-process inspections will become part of the Work Order Package. Aeroweld does not use outside services to perform work that could require in-process inspection.

10.10 Final Inspection and Return to Service The paperwork requirements to document final inspection and return to service are different depending on the work involved. The final inspection and results of NDT work will be documented by form AW-1. In most cases, the final inspection of welding, machining, and heat treating will be documented by the issuance of an 8130-3. When the Chief Inspector feels that the final inspection of an item requires additional documentation, he will require that form AW-37 be completed as well. The Chief Inspector will also designate a trained, qualified, and authorized person to perform the final inspection. No aircraft, engine or component may be approved for return to service until the work order and other records have been reviewed for completeness and accepted by the Chief Inspector. If any item is found to be not satisfactory during the final inspection, it will be documented using from AW-37 or AW-25. At the completion of rework procedures, the item will be re-inspected by the original inspector. The Final Inspection will not be complete until the item has passed inspections. Prior to approval for return to service an inspector will audit the records as identified by the work order, to determine that all work has been inspected as required for compliance with this inspection system. The assigned inspector will review records for completion by authorized personnel and certify that the article is airworthy with respect to the work performed. He then will approve the article for return to service by signing the 8130-3 (AW-10).



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The item will also be identified as appropriate. Small parts and assemblies will have an Aeroweld Part Identification Tag (AW-3). Work that does not lend itself to having a tag attached (Example: Borescope inspection of an on wing engine) will be identified by having the service performed recorded in aircraft maintenance log book or appropriate work orders when aircraft log books are not applicable.

10.10.1 Major Repairs and Alterations

The Chief Inspector or his designated representative will be responsible for establishing that the major repair or major alteration was performed in accordance with the requirements of CFR 43 and will sign the conformity statement (item 6) on FAA Form 337 (AW-15). A statement of notification that “Adjustment of your continuous airworthiness maintenance program may be necessary” will be noted in block 8 of the form 337 (AW-15) or in the logbook entry.

Authorized personnel responsible for the approval for return to service of aircraft, engines or accessories will indicate such approval by signing the approval for return to service (item 7) on FAA Form 337 (AW-15). Appropriate entries will be made in the aircraft record pertinent to the repairs and alterations accomplished by the repair station. Specific reference will be made by the calendar date to the applicable FAA Form 337 (AW-15).

FAA Form 337 (AW-15) will consist of two originals and one photocopy. Original signature copies will be sent to owner/operators and to the FAA. The photocopy will be maintained as part of Aeroweld records.



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10.11 Record keeping System and Procedures Detailed records of work performed by the repair station will be maintained in a work order file retained by the Chief Inspector. These files contain all documents used to record inspections and any other work performed. Documents that may be contained in the work order file include, but are not limited to:

Copy of Form AW-1 NDT Report Copy of Form AW-15 Shipper Copy of Form AW-18 Work Order Copy of Form AW-10 8130-3 Any other paper work to support the work performed.

All records will be retained for a minimum of 2 years from the date the article was shipped. All records will be available for inspection by the FAA and the National Transportation Safety Board. The customer will describe what records they will receive in the PO and or contract. All NDT services will have at the minimum AW-1 filled out. Depending on the customers requirements they may also receive a 8130-3. Heat Treat parts will have a certificate of conformance and a 8130-3 completed if required by the customer. Instructions for competing forms used by the repair station can be found with a sample of each form in Appendix D of this manual. FAA forms used by the repair station will be completed in accordance with instructions provided for those forms. Form 8130-3 will be completed using FAA Order 8130.21, as amended. As work steps are completed, the person performing the step will initial the appropriate place on the document for that work item. Where applicable, inspectors indicate the acceptance of the work or inspection performed by placing their initials or signature next to the technician’s on the work order document. Prior to a form being released to the shop, any blocks on the form that are not applicable will be so indicated. Any block or space that is not to be filled out will have “n/a” written in the space with the initials of the Quality Manager, or his designee, as may be applicable. While the form is in the shop, if correction to a written entry needs to be made on a form or record, a single line will be drawn through the text and initialed by the person making the correction. Part of the final inspection will be the review of all applicable forms for completeness and indications of change. Records of special inspections, such as hydrostatic test, functional test, etc. shall be listed on the 8130-3.



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10.12 Reports of Failures, Malfunctions, or Defects

Should Aeroweld, Inc. ever become aware of conditions of a part that could seriously affect airworthiness, the Accountable Manager is responsible for the proper and timely filing of reports on this condition. These reports will be made in accordance with the following instructions:

(a) .Aeroweld will report to the FAA within 96 hours after it discovers any serious defect in, or other recurring unairworthy condition of an aircraft, power plant, or propeller, or any component thereof. The report will be made utilizing the Online Service Difficulty Report site, describing the defect or malfunction completely without withholding any pertinent information. Two copies of the online entry form will be printed. One copy will be kept in the QA department and the second will be forwarded to the FSDO. The use of this form is self explanatory on the Web site:

https://av-info.faa.gov/SDRX

(b) If the defect or malfunction could result in an imminent hazard to flight, the

Repair Station will contact the FSDO by phone to ensure they have been notified immediately.

10.13 Scrap Parts Program

When a part or component is deemed beyond economical repair a Rejected Tag (AW-2) will be completed and attached to the defective item. The item shall be returned to the owner/operator for disposition. If the owner/operator chooses not to have the defective item returned, Aeroweld shall scrap the part by mutilation in such a manner that the item is not usable on an aircraft. Any identification tags will be removed and retained with the scrap record. The scrap record shall contain a copy of the purchase order, the AW-2, the scrap authorization from the owner/operator and the ID if applicable. Scrap records shall be retained indefinitely and will have the name and signature of the person and witness conducting the scrap.

The owner/operator shall authorize the scrap in writing prior to the scraping by Aeroweld. The Chief Inspector is responsible for the scrap parts program and in his absence the Director of Quality shall assume these duties.

10.14 Correcting Repair Station Deficiencies



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The Accountable Manager has the overall responsibility for correcting all Repair Station Deficiencies. Any deficiencies discovered in repair station policy or procedures will immediately be brought to the attention of the Accountable Manager. A thorough review of the problem will be performed and improvements to the procedures will be developed to correct the deficiency. The RSM will be revised to incorporate the corrected policy and procedures. If a deficiency in repair station policy or procedures is discovered, corrective action will be taken immediately to remedy the problem. Corrective action would be appropriate in two situations under this repair station’s system:

• Prior to the work being approved for return to service; and, • After the work has been completed and approved for return to service.

Whenever an inspection or work scope determines that a maintenance step or function has been accomplished incorrectly, the work will be repeated and inspected to ensure proper completion. The Accountable Manager will review this work process to ensure that the improper work was not the result of a deficiency in facilities, equipment, tooling or material. If it is discovered that any part, for any reason, was improperly approved for return to service, the repair station will immediately rectify the situation with the customer. Additionally, the Accountable Manager will determine whether the incident should be reported to the FAA under the Voluntary Disclosure procedure contained in AC 00-58. The Accountable Manager with the assistance of the Director of Quality shall determine the root cause of the deficiency by utilizing the “5 WHYS” and initiate a CAR on form AW-23 along with the corrective action. All repair station deficiencies affecting the airworthiness of any aircraft shall have the corrective action implemented within 24 hours. All deficiencies not affecting the airworthiness of any aircraft shall have the corrective action implemented within 14 business days. The Accountable Manager will continue to monitor the performance of the Repair Station, with emphasis on the deficiency to ensure the corrective action has been effective. All documentation associated with the deficiency, AW-23, memos, and training if required shall be retained for a minimum of two years. Self-Evaluation records are confidential internal documents that are the property of Aeroweld; however, the Accountable Manager will consider submitting a voluntary disclosure report if a potential regulatory violation is involved.

10.15 Technical Data



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Aeroweld has a technical library consisting of industry standards, OEM’s Nondestructive Test Manuals and other supporting technical data. It is Aeroweld’s’ intention to ensure the library is maintained current by periodically checking the various sources responsible for maintaining these data to determine the most current revision status. Regardless, Aeroweld understands that following documents and data must be current and accessible when the relevant work is being performed: The Quality Manager has the primary responsibility for the technical library with the Director of Quality assuming these duties in his absence.

• Airworthiness directives (AD’s) • Instructions for continued airworthiness • Maintenance manuals (OEM Nondestructive Test Manual) • Overhaul manuals • Standard practice manuals • Service bulletins • Other applicable data acceptable to or approved by the FAA

For aircraft operated under CFR 91, 121, 125, 129 and 135 the technical data used for the inspection(s) shall be supplied by the owner/operator of the aircraft unless Aeroweld maintains current technical date for that airframe. If technical date requires translation to English the customer will be responsible for translation, quality checks, revisions, and distribution.

All work conducted by the repair station will be accomplished in accordance with current technical data applicable to the scope of work being performed. The repair station will not approve for return to service any article unless work was performed in accordance with applicable approved technical data or data acceptable to the FAA. Aeroweld, Inc., Inc. will ensure that all applicable technical service publications are available before accepting work to be performed under the repair station certificate ratings. Applicable technical publications and data will be located on the premises and under the repair station’s control when the work is being done. The Quality Manager, depending on the type of data, maintains technical data. The Production Manager maintains all data related to parts, assemblies, and FAA Regulations. The Quality Manager is responsible to ensure that the technical data is maintained in a current condition at all times and will periodically check the revision status of all technical publications. Any publication that is found to be out-of-date will be marked “Outdated - for reference only.”



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10.16 Tools and Equipment Aeroweld, Inc., Inc. will use the tools and equipment recommended by the manufacturer. Tools and equipment will be stored properly and maintained in good working order.

10.17 Equivalent and Fabricated Special Tools Aeroweld, Inc. Services Company, Inc. uses only tools and equipment recommended by the respective manufacturers.

10.18 Calibration Policy and Procedures

Precision tools and test equipment used by the repair station will be subject to periodic checks and calibration. Measuring tools and test equipment (MTE) used for this purpose must be calibrated according to the procedures and at the intervals prescribed by the manufacturer of the tool or equipment or industry standards. All calibration standards used will be traceable to the National Institute of Standards and Technology (NIST) standards. The Chief Inspector will maintain a list of all tools and equipment requiring calibration. When a new tool is brought into the system the Chief Inspector will assign a unique number for traceability. The number will be affixed to the tool by mechanical engraving, adhesive labels, indelible ink marking, steel stamp, etc. Calibration schedules will be tracked in the company calendar database. This list will include the inspection interval for each item as well as the date it was last calibrated. The Chief Inspector is also responsible to make sure that any tool or equipment that has not been calibrated within the required timeframe is removed from use until calibration is performed. The Director of Quality may extend the calibration recall of a tool one time between calibration cycles for 15 days due to unforeseen circumstances provided that the tool was in tolerance the last calibration cycle. Tools and equipment requiring calibration will be appropriately labeled with the vendor’s calibration label to indicate calibration status. When it is impractical to apply a calibration label directly to an item, the calibration label may be affixed to the item’s container. Precision tools and measurement equipment that do not require periodic calibration will have a label marked NCR (No calibration required). Tools or equipment may be used until the last day of the month when calibration is due.

Contractors will be used for calibration of measuring and test equipment. The Chief Inspector will ensure that any contractor used follows a documented calibration system consistent with the standards of NIST. These standards require them to produce a calibration certificate or record for each item of equipment including:



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• the work order number of the company that performed the calibration; • a description or identification of the item; • the date of calibration; • the date next calibration is due;

In addition, the Work Order provided by the company performing the calibration must contain at a minimum:

• the standard used to perform the calibration; • the method used to perform the calibration; • the results of the calibration • any calibration actions taken. • the certificate or report number. • Test points if applicable

If any out of tolerance condition is determined during the process of calibration, the Chief Inspector will attempt to determine what caused the out of tolerance condition to occur. The Chief Inspector is also responsible to determine if the out of tolerance condition could have had an adverse effect work performed since the date of the last calibration. The Chief Inspector will review these conditions with the Director Quality and appropriate action as necessary will be taken. The Chief Inspector is responsible for the calibration system and will retain all calibration certificates or records for at least two years. He / She will maintain a current list of calibrated equipment by name, model or part number, serial number, date of last calibration, and next calibration due date. Employee owned measuring and test equipment that is used in the facility will be included in the calibration system.

New precision tools and measurement equipment will be evaluated for calibration requirements before being place into service. Measuring and test equipment that requires calibration will be removed from service until calibration is accomplished. Tools that are overdue shall not be used until calibration is accomplished. Every effort shall be made to find tools that are lost. If a tool cannot be located within 30 days then that tool shall be deleted from the list. Borrowed, Leased, or Rented calibrated tooling shall be evaluated by the Chief Inspector to verify compliance with this manual. He shall verify that the calibration certificate is meets the requirements of this manual and that the calibration due dates match the calibration sticker on the tool.



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10.19 Calibration Reference Standards Calibration reference standards do not require periodic calibration; however they do require a certificate of conformance when they are manufactured. If Aeroweld chooses to manufacture a reference standard the NDT Level III will be required to certify the standard to the drawing. The certificate should include the following if applicable:

• Length, Width, Height • Material Type • EDM Notch dimensions • Conductivity and Hardness This information shall be documented on from AW-39, Certificate of Conformance Reference Standards. All reference standards shall be inspected prior to use by the NDT Technician for damage that may cause inaccurate readings. All reference standards will be stored in a manor to prevent damage due to environmental conditions.



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APPENDIX A: DESCRIPTION OF HOUSING AND FACILITIES

This repair station will not change the location of its housing without written approval from the FAA. In addition, no changes will be made to the housing or facilities that could have a significant effect on the repair station’s ability to perform the maintenance, preventive maintenance, or alterations under the repair station certificate and operations specifications without approval from the FAA.

433 Breesport Floor Plan

Office Office

Office

Office

Office

Office

Break room Welding Shop

Supply Room

Tech Room

Reception Area

Non Aircraft Closet

Non-Aircraft Closet

NDT

Bay Doors

Bay Doors

♀♂

♀♂

Storage

Bond Room



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143 West Rhapsody ( Heat Treat Oven Location)



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APPENDIX B: APPROVED CONTRACT MAINTENANCE LIST

A list of approved contract maintenance companies will be maintained by the Quality Manager and filed in his office.


AEROWELD, INC Rev 10 Date: 9/14/12

APPENDIX C: CAPABILITIES LIST

AEROWELD, INC.

Capabilities List Revision

FAA APPROVED REPAIR STATION NO: W2XR853X

REVISION APPROVAL DATE

9 06/20/12



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Capabilities List

Make Model / Part Number Process Date SAAB SF-340A/340A/340B RT 08/05/08 Boeing B767 RT 08/14/08 Airbus A300 RT 08/14/08 Airbus A310 RT 08/14/08 Airbus A318/A319/A320/A321 RT 08/14/08

Fairing Strut Assy

25UM781/23A125 RT 08/27/08

Hawker 750/800/800XP/850XP/900XP RT 09/09/08 Boeing B747 RT 09/23/08

Lockheed Martin

C-130 RT 07/27/09

De Havilland DH-1/C1-W-845 / 846 RT 08/04/10 Kiddie

Graviner Fire Bottles listed in SB 26-

080 RT 02/06/12

Boeing / Douglas

DC-9 / MD-80 RT 06/20/12

Boeing / Douglas

MD-11 RT 06/20/12

Boeing B757 RT 06/20/12



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