Aug 2015 Future Defence Aviation Safety Regulation Module 2 - EMAR Part 21 – Aircraft Design, Certification and Production.

Aug 2015

Future Defence Aviation Safety Regulation Module 2 - EMAR Part 21 – Aircraft Design, Certification and Production

Module 2: EMAR Part 21 – Design, Certification, Production

• Overview of Part 21• Organisational approvals (Subparts G, F, J)• Expansion on other Subparts (A, B, D, E, H, K, M, O,P)• Key definitions• Airworthiness Instruments

Scope

EMAR Structure

MAWABasic Framework

Document

Engineering & Maintenance Stream Maintenance Training & Authorisation Stream

Initial Airworthiness

Continuing Airworthiness

EMAR 21

EMAR M

EMAR 145

EMAR 66

EMAR 147

EMAR Part 21• Initial Airworthiness

– Design, Production and Certification– Airworthiness Instruments– Change to existing type design– Includes Aircraft and related products, parts and

appliances

• Key differences to TAREG– Contains all elements supporting initial airworthiness – Does not cover activities supporting continuing

airworthiness (eg configuration item regulations)

Overview

EMAR Part 21 Section A contents by Subpart• A – General provisions• B – Military Type-Certificates and Military

Restricted Type-Certificates• C – (Not applicable)• D – Changes to Military Type-Certificates

and Military Restricted Type-Certificates• E – Military Supplemental Type-

Certificates • F – Production without Military

Production Organisation Approval• G – Military Production Organisation

Approval• H – Military Certificates of Airworthiness

and Military Restricted Certificates of Airworthiness

• I – Noise Certificates (to be added later if required)

• J – Military Design Organisation Approval

• K – Parts and Appliances• L – (Not applicable)• M – Repairs• N – (Not applicable)• O – European Military Technical

Standard Order Authorisations• P – Permit to Fly• Q – Identification of Products, Parts

and Appliances

EMAR Part 21 Section A contents by Subpart• A – General provisions• B – Military Type-Certificates and Military

Restricted Type-Certificates• C – (Not applicable)• D – Changes to Military Type-Certificates

and Military Restricted Type-Certificates• E – Military Supplemental Type-

Certificates • F – Production without Military

Production Organisation Approval• G – Military Production Organisation

Approval• H – Military Certificates of Airworthiness

and Military Restricted Certificates of Airworthiness

• I – Noise Certificates (to be added later if required)

• J – Military Design Organisation Approval

• K – Parts and Appliances• L – (Not applicable)• M – Repairs• N – (Not applicable)• O – European Military Technical

Standard Order Authorisations• P – Permit to Fly• Q – Identification of Products, Parts

and Appliances

EMAR 21 - SUBPART G• Military Production Organisational Approval (MPOA)

– Rules for showing compliance of products, parts, appliance with applicable design data through an approved organisation

– Established and maintained quality system– Release artefacts

• Complete aircraft: Statement of Conformity• Parts and appliances: Authorised Release Certificate

– Production Organisation Exposition– No design privileges associated with this subpart

• Key differences to TAREG– TAREG do not regulate production organisations

Organisational Approvals

Part 21G Key Positions• Chief Executive

– Provides necessary resources

• Accountable Manager– Ensures production is performed to req standards

• Responsible Manager– Responsible to cover all responsibilities in Subpart G– Reports to Accountable Manager

• Quality Manager– the compliance assurance manager

Key Positions

References:

-EMAR 21.A.145(c)

-GM 21A.145(c)(1)

-GM 21A.145(c)(2)

EMAR 21 – SUBPART F• Production without military production organisation approval

(MPOA)– Details procedure for demonstrating conformity with Subpart G

without having gained the formal MPOA– Production Inspection System, not independent quality system– Valid for 12 months– E.g. producing/installing simple parts for a modification upgrade, for

which production organisational approval considered too costly

• Key differences to TAREG– TAREG do not regulate production organisations– Limited production regulations (3.5.19) – sustainment,

design/modification context

Organisational Approvals

EMAR 21 - SUBPART J• Military Design Organisation Approval (MDOA)

– Procedure for approval• Design assurance system• Design Organisation Exposition• Ability to classify designs and repairs (major or minor)• Privileges (scope, e.g approval of minor changes to type design)• Obligations of the holder

• Key differences to TAREG– EMAR do not contain prescriptive Design Control System elements (such as

Judgement of Significance, levels of EA), nor Design Acceptance, Incorporation Approval (IA) or Service Release (SR).

– Intent of these functions are addressed through distinct MTC holder responsibilities, clearer organisational and individual accountabilities and introduction of CAMO (IA and SR)

– DGTA-ADF will run Compliance Assurance Program for all Military Design Orgs

Organisational Approvals

Part 21J Key Positions• Chief Executive

– Provides necessary resources• Head of Design

– Responsible for all departments conducting design– Similar to SDE

• Chief of the Office of Airworthiness– Responsible for coordinating airworthiness matters– Similar to ‘Certification Manager’ position in acq project

office• Chief of the independent monitoring function of

design assurance– Effectively the compliance assurance manager of 21J org

References:

-GM No. 1 to 21A.243(d)

Key Positions

Part 21J Exposition• Military Design Organisation Exposition (MDOE) requires:

– Organisation – Scope of work

• Products, or changes to products to be designed• List of types and models• Privileges• Scope of repair design (i.e. structures, systems, engines)

– Design assurance system • Including assigned responsibilities

– Management of changes to type design and design of repairs• Config control ; Classification ; Approval of minor changes to type design & minor repairs

– Quality system– Control of subcontractors– Collecting/investigating of failures, malfunctions and defects– Co-ordination with production– Recording system

• For type design, drawings– Documentation control

Exposition

References:

- AMC No.1 to 21A.243(a)

- AMC No.2 to 21A.243(a)

EMAR Part 21 Section A contents by Subpart• A – General provisions• B – Military Type-Certificates and Military

Restricted Type-Certificates• C – (Not applicable)• D – Changes to Military Type-Certificates

and Military Restricted Type-Certificates• E – Military Supplemental Type-

Certificates • F – Production without Military

Production Organisation Approval• G – Military Production Organisation

Approval• H – Military Certificates of Airworthiness

and Military Restricted Certificates of Airworthiness

• I – Noise Certificates (to be added later if required)

• J – Military Design Organisation Approval

• K – Parts and Appliances• L – (Not applicable)• M – Repairs• N – (Not applicable)• O – European Military Technical

Standard Order Authorisations• P – Permit to Fly• Q – Identification of Products, Parts

and Appliances

EMAR 21 - SUBPART A• General Provisions

– Requirements to manage failures, malfunctions and defects

– Airworthiness Directives– Coordination between design and production

• Key differences to Defence airworthiness regs– EMAR (and the rest of the world) use ADs for the Authority

to mandate actions to be performed to restore an aircraft to acceptable level of safety.

– Defence use ADs to issues airworthiness policy or as an instrument to support flight operations

Other Subparts

EMAR 21 - SUBPART B & E• SUBPART B: Military type-certificates (MTCs) and military

restricted type-certificates (MRTCs)

– Procedure for issuing:• MTC for products (Aircraft, Engines, Propellers)• MRTC for aircraft

– MRTC used to support military aviation operations prior to completion of all certification elements

– Airworthiness codes (EMACC)– Type-cert basis– Certification Program Plan– MTC holder obligations– Instructions for continuing airworthiness

Other Subparts

EMAR 21 – Military Type Certificate Holder• MTCH Obligations:

– System for collecting, investigating and analysing Failures, Malfunctions and Defects

– Airworthiness Directives– Coordination between design and production– Record Keeping– Manuals – ICA– Demonstrate capability by holding Military Design Organisation

Approval

Reference:

-EMAR 21.A.44

Other Subparts

EMAR 21 - SUBPART B & E• SUBPART E: Supplemental Type Certificates

– A major change to Type Design is proposed and :– Applicant is not the Military Type Certificate Holder

• Key differences to TAREG– EMAR less prescriptive– EMAR require identification of a MTC Holder and regulate associated

obligations for continuing validity of the Type Certificate– Defence does not contain an aw code – instead AAP7001.054 ADRM

Other Subparts

EMAR 21 - SUBPART D• Changes to military type-certificates and

military restricted type-certificates – Procedure for approval of changes to type designs

and type-cert– Classification of changes – Major and minor changes (GM is comprehensive)– Airworthiness codes– Design Approval– Instructions for continuing airworthiness

Other Subparts

EMAR 21 - SUBPART H• Military certificates of airworthiness and military restricted

certificates of airworthiness– Procedure for issuing airworthiness certificates applicable to a MTC or

a MRTC

• Key differences to TAREG– Application of Defence airworthiness regs typically use Special Flight

Permits prior to issuing AMTC/SR & Certificates of Airworthiness– Defence airworthiness regs do not allow issue of a certificate of

airworthiness under SFP. Instead “draft” Certificate of Airworthiness often used to support DAR attestation to load aircraft on Defence State Register

Other Subparts

EMAR 21 - SUBPART K• Parts and Appliances

– Describes approval and compliance of parts and appliances

– Installation of parts on type-certified products – Standard Part vs Non standard Part

• Key differences to TAREG– TAREG implicitly cover through substitution (3.5.7)

and certification processes (design emphasis only). No TSO requirement in TAREG

Other Subparts

EMAR 21 - SUBPART M• Repairs

– ‘Repair’: elimination of damage and/or restoration to an airworthy condition. Excludes EMTSO.

– Major or Minor– Approval of Repairs – Repair Embodiment– Unrepaired damage– Record keeping and ICA

• Key differences to TAREG– EMAR treat repair design as a separate privilege (scope) to design.

TAREG treat repair as a type of design, covered under ‘deviation’. – TAREG specify specific requirements for structural repairs. EMAR

utilise classification of repair to determine rigour required.

Other Subparts

EMAR 21 - SUBPART O• Technical Standard Order (FAA)

– A TSO is a minimum performance standard for specified materials, parts, and appliances used on civil aircraft.

– A TSO Authorization is not an approval to install and use the article in the aircraft

• European Military technical standard order authorisations (EMTSO)– Procedure for issuing EMTSO authorisations

• TSO covers design and production approval• Declaration of Design and Performance (DDP) – akin to a TCDS

• Key differences to TAREG– TAREG do not regulate in this area. Implicitly cover TSO / Military TSO through

substitution (3.5.7) and certification processes (design emphasis only).

Organisational Approvals

EMAR 21 - SUBPART P• Military permit to fly

– Procedure for issuing military permits to fly• Approving flight conditions, eg Flight Test, Exhibition, Ferry• Can be issued for aircraft that do not meet or have not been

shown to meet applicable airworthiness requirements but are capable of safe flight.

• Key differences to Defence airworthiness regs– No direct equivalent– Similarities to some uses of a Special Flight Permit,

Airworthiness Directive, Flight Test Permit

Other Subparts

Key Definitions• Airworthiness• Airworthiness Codes• Authority• Airworthiness Directive (AD)• Certificate of Release to Service • Certification• Continued (design)

airworthiness• Continuing airworthiness• Derogation• Exposition• Fit for Flight

Key Definitions

• Military Type Certificate (MTC)• Military Restricted Type

Certificate (MRTC)• Military Supplemental Type

Certificate• Products, Parts and Appliances• Repair• Special Conditions• Type Certification Basis • Type Certificate Holder • Type Design

Airworthiness Instruments

CURRENT INSTRUMENTS (MILAVREG 3) PROPOSED INSTRUMENTS (EASA)

Current Instrument

Issued By Issued To

AMTC Defence AA NIL

UASOP DAA / OAA NIL

SFP Defence AA NIL

STC Defence AA NIL

FTP FTAAFlight Test

Organisation

AD Defence AA Various

SR Defence AA NIL

NIL

DASR Instrument

Replaces

Issued By Issued To

MTC AMTC Defence AA Part 21 (MTC Holder)

Military Restricted Type Cert (MRTC)

SFPUASOP

Defence AA[1] Part 21 (MTC Holder)

STC STC Defence AA Part 21 (MTC Holder)

Permit to Fly (PTF)SFPFTPAD

Defence AA / FTAA

MAOC Holder / Flight Test Organisation

MAOC SR Defence AA MAOC Holder

AD[2] Nil DGTA CAMO

1 Issue of an MRTC for a UAS may be delegated to Force Element / Senior Operational Commander2 EMAR Definition of AD: A document issued or adopted by the authority which mandates actions to be performed on an aircraft to restore an acceptable level of safety, when evidence shows that the safety level of this aircraft may otherwise be compromised.

Questions/Discussion?