Moe -15

MAINTENANCE ORGANIZATION EXPOSITION (MOE)

DECCAN AVIATION LIMITED Jakkur Airport, Bellary Road Bangalore -560 064 India Tel : +91 – 802 – 856 – 7523 Fax : +91 – 802 – 856 – 7998 E mail : [email protected] [email protected]

DECCAN AVIATION AVIATION LIMITED CARCAR-145 APPROVED MAINTENANCE ORGANISATION

MAINTENANCE ORGANIZATION EXPOSITION (MOE) Approved by The Director of Airworthiness, Civil Aviation Department, Bangalore vide letter no. Q / Deccan (NS) /1722 dated 27th August 2008 NOTE: This exposition bearing issue no.01 dated Aug. 2008 shall provide the policies of the organization. Procedures and practices to be followed to meet the policy requirements are provided in the Engineering Procedures Manual (EPM), Logistics Procedures Manual (LPM), Shop Procedure Manual (SPM), Forms Manual and Training Manual, which are required to be read in conjunction with this MOE

******************** ******************** Name of MOE Holder Kolkata – Line station

Location Kolkata

Copy No. 15

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DECCAN AVIATION LIMITED

MAINTENANCE ORGANISATION EXPOSITION REVISION RECORD

Revision Number

Revision Date

Details of Pages Revised

Rev. 0

Feb. 2008

All Pages

Rev. 1

Aug. 2008

All Pages

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DECCAN AVIATION LIMITED

MAINTENANCE ORGANISATION EXPOSITION LIST OF EFFECTIVE PAGES

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DECCAN AVIATION LIMITED

MAINTENANCE ORGANISATION EXPOSITION LIST OF EFFECTIVE PAGES

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DECCAN AVIATION LIMITED

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TABLE OF CONTENTS

: Aug 2008

DECCAN AVIATION LIMITED

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TABLE OF CONTENTS TABLE OF CONTENTS Title

Part Part - 0 0.1 0.2

Part - 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

Part Part 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

2.9 2.10 2.11

General Introduction Definition

Page No 1,2 3

Management Corporate commitment by the accountable manager Safety and quality policy Management personnel – post holders Duties & responsibilities of the management personnel Management organization chart List of certifying staff Manpower resources General description of facilities at each address intended to be approved Organization’s Activities Notification procedure to DGCA regarding changes to organization’s activities / approvals / location / personnel Exposition issue / amendment procedure

Title Maintenance Procedures Supplier evaluation and subcontractor control procedure Acceptance / inspection of aircraft components & materials Tagging, storage and release of aircraft components and material to aircraft maintenance Acceptance of tools and equipment & control of inspection / servicing requirements including alternate tools & equipment Calibration of tools and equipment Use of tools & equipment by staff (including alternate tools) Cleanliness standards of maintenance facilities Maintenance data / instructions & relationship to aircraft / aircraft component manufacturer’s instructions including updating & availability to staff Repair Aircraft maintenance programme compliance

2.12 2.13

Airworthiness directives procedure / DGCA mandatory modification / Alert Service Bulletin – Control Procedure Optional modification procedure Maintenance documentation in use and completion of the same

2.14

Technical (maintenance) records control

2.15 2.16 2.17 2.18 2.19 2.20 2.21

Rectification of defect arising during base / line maintenance Release to service procedure Records for the contracted operator (customer) Reporting of occurrences (Major defects / incidents & accidents) Return of defective aircraft components to store Dispatch of defective components to outside contractors Control of computer maintenance record systems

1 2, 3, 4 5, 6, 7 8 to 13 14 to 18 19, 20 21, 22 23 to 38 39 to 48 49, 50 51, 52, 53

Page No 1, 2, 3, 4 5, 6, 7, 8 9, 10, 11, 12, 13, 14 15, 16, 17, 18 19, 20, 21, 22 23, 24, 25 26, 27 28, 29, 30, 31, 32, 33, 34, 35, 36, 37 38, 39 40, 41, 42, 43, 44, 45 46, 47, 48 49, 50 51, 52, 53, 54, 55, 56 57, 58, 59, 60, 61, 62, 63, 64 65, 66, 67 68, 69, 70, 71, 72 73 74, 75, 76, 77, 78 79, 80, 81 82, 83 84, 85, 86

DECCAN AVIATION LIMITED

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TABLE OF CONTENTS

Part 2.22 2.23 2.24 2.25 2.26 2.27 2.28

Part

Title

87, 88 89, 90 91,92, 93, 94, 95 96, 97, 98, 99 100, 101 102, 103

Title

Page No

L2 L2.1 L2.2

Additional Line Maintenance Procedures Line maintenance control of aircraft components, tools, equipments, Etc. Line maintenance procedures related to servicing / fuelling etc.

L2.3 L2.4 L2.5 L2.6 L2.7

Line maintenance control of defects and repetitive defects Line procedure for completion of the technical log Line procedure for pooled parts and loan parts Line procedure for return of defective parts removed from aircraft Line procedure for control of critical tasks

Part

Title

3 3.1 3.2 3.3

Quality Procedures Quality audit of organization procedures Quality audit of aircraft / component Quality audit findings – reporting -remedial action procedure

3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 Annexure -1

Authorized staff qualifications and training procedures Certifying staff records Quality audit personnel Support / Certifying staff Task trained and authorized persons Aircraft or component maintenance task exemption process control Concession control for deviation from organization’s procedures Qualification procedure for specialized activities such as NDT / NDI, etc. Control of manufacturers’ and other maintenance working teams Human factors training procedure Competence assessment of personnel Requirements for Issue of approval / authorization

Part 4.1 4.2 4.3

Page No

Control of man-hour planning versus scheduled maintenance work Control of critical tasks Specific maintenance procedures /ground handling Procedures to detect and rectify maintenance errors Shift/ task handover procedures Procedures for the notification of maintenance data inaccuracies and ambiguities to the type certificate holder Production planning procedure

Title Contracted operators Operator’s procedures and paperwork Contracted operator’s records completion

104, 105

1, 2, 3, 4 5, 6, 7, 8, 9, 10, 11 12, 13, 14, 15 16, 17, 18, 19, 20 21, 22, 23, 24 25, 26 27, 28

Page No 1, 2, 3, 4, 5, 6, 7 8, 9, 10 11, 12, 13, 14, 15, 16 17, 18, 19, 20, 21 22, 23 24, 25 26 27 28 29, 30 31, 32 33, 34, 35 36, 37, 38 39, 40, 41 1, 2, 3, 4

Page No 1 2, 3, 4, 5 6

DECCAN AVIATION LIMITED

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TABLE OF CONTENTS

Part Part 5 5.1 5.2 5.3 5.4

Title Forms Sample of documents List of sub – contractors List of line maintenance stations List of contracted car-145 organization as per car-145.70 (a) (16)

Part

Page No 1 2 3 4

Title

Page No

Part 6 6.1 6.2 6.3

Operator’s Maintenance Procedures Basic maintenance procedures Engine performance monitoring (Trend Monitoring) Engine oil consumption

1, 2 2 3

6.4 6.5 6.6 6.7 6.8 6.9 6.10

Power assurance check Continued airworthiness of aged aircraft Certificate of registration Aero mobile station license Issue of certificate of airworthiness Review of certificate of airworthiness Renewal of certificate of airworthiness

3 3, 4 4 4 4 4 5

6.11 6.12 6.13

Issue of export certificate of airworthiness Quality check of fuel Quality check of oil

5 5 5

6.14 6.15

Quality check of hydraulic fluid Ferry flight permission

5 6

6.16

Weighing of aircraft

6

6.17

Carriage of documents on board the aircraft

6

6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25

CVR / DFDR read outs and recording integrity Test Flights First – aid – kit Furnishing materials Minimum Equipment list (MEL) Procedure for certifying the components from an accidental aircraft Aerial work operations Carriage of acceptable dangerous goods

6 7 7 7 7, 8 8 8 9

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DECCAN AVIATION LIMITED

MAINTENANCE ORGANISATION EXPOSITION DATE

: Aug 2008

DISTRIBUTION LIST

Name of MOE Holder O/o D.G.C.A ( Head Quarters) Director of Airworthiness ( Bangalore ) Accountable Manager Chief Engineer Quality Manager Library - Bangalore Director of Airworthiness - Delhi Delhi - Line Station Jammu – Line Station Director of Airworthiness - Mumbai Mumbai – Line station Raigarh – Line station Surat – Line Station Director of Airworthiness - Kolkata Kolkata – Line station Director of Airworthiness - Chennai Chennai – Line station Controller of Airworthiness - Bhubaneswar Bhubaneswar – Line station Controller of Airworthiness, Hyderabad Hyderabad– Line Station Vizag – Line Station Katra – Line Station

Location New Delhi Bangalore Bangalore Bangalore Bangalore Bangalore New Delhi New Delhi Jammu Mumbai Mumbai Raigarh Surat Kolkata Kolkata Chennai Chennai Bhubaneswar Bhubaneswar Hyderabad Hyderabad Vizag Katra

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Copy No. 1 2 3 4 5 (Master Copy) 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

DECCAN AVIATION LIMITED

MAINTENANCE ORGANISATION EXPOSITION ABBREVIATIONS

ABBREVIATIONS USED: AD ADD AMC AMP AOG ATA AWL

Airworthiness Directive Acceptable Deferred Defect Acceptable Means of Compliance Aircraft Maintenance Programme Aircraft on Ground Air Transport Association Airworthiness Limitation

CAR C of A CDL CMR CRS CVR

Civil Aviation Requirements Certificate of Airworthiness Configuration Deviation List Certificate of Maintenance Review Certificate of Release to Service Cockpit Voice Recorder

DAL DGCA

Deccan Aviation Limited Directorate General of Civil Aviation

ENG EO EPM

Engineering Engineering Order Engineering Procedures Manual

FDR

Flight Data Recorder

GD GEP GR

Goods Dispatch General Engineering Procedures Goods Receipt

HQ

Headquarter

IATA IEM IMS

International Air Transport Association Interpretative and Explanatory Material Inventory Management System

JAA JAR

Joint Aviation Authorities Joint Aviation Requirements

LMP

Line Maintenance Procedures

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DECCAN AVIATION LIMITED

MAINTENANCE ORGANISATION EXPOSITION ABBREVIATIONS

MEL MMEL MOE MMP MO MOR MPD MRB MSN

Minimum Equipment List Master Minimum Equipment List Maintenance Organisation Exposition Maintenance Management Procedure Maintenance Organisation Mandatory Occurrence Report Maintenance Planning Document Maintenance Review Board Manufacturer Serial Number

NDT NDI

Non Destructive Test Non Destructive Inspection

OEM OMS OOP

Original Equipment Manufacturer Occurrence Management System Out Of Phase

PD PMA

Planning Department Parts Manufacture Approval

QD QSP

Quality Department Quality System Procedures

SB SIL SL SMI SPM SRM

Service Bulletin Service Instruction/Information Letter Service Letter Scheduled Maintenance Inspection Standard Practices Manual Structural Repair Manual

TC TI TIL

Type Certificate Technical Instruction Technical Information Letter

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – 0 GENERAL ORGANIZATION

0.1

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INTRODUCTION a). M/s Deccan Aviation Limited was established in 1995 by a group of retired pilots from Indian Army Aviation wing with the objective of providing efficient and safe air transport services for Charters, Heli-Tourism, Film Shooting, Medical Evacuation etc. to various domestic destinations utilizing a mixed fleet of fixed and rotary wing aircraft. b). Deccan Aviation is also involved in the maintenance of aircraft used for commercial / private air transport and components intended for fitment thereto. c). Deccan Aviation presently owns (operates and maintains) One Bell 206B3, One 206L3, Three Bell 407, One AS 355F1 Helicopters and One Pilatus PC-12 & One King Air B200 airplane. d). Deccan Aviation also operating under lease, One Bell 206B3, One Bell 212, One Bell 412 Helicopter and One Pilatus PC-12 airplane. e). Deccan Aviation also provides operational support (man power for operation) for aircraft owners / operators under one-off / long term contract. f). This Maintenance Organisation Exposition (MOE) defines the Quality and Safety policy followed by the Engineering Department in carrying out Maintenance, adhering to various statutory requirements promulgated by DGCA and manufacturer’s instructions to ensure highest degree of Airworthiness Standards and safety of aircraft. g). This MOE is the main reference document for all Maintenance and Quality activities of M/s Deccan Aviation Limited and forms the basis for CAR-145 Maintenance Approval (issue & continuation of approval) for the maintenance of aircraft and components. h). This MOE contains the scope of work deemed to constitute approval and along with the associated manuals, shows how the organization intends to comply with the CAR-145 requirements. i). This Maintenance Organisation Exposition is split into various parts as described below ; Part - 0 Part - 1 Part - 2 Part - L2 Part – 3 Part – 4 Part – 5 Part – 6

General Organization The Management. Maintenance Procedures Additional Line Maintenance Procedures Quality System Procedures Contracted Operator’s Procedures Forms Operator’s Maintenance Procedures

j). Aircraft maintenance organization involved in maintenance of aircraft used for commercial air transport and components intended for fitment thereto is required to be approved by DGCA in accordance with the provision of CAR-145. k). Competent authority to approve and regulate the aircraft maintenance organization approved as per CAR-145, having their principle place of business in India or any other country shall be the DGCA. l). Contents of MOE is be approved by the DGCA and subsequent amendments to remain an up-to-date description of the organization and its policies, will be made only after specific approval from DGCA. This Maintenance Organisation Exposition meets the requirement of CAR-145 for grant of approval to carryout maintenance of aircraft or its components in accordance with manufacturer’s instructions, aircraft rules, CAR’s and any other instructions issued by the DGCA.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – 0 GENERAL ORGANIZATION

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m). This MOE is prepared as per guidelines stipulated in CAR145.A.70, for use of all maintenance, quality & logistics personnel, associated with the maintenance and airworthiness of aircraft.

n). The Maintenance Organization Exposition will be distributed as per the distribution list given in the MOE. o). This is a dynamic document and will be kept continuously updated by the Quality Manager as and when there are changes to the manufacturer’s requirements, maintenance policies, applicable aircraft rules, civil aviation requirements and other instructions issued by DGCA from time to time. p). MOE will be amended time to time whenever there is a change Name / Location of the Organization, Accountable Manager / Nominated Personnel (Nominated by Organisation and Accepted by DGCA) or the facilities, equipment, tools, procedures, work scope or certifying staff that could affect the approval of the organization. q). Amendments requiring approval will be submitted to The Regional Airworthiness Office, Bangalore for approval. r). Approved copy of amendment will be distributed to all Controlled copy holders by Quality Department, under covering letter for carrying out the amendment in the MOE held by them. s). Detailed procedure of amendment is described at para 1.11 of this MOE

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – 0 GENERAL ORGANIZATION

0.2

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DEFINITION

Large aircraft

Large aircraft means an aircraft, classified as an aero plane with a maximum take of mass of more than 5700kg, or a multi engine helicopter

Certifying Staff

Certifying staff means personnel responsible for the release of an aircraft or a component after maintenance.

Component

Component means any engine, propeller, part or appliance.

Human Factors

Human factors means principles which apply to aeronautical design, certification, training, operations and maintenance and which seek interface between the human and other system components by proper consideration of human performance.

Human Performance

Human performance means human capabilities and limitations which have an impact on the safety and efficiency of aeronautical operations.

Support Staff

Support staff means those DGCA licensed engineers / approval holders issued in accordance with Rule 61 and approved by the organization to ensure that all relevant tasks or inspections in base / shop environment, have been carried out to the required standard and does not hold necessary release to service certification privileges.

Certifying Staff

Certifying staff means personnel responsible for the release of an aircraft or a component after maintenance. Such certifying staffs are issued with Certification Authorization by Quality Manager after ensuring qualification, experience and competence.

Relevant aircraft and / or components

Relevant aircraft and/or component means those aircraft or components specified in the particular certification authorization

Certification authorization

Certification authorization means the authorization issued to certifying staff by the organization and which specifies the fact that they may sign certificates of release to service with in the limitations stated in such authorization on behalf of the approved organization

Maintenance Organization Exposition

Maintenance Organization Exposition means the document or documents that contain the material specifying the scope of work deemed to constitute approval and showing how the organization intends to comply with the CAR-145 requirements.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.1

CORPORATE COMMITMENT BY THE ACCOUNTABLE MANAGER (Ref: CAR 145.A.70.a.1)

This exposition and any associated referenced manuals define the organisation and procedures upon which the DGCA CAR 145 approval of Deccan Aviation Limited is based as required by CAR 145.7A.70. These procedures are approved by the undersigned and must be complied with, as applicable, when work / orders are being progressed under the term of the CAR 145 approval. It is accepted that these procedures do not override the necessity of complying with any new or amended regulation published by the DGCA from time to time where these new or amended regulations are in conflict with these procedures. It is understood that the DGCA shall approve this organisation whilst the DGCA is satisfied that the procedures are being followed and work standards maintained. It is further understood that the DGCA reserves the right to suspend, limit or revoke the CAR 145 approval of the organisation, if DGCA has evidence that procedures are not followed or standards not upheld.

Signed :

Dated

: 18-08-2008

Name

: Col. Jayanth Poovaiah (Retd)

Title

: Accountable Manager and Director

For and On behalf of DECCAN AVIATION LIMITED

Countersigned:

Dated

: 18-08-2008

Name

: Capt.G.R.Gopinath (Retd)

Title

: Managing Director

For and On behalf of DECCAN AVIATION LIMITED

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.2

SAFETY AND QUALITY POLICY (Ref: CAR 145.A.65 & 145.A.70.a.2)

a). Accountable Manager will establish a safety and quality policy for the organization and ensure that the same is included in the Maintenance Organization Exposition. (CAR 145.A.65.a refers). b). Accountable Manager will ensure thru post holders (chief engineer & quality manager), taking in to account the human factors and human performance, that the procedures are established to comply with applicable regulations and ensure good maintenance practices, so that aircraft / component may be released to service in accordance with CAR 145 requirements.

1.2.1

ORGANIZATION’S GOAL

NO ACCIDENTS. NO HARM TO THE PEOPLE & NO DAMAGE TO THE ENVIRONMENT.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.2.2

SAFETY POLICY

All employees of the organization are responsible for ensuring safety at all times. Good Safety performance is important to the success of Aviation business. Through our policy of continuous improvement, we will maximize the inherent safety of our operations by reducing incidents and accidents. We undertake to provide a quality service which can be used with confidence by our customers. To achieve our Goal of Utmost Safety, we will adopt the following policies; •

Recognize SAFETY as a prime consideration at all times

•

Adopt Safety management in the organization

•

Apply human factor principles to all our decisions

•

Encourage full reporting of all hazards, incidents, occurrences associated with our maintenance and Operation.

•

Recognize that compliance with laid down procedures, quality standards, safety standards and regulations is the duty of all personnel.

•

Recognize the need for all personnel to co-operate with the quality auditors

•

Consult, listen and respond openly to our staff and customers.

•

Work with others – our partners, supplier, competitors and regulators – to raise the safety standards.

•

Recognize those who contribute to improve safety performance

Col. Jayanth Poovaiah (Retd) Accountable Manager

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.2.3

QUALITY POLICY

Quality Policy of the organization is stated below

To carryout maintenance on aircraft & components which will result in release of airworthy aircraft and component, which meets the airworthiness requirements and standards spelt out by the manufacturer, airworthiness authority of the country of manufacture and DGCA.

Deccan aims; •

TO PROVIDE HIGHEST STANDARDS OF QUALITY SERVICE TO OUR CUSTOMERS.

•

TO CONSTANTLY STRIVE & IMPROVE THE STANDARDS, THERE BY MAINTAINING OUR POSITION AS A LEADING SERVICE PROVIDER OF AIRCRAFT MAINTENANCE AND ASSOCIATED ACTIVITIES.

The organization requirements and procedural aspects of this policy are covered in the Company’s Maintenance Organization Exposition, Engineering Procedures Manual and other associated manuals It is the responsibility of all management personnel to implement the Quality Policy and procedures set out in this and associated manuals and to ensure that they are understood and followed by all members of staff. These procedures ensure compliance with Quality Requirements of the Airworthiness Authorities. Quality will be ensured by the Quality Department and all other employees of the organization as TEAMWORK. It is the responsibility of all of us to comply with this policy, co-operate with the Quality Department in the execution of their duties and strive to improve Quality Standards at every opportunity.

Capt. Jayanth Poovaiah (Retd) Accountable Manager

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.3

MANAGEMENT PERSONNEL (Ref: CAR 145.A.30 & EPM Section-1, Chapter 13)

a). Management Personnel for the purpose of CAR-145 approval will consist of the following personnel who will be responsible to ensure that the AMO complies with the requirements of CAR-145;

i).

Accountable Manager

;

Col. Jayanth Poovaiah (Retd).

ii).

Quality Manager

:

Mr. R. Meenakshisundaram

iii).

Chief Engineer

:

Mr. S. U. Khan

iv).

Regional Engineering Manager Bangalore Region (Including Sub-Base Hyderabad and Line stations Chennai / Koppal, Tornagallu, Vizag)

:

Mr. Chandrasekhar ( DGCA FORM-4 NOT REQUIRED)

Regional Engineering Manager Delhi Region (Including Sub-Base -Jammu / and Line station -Katra)

:

Mr. Surjeet Saini ( DGCA FORM-4 NOT REQUIRED)

Regional Engineering Manager Mumbai Region (Including sub-Base Surat & Raigarh)

:

Mr. Harinathan ( DGCA FORM-4 NOT REQUIRED)

Regional Engineering Manager Kolkata Region (Including Sub-Base Bhubaneswar)

:

Mr. Saikat Mukherjee ( DGCA FORM-4 NOT REQUIRED)

v).

vi).

vii).

b). Accountable Manager, Quality Manager & Chief Engineer will be stationed at Bangalore, the head office of the organization. c). Management of Line, Base & Shop maintenance functions of the CAR-145 approved maintenance organization will be carried out by one person and he is designated as Chief Engineer. d). Regional Engineering Manager will generally be located at each sub-base and are permitted to interact with the respective Regional / Sub-regional Airworthiness Office. e). Detailed responsibilities of the management personnel are provided in EPM Section-1, Chapter-13

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.3.1

ACCOUNTABLE MANAGER

a.

Managing Director will appoint a suitable person as an Accountable Manager, with corporate and financial authority for ensuring that all maintenance activities are carried out to the standard required by the CAR-145. (CAR 145.A.30a refers).

b.

Accountable manager will;

c.

1.3.2

1.

Ensure that all necessary resources are available to accomplish maintenance in accordance with CAR 145.A.65.b to support the organization approval. (CAR 145.A.30.a.1 refers).

2.

Establish and promote the safety and quality policy specified in CAR 145.A.65.a (CAR 145.a.30.a.2 refers).

3.

Demonstrate to DGCA, the basic understanding of CAR 145 requirement and familiarity with human factor principles. (CAR 145.A.30.a.3 refers).

Accountable manager will ensure that the nominated personnel (post holder’s) have sufficient background and satisfactory experience related to aircraft / component maintenance, quality auditing and are able to demonstrate relevant domain knowledge and also demonstrate the working knowledge of the CAR.(CAR 145.A.30.b.3 refers)

INTIMATION OF NOMINATED PERSONNEL (Post Holder’s) TO DGCA (Ref: CAR 145.A.30.b.2)

a.

Accountable Manager will nominate a Quality Manager with responsibility for monitoring the Quality system, including the associated feedback system as required by CAR 145.65.c, and forward his/her credentials along with DGCA FORM 4 to Regional Airworthiness Office, Bangalore under confidential cover. (CAR 145.A.30.b.2 refers).

b.

Quality Manager will have direct access to the Accountable Manager to ensure that the Accountable Manager is kept properly informed on Quality and regulation compliance matters. (CAR 145.A.30.c refers)

c.

Accountable Manager will also appoint a Chief Engineer, with a responsibility for ensuring that all Maintenance activities (Line, Base, Component, Specialized activities) are carried out to the standards specified in CAR 145.A.65. and forward his/her credentials along with DGCA FORM 4 to Regional Airworthiness Office, Bangalore under confidential cover. (CAR 145.A.30.b.2 refers).

d.

Whenever there is any change in the Post Holders, such changes will immediately be intimated to the Regional Airworthiness Office, Bangalore and the Accountable Manager will nominate the new persons meeting the qualification requirements given in MOE 1.3.3, for the acceptance of the Regional Airworthiness Office, Bangalore.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.3.3

QUALIFICATION, EXPERIENCE AND TRAINING REQUIREMENT OF NOMINATED POST HOLDER’S

1.3.3.1 CHIEF ENGINEER a). Chief engineer will have the following minimum qualifications and experience; i)

Licensed Aircraft Maintenance Engineer as per DGCA requirement.

ii)

Ten years practical experience as an AME in aircraft maintenance, out of which a minimum of 3 years in managerial capacity.

iii)

Familiar with basic requirement of CAR 145.

iv)

Familiar with human factor principles.

v)

Must be endorsed / type trained in various aircraft, under maintenance, with the organization.

1.3.3.2 QUALITY MANAGER

a). Qualification and experience requirements of quality manager are; i)

Licensed Aircraft Maintenance Engineer as per DGCA requirement.

ii)

Ten years practical experience as an AME in aircraft maintenance out of which, a minimum of 3 years experience in quality department.

iii)

Must be endorsed / type trained in various aircraft, under maintenance, with the organization.

iv)

Familiar with the basic requirements of CAR 145 and human factor principle

1.3.3.3 TRAINING REQUIREMENTS

a). Post holders nominated by Accountable manager will fulfill the requirement of initial training prior to change over to CAR-145 / during induction and refresher training at least once in every 24 months.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.4

DUTIES & RESPONSIBILITIES OF THE MANAGEMENT PERSONNEL (Ref: CAR 145.A.25 a, b, c, d & EPM Section-1, Chapter-13 & 15)

1.4.1

ACCOUNTABLE MANAGER

1.

The accountable manager is responsible for ensuring that maintenance carried out by the approved maintenance organisation meets the standards required by Manufacturer / DGCA.

2.

He is responsible for ensuring that necessary finance, manpower resources and facilities are available to enable the CAR-145 approved organization to perform the maintenance activities in accordance with the scope of approval.

3.

He is responsible for establishing and promoting the safety and quality policies specified in CAR-145.A.65(a)

4.

He is responsible for nominating senior person’s meeting the requirements provided in this MOE as Chief Engineer & Quality Manager to head the maintenance and quality departments of the organization.

5.

He is responsible for ensuring facilities are provided for training and assessing the competence of all personnel including management personnel.

6.

He will ensure that appropriate instructions are developed, documented and followed for compliance in the form of MOE and associated procedure manuals.

7.

He will nominate a suitably qualified senior person during lengthy absence of any post holder.

8.

He will ensure through review meetings that the quality non-conformities raised, Incident / Accident findings are actioned as per established procedure, to meet the intended standards and to prevent recurrence.

9.

He will take appropriate preventive action against erring personnel.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.4.2

CHIEF ENGINEER RESPONSIBLE TO: ACCOUNTABLE MANAGER

1.

Chief Engineer is responsible for execution of all engineering activities such as Line, Base, Component Maintenance & Specialized activities, within the organization scope of approval.

2.

Chief Engineer is responsible to; (ensure that the organization meets the requirement / standards in the following areas)

Maintenance Data; a.

Ensure availability of relevant and updated maintenance data to carryout the intended work in accordance with the organizations scope of approval.

b.

Ensure Aircraft maintenance programme is prepared / revised in accordance with the latest revisions of the Maintenance Data and approval for the same is obtained from the Regional Airworthiness Office, Bangalore.

c.

Ensure Inspection schedules are prepared / revised in accordance with the latest Maintenance Programme and as per the procedure established.

d.

Ensure proper arrangement is made for obtaining timely revision services from the publishers of the maintenance data.

e.

Ensure procedures are established to circulate maintenance data to various line / base / shop stations under controlled copy numbers and obtain feedback about updation & compliance.

f.

Establish Procedures to assess, plan and comply / implement the requirements of Technical literature such as Service Bulletins, Airworthiness Directives, and Mandatory Modifications etc.

Facilities; g.

Establish facilities appropriate to carryout the planned work, prior to the commencement of the work.

h.

Ensure working environment is appropriate to the tasks being undertaken.

i.

Establish office accommodation appropriate to the management of the planned work.

j.

Ensure availability of controlled and calibrated instruments, Special tools, equipment (including GSE), general tools and materials to perform the planned tasks.

k.

Establish Standard practices and procedures for use within the organisation, derived from approved sources, and keeping them up to date.

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Man power; l.

Ensure adequate man power is available to plan, perform / supervise, certify the maintenance activities.

m.

Ensure required man power is recruited after competence assessment to meet the organization requirements on routine basis.

n.

Ensure available man power is sufficiently trained on Induction, On Job and periodically to update the skills of the manpower to carryout the intended functions.

Training o.

Ensure competence of all personnel engaged in maintenance by establishing a programme of induction training and continuation training (including human factors training) using; 1.

Internal and External sources,

2.

On the job instruction and evaluation,

3.

Examination and testing (as necessary).

Inspection & Certification; p.

Ensure Standard procedures are established and published within the organisation, to achieve good maintenance practices and compliance with DGCA requirements and for establishing a system for the organisation to ensure that work is accomplished to the highest standards of airworthiness and workmanship.

q.

Ensure human factor limitations are considered while planning general / shift / one-off maintenance activities.

r.

Establish procedures for Satisfactory completion and certification of all work required by contracted operator / customer, in accordance with the maintenance contract / work specification.

s.

Ensure that organization’s procedures and standards are complied with, when carrying out the maintenance.

t.

Establish procedure, so that all maintenance activities are properly documented and such records are retained safely and securely till the pre-defined statutory time period.

u.

Ensure Airworthiness standard of aircraft, by monitoring life of components, inspection of systems, compliance of service bulletins, airworthiness directives, mandatory modifications and ensuring timely compliance action.

v.

Ensure thru the work force under his control that the quality of workmanship in the final product is to a standard acceptable to the organization and DGCA

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Logistics including storage; w.

Ensure materials are procured from company approved sources and are airworthy.

x.

Establish procedure for inspection and acceptance of materials into Bonded stores.

y.

Establish proper storage facilities for aircraft spares, consumables and other commercial items.

z.

Establish procedure for issue of materials for maintenance and ensure proper procedure for return of parts from maintenance to stores / repair agencies.

Non-conformities Correction aa.

Ensure that quality deficiency observations (Non-conformities) arising from Independent Quality system audits are responded to in proper and timely manner with corrective action to prevent re-occurrence.

Feedback to Accountable Manager / Manufacturer / DGCA bb.

Establish procedure for notifying the accountable manager whenever deficiencies emerge which require his attention in respect of finance and the acceptability of standards.

cc.

Establish procedure for reporting to the manufacturer and to DGCA any occurrence to the aircraft (or a component), which could affect airworthiness and hazard safety of the aircraft or its occupants.

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1.4.3

QUALITY MANAGER RESPONSIBLE TO: ACCOUNTABLE MANAGER

a.

The Quality Manager is responsible for establishing an independent quality system, including the associated feedback system to monitor compliance with DGCA requirements.

b.

The Quality Manager is responsible for preparing and implementing a quality audit programme in which compliance with all maintenance procedures are reviewed at regular intervals, in relation to the aircraft maintained by DAL and any observed non-compliances or poor standards are brought to the attention of the person concerned via the respective manager’s.

c.

Quality Manager is responsible to provide feedback to the accountable manager in the event of any reported discrepancy not being adequately attended to, by the relevant person, or in respect of any disagreement over the nature of a discrepancy.

d.

With specific reference to the CAR 145 approval, the quality manager is responsible for:1.

Creating a quality audit system to assess whether the organization is functioning as per policies listed in MOE and procedures laid out in the procedure manuals and whether the aircraft /component is being maintained or serviced in accordance with the appropriate maintenance data.

2.

Evaluating the quality system procedures established by the organization and approve the same.

3.

Establishing audit plan and programme and monitor execution of the same to assess compliance of regulations / standards / procedures and its effectiveness.

4.

Assessing suppliers / contractors for extension of the quality system, to the satisfaction of DGCA.

5.

Assessing suppliers of new and used components, and materials, for satisfactory product quality in relation to the requirements of the organization.

6.

Assessing external specialist and issue authorization, for services required by the company for maintenance activities.

7.

Establishing Standard practices and procedures for use within the organisation, derived from approved sources, and keeping them up to date.

8.

Reviewing of audit findings and action (corrective & preventive) taken by the organization to prevent re-occurrence.

9.

Liaisoning with DGCA on all matters concerning quality and safety.

10. Assessing the capabilities and issue company approvals to support staff for carrying out scheduled / unscheduled maintenance. 11. Assessing the capabilities and issue company authorization to certifying staff for carrying out scheduled / unscheduled maintenance and for issuing CRS certificate.

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12. Encouraging all maintenance personnel for timely and fearlessly reporting in-accuracies or mistakes committed by them to the management, so that no aircraft is released with deficiencies. 13. Auditing of completed documents/ work packages / inspection schedules and provide feedback in the form of non-compliances or technical circulars. 14. Amendment of MOE and submitting the proposed amendments to DGCA for approval.

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1.5 MANAGEMENT ORGANISATION CHART (Ref: EPM Section-1, Chapter-13)

Managing Director Capt. G.R. Gopinath

Accountable Manager Col. Jayanth Poovaiah (Retd)

Chief Engineer

Quality Manager

Mr. S.U. Khan

Mr. R. Meenakshisundaram

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PART - 1 - MANAGEMENT 1.5.1 ENGINEERING ORGANISATION CHART

(Ref: EPM Section-1, Chapter-14) Managing Director

Accountable Manager

Chief Engineer

Manager – Technical Services

Head - Logistics

Training Manager

Tech Officer (Records) Tech Officer (Software) Tech Officer (Planning)

Quality Manager

Component Overhaul / Repair shop personnel

Sub-Base / Line Station Personnel

Tech. Officer (Quality)

Wheels & Brake shop In-charge Certifying Staff Technical Officer Technician

Stores Inspector

Tools & Equipment In-Charge

Training Instructor Tech officer

Battery Shop-Incharge Certifying staff Technician

(Directives & Occurrences)

Technical Officer (Training) Tech Officer

Helicopter Component Shop-In-charge

(AMP & Schedules)

Certifying staff Technician

Tech. Officer (Library)

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Quality Auditor

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1.5.2

SUB-BASE / LINE STATION ENGINEERING ORGANIZATION CHART

CHIEF ENGINEER

Regional Engineering Manager Engineering Manager / Engineering In – charge (Hyderabad, Chennai, Koppal, Tornagallu, Vizag) (Surat, Raigarh), (Jammu, Katra) (Bhubaneswar)

Support / Certifying Staff

Foreman / Technicians

Technical Officers

Stores / In-Charge

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PART - 1 - MANAGEMENT 1.5.3

BASE / SUB-BASE / LINE STATION ENGINEERING PERSONNEL & THEIR FUNCTIONS

a.

Organization provides maintenance services to customers at various locations with in the country, apart from Bangalore, the main base. Such locations are identified as sub-base or line station depending on whether the location is approved by DGCA for carrying out scheduled inspections or not.

b.

Locations other than Bangalore, which are approved by DGCA, are designated as Sub-base. Locations where the aircraft is operating for more than 15days are designated as line (usually operating) station.

c.

At Bangalore, all support / certifying staff & non-certifying staff will report to the Regional engineering manager, who in turn will report to the Chief engineer. Regional Engineering Manager at Bangalore base will not liaise with the Regional airworthiness Office, Bangalore

d.

Chief engineer at Bangalore will only liaise with the Regional Airworthiness Office with respect to production engineering (Maintenance) matters.

e.

Tech. Officers at Bangalore are given individual portfolio (such as software, records, directives, library etc) and all tech. officers will be reporting to Manager – Technical services, who will inturn, report to the chief engineer.

f.

Stores in-charge at Bangalore is designated as Stores inspector. Stores inspector & tools & equipment in-charge will report to Head-Logistics.

g.

Sub-base stations (Mumbai / Delhi / Kolkata) will be headed by Regional Engineering Manager who will report to Chief engineer and also liaise with the respective regional airworthiness / air safety office with respect to the airworthiness / air safety related matters of respective sub-bases and other sub-bases / line stations falling under their purview.

h.

Other sub-bases such as (Surat / Raigarh /Jammu / Chennai / Bhubaneswar) will be headed by Engineering Manager / in-charge and reporting to their respective regional engineering manager.

i.

Tech. services personnel at sub-base are designated as Tech. Officer (sub-base). Logistics & stores personnel at sub-base are designated as stores in-charge (sub-base).

j.

All support / certifying staff, non-certifying staff, Tech. services staff and Logistics staff (including stores personnel) at sub-bases or line station will report to the Regional / Base engineering manager or in-charge of respective stations.

k.

Support / Certifying staff may be required to communicate with chief engineer directly on various issues to avoid communication gap /delay, but such communications will be intimated / copied to respective Regional / Base engineering manager for information

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PART - 1 - MANAGEMENT l.

Tech. services functions at sub-base will be carried out by Tech. Officer (sub-base), who will also communicate / co-ordinate with Manager – Tech. services and other Tech. Officers at Bangalore to carryout the Tech. services function. Functions such as preparation / approval of maintenance programme, inspection schedules will be the functions of Tech. Officer at Base only

m.

All logistics & stores function at sub-base will be carried out by stores in-charge (sub-base), who will also communicate / co-ordinate with Head-Logistics & Stores inspector at Bangalore to carryout the logistics and stores function.

n.

Line stations are headed by a certifying staff designated as Engineer in-charge and supported by non-certifying staff. In such stations, tech. services function & logistics functions will be handled by the engineer in-charge.

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PART - 1 - MANAGEMENT 1.6

LIST OF CERTIFYING STAFF & SUPPORT STAFF (CAR 145.A.35.j, & EPM Section-3, Chapter-28)

a).

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

List of Certifying and Support staff employed by the Organization are given below and the details are maintained in a folder in Quality Department.

Name Mr. S.U.Khan Mr. K. Chandrashekar Mr. Abhimanyu Verma Mr. Ranjan Rao Mr. Arvind Kumar Mr. M.K.Ramaswamy Mr. Sunil Kumar Mr. Satyam Singh Patel Mr. Rajendra Kr. Verma Mr. Mayank Singh Mr. Jees George Mr. Manas Goswami Ms. Nita Talreja Mr. Farooq Zeeshan Mr. P.T. Suresh Mr. Mohit Mahajan Mr. Soundarakumaraswamy Mr. Lingoji Rao Mr. Tojo Cherian Mr . A. Palani Mr. Vidyashankar Mr. Harinathan Mr. Amit Sharma Mr. Sandeep Pillay Mr. Sumit Mozika Mr. Sanjeev Kumar Mishra Mr. Ashveny Porwal Mr. Shashi Shankar Raju Mr. Santosh Kr. Verma Mr. Mohammad Parvej Khan Mr. Jagesh Choudhary Mr. Sameer Kumar Mr. Shubranshu Nair Mr. Surjeet Saini Mr. Aditya Prakash Mr. Rakesh Kumar Singh Mr. G.C.Shukla Mr. Debabrata Upadhyay Mr. Deepak Upadhyay Mr. Avadhesh Gupta Ms. Abhilasha Kumari Mr. Arun Choudhary Ms. Surabhi Mr. Jitendra Kumar Singh Mr. Rakesh Kumar Mr. Anish Suresh Mr. Arun Prabhu Mr. Amit Ranade

Cat. Bangalore Ban-Comp Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bangalore Bang-Batt Bang-Batt Bang-W&B Bang-W&B Bang-W&B Bang-W&B Mumbai Mumbai Mumbai Mumbai Mumbai Mumbai Mumbai Mumbai Mumbai Surat Surat Surat Delhi Delhi Delhi Delhi Delhi Delhi Delhi Delhi Delhi Delhi Delhi Delhi Hyderabad Hyderabad Hyderabad

A&C A&C A&C A&C A R A&C A&C A&C A&C A&C A&C A&C A&C A&C E&R E, I &R A&C A&C NDT NDT A&C A&C A&C R A&C A&C A&C A&C A&C A&C R A&C A&C A&C A&C A&C A&C A&C A&C R A & C(B) A&C A&C A&C A&C A&C A&C

Lic.No.

Line / Base / Component CERTIFICATION LIMIT

2963 7010 6869 7746 8981(B) 6267 7736(B) 8376(B) 8904 7170(B) 7456(B)

Line / Base Line / Base / Component Line / Base Line / Base Line Line / Base Line Line Line / Base Line Line Line Line Line Line Component Line / Base / Component Component Component NDI NDI Line / Base / Component Line / Base Line / Base Line / Base Line Line Line / Base Line Line Line / Base Line / Base Line Line Line / Base Line / Base Line / Base Line / Base Line / Base Line Line / Base Line Line Line Line Line / Base Line / Base Line / Base

9238 (B) 7688(B) 11179(B) 10006(B) 8242 2815 7490 C of C C of C 6638 7496 6775 8537 7648(B) 8972(B) 7604 9911(B) 9914(B) 6993 7354 8674(B) 2937 6363 6923 3449 7997 9150 9998(B) 8487 7838 10507(B) 7188 10573 8939 6652 7447

Remarks

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Mr. Kaushik Saha Mr. Saikat Mukherjee Mr. S.K.Pandey Mr. Shobit Gupta Mr. Ajit Mr. Kanda Mr. K.R. Pemmaiah

Kolkata Kolkata Bhubaneswar Raigarh Delhi Delhi Bangalore

A&C A&C A&C A&C A&C A&C A&C

6515 6742 7743 8887(B) 7011 2173 8254

Line / Base Line / Base Line / Base Line Line / Base Line Line / Base

Operator’s employee Operator’s employee Operator’s employee

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MANPOWER RESOURCES ( Line / Base / Component Maintenance) (Ref: CAR 145.A30.d, e, f & EPM Section-1, Chapter-14, Section-3, Chapter-9 & 23) a).

Organization is approved to carryout maintenance on the following categories of aircraft / component under CAR-145 approval; 1.

Line / Base Maintenance of Aircraft below 5700 Kg.

2.

Line / Base Maintenance of Helicopters.

3.

Component Maintenance i. ii. iii. iv.

Helicopter airframe dynamic components ( C-10 & C-11) Nickel –Cadmium Batteries ( C-5 ) Wheels & Brakes of Heavy Aircraft ( C-14 ) Engine (B-1)

b).

Base maintenance of airplane / helicopter are carried out at larger intervals, hence the base certifying staff also function as line certifying staff, to meet organization requirements.

c).

Resources (Numbers) of Base / Line / Component certifying staff available at various line / base station are listed below region wise, with respect to the type and number of aircraft or component under maintenance at each station.

d).

Manpower resources list will be updated by Quality Manager on quarterly basis and doesn’t require approval by Regional Airworthiness Office, Bangalore.

Location

Details of aircraft / component under Maintenance Type Regna

Bell 206B3

Bangalore

VT-DCA VT-DAS VT-OMC Bell 407 VT-SGP VT-VSL AS 355 F1 VT-DAX Schweizer 330 VT-KDO VT-JSW Caravan 208B VT-AHB VT-TAE P68 C VT-TLF VT-TLH King Air C90A VT-SSL Component Maintenance shop Battery shop Wheels and Brake shop

No. of Staff available for Maintenance ( Line / Base / Component) Certifying / Technicians Tech –Services* Quality Support staff * Tech-Services include Maint. Data / Records / Planning staff

15

28 12

1 2 4

1 8 31

2

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PART - 1 - MANAGEMENT Location

Delhi (Including Jammu & Katra stations)

Details of aircraft / component under Maintenance Type Regn

Bell 206B3 Bell 206L3 Bell 230 EC-145 King Air C90 Pilatus PC-12

VT-NTV VT-DAL VT-PPR VT-VNJ VT-SLK VT-EQO VT-DAR VT-JSL VT-MEG

No. of Staff available for Maintenance ( Line / Base / Component) Certifying / Technicians Tech –Services* Quality Support staff * Tech-Services include Maint. Data / Records / Planning staff

14

17

6

Nil

VT-AGJ VT-MSR VT-DAI VT-DAV VT-DAF VT-DAM VT-JIN

9

7

1

Nil

Surat Raigarh

Bell 206 B3 Bell 407 Bell 412 Pilatus PC-12 King Air B200 Bell 212 Caravan 208B

3 1

4 2

1 Nil

Nil Nil

Kolkata

Citation CJ2

VT-DOV VT-DAZ

2 1

2 4

Nil 1

Nil Nil

VT-DOV VT-DAW VT-PAR

3

5

Nil

Nil Nil Nil

55

109

21

2

Mumbai

Bhubaneshwar Bell 407

Hyderabad

Citation CJ1+ Bell 407 Bell 206L4

Total No of Personnel at all station.

e).

Few operator’s employ technical staff (who are licensed as per DGCA requirements and nonlicensed technical personnel) and attach those staff with the organization to work on their aircraft. Such personnel will also be counted in the man power resources, as long as such agreement is in place. Such owner / operator sponsored technical personnel will follow the policies and procedures laid down by the organization in this MOE and associated procedure manuals for discharging their functions. Such personnel, if qualified as per requirements, will be issued with approval /authorization to perform maintenance work on the aircraft.

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PART - 1 - MANAGEMENT 1.8

GENERAL DESCRIPTION OF FACILITIES AT EACH ADDRESS INTENDED TO BE APPROVED (Ref: CAR 145.A.25, EPM Section-1, Chapter-15)

a).

Brief detail about each of the facilities approved for line / base / component maintenance are provided in sub-paragraph of this chapter, location wise.

b).

General requirements of various facilities such as Base / Line / Shop are provided in EPM Section-1, Chapter-15.

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PART - 1 - MANAGEMENT 1.8.1

BASE MAINTENANCE FACILITY – BANGALAORE

Bangalore – Line / Base / Component Maintenance Facility Address: Jakkur Airport, Bellary Road, Bangalore – 560064, India Telephone : +91- 802-856-7523, 802-856-7524, 804-245-9696 Fax : +91-802-856-7998, 802-856-7525 Email – [email protected], [email protected], [email protected]


Area is leased by Govt. of Karnataka to the organization. All structures including hangar / office area are built by the organization




Bangalore facility has a hangar space area of approximately 3600 sq. feet, capable of accommodating four to five helicopters with its rotor blades removed. Hangar is closed from all sides, enabling the maintenance personnel to carryout their functions during rain.




Day’s room temperature varies from 20°C to 30°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Ten overhead fixed halogen lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, stand for stacking rotor blades etc.

Access

Area

Temp.

Line & Base Maintenance facility at Bangalore

Lighting
Equipment



Stores




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage. Air conditioned office space of about 3000 sq. ft is available to seat 20 plus staff belonging to Maintenance, Tech-services, Quality, logistics department. 15 seat conference cum training facility with overhead projector is available for conducting induction / refresher training.


Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 800 sq.ft (approx.) for storing of parts / components etc. Receipt and Dispatch section is located in an area of 300 sq.ft (approx). Quarantine / Repair / Scrap stores are located in a segregated area of 150 Sq. ft.

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PART - 1 - MANAGEMENT 1.8.2

COMPONENT MAINTENANCE FACILITIES - BANGALORE

Access

Area




Area is leased by Govt. of Karnataka to the organization. All structures including hangar / office area are built by the organization.




Component Maintenance facility is located on the ground floor adjacent to the hangar and is spread out in an area of approx. 1000 sq. ft




Battery shop facility is located on the first floor of the building adjacent to the hangar and is spread out in an area of approx. 1200 sq.ft




Wheels and Brake shop is located on the entire ground floor of the building adjacent to the hangar and is spread out in an area of 4000 sq.ft Helicopter airframe component overhaul facility and Battery shop facility is air conditioned to maintain a temperature of about 20°C


Temp. Component Maintenance facility at Bangalore




Wheels and Brake shop is non-air conditioned facility and Day’s room temperature varies from 20°C to 30°C, hence environment control of wheels and brake shop is not necessary.

Dust Pollution




Dust and airborne contamination is less and the shops are kept clean by routine cleaning of all area in and around the shop.

Noise Pollution




Noise pollution is less in the area, where the shops are situated and hence doesn’t affect distract personnel from carrying out the intended task.




Shop areas are designed in such a way that natural lighting is available in the shop and sufficient lights are also provided, to ensure that any maintenance activity can be carried out in an efficient manner. Helicopter airframe component shop is provided with degreasing equipment for cleaning parts, shot blaster for blast removal of paints / coatings etc, 10 ton hydraulic press for pressing /ejecting parts such as bearings, liners etc, oven for heating / baking parts and necessary general and special tools to carryout the work, with in the granted scope of approval.

Lighting


Equipment




Battery shop is provided with sufficient numbers of battery dischargers / chargers for carrying out the battery capacity testing, overhaul and necessary general and special tools to carryout the work, with in the granted scope of approval.




Wheels and Brake shop is provided with equipments such as tire bead breaker, fixture for holding wheels while disassembly / assembly, cage for tire inflation, support stands for storage of tires, balancing equipment, surface plate with DTI, Hardness tester etc. Dedicated Paint stripping and cleaning room for removal of paints from hub assemblies. Dedicated rooms and necessary equipment for Non Destructive inspection such as Magnetic particle, Fluorescent Penetrant, Eddy current inspection are available with in the premises of the wheel and brake shop.




Lifting assembly for brake units for disassembly of the brake, hydraulic test rig for testing brake assemblies are also available in the wheel and brake shop.

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PART - 1 - MANAGEMENT 1.8.3

BASE (Sub-base) MAINTENANCE FACILITY – DELHI

Delhi – Line Maintenance Facility Address: Hangar No.2, Palam airport, NewDelhi. Telephone : +91- 11-25673174, 11-25674809, 11-26520036,11-32909542 Fax : +91-11-26520034 Email – [email protected]; [email protected]; [email protected]


Area is leased by Delhi International Airport Limited (DIAL) to the organization. All structures including hangar / office area are built by DIAL.




Hangar is common use hangar, allotted for various operators. Deccan has a hangar space area of approximately 1500 sq. feet, capable of accommodating three helicopters with its rotor blades removed. Hangar is closed from three sides, enabling the maintenance personnel to carryout their functions during rain.




Day’s room (Hangar) temperature varies from 15°C to 40°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Multiple overhead fixed halogen lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, stand for stacking rotor blades etc.

Access

Area

Temp.

Line & Base Maintenance facility at Delhi

Lighting
Equipment



Stores

Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 100 sq.ft (approx.) for storing of parts / components etc. Receipt and Dispatch section is located in an area of 100 sq.ft (approx). Quarantine / Repair / Scrap stores are located in a segregated area of 100 Sq. ft.




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 800 sq. ft is available to seat 15 plus staff belonging to Maintenance, Tech-services, Quality, logistics department..

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PART - 1 - MANAGEMENT 1.8.4

BASE (Sub-base) MAINTENANCE FACILITY – MUMBAI

Mumbai – Line / Base Maintenance Facility Address : Hangar No.8, Juhu airport, Mumbai - 40049 Telephone : +91- 222-661-1601, 222-661-4330 Fax : +91-222-661-1601 Email – [email protected], [email protected]


Area is leased from AAI to the organization. All internal structures of office area are built by the organization except the external hangar structure.




Mumbai facility has a hangar space area of approximately 463 sq. mts, capable of accommodating two to three helicopters with its rotor blades removed. Hangar is closed from all sides, enabling the maintenance personnel to carryout their functions during rain.




Day’s room temperature varies from 20°C to 32°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Six overhead fixed halogen lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, 230V power supply, 28V ground battery power supply, pneumatic air source, aircraft jacks, wash cart and stand for stacking rotor blades etc.

Access

Area

Temp.

Line & Base Maintenance facility at Mumbai

Lighting
Equipment



Stores




Quarantine / Scrap stores are located in a segregated area.




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage bins/Storage Racks are strong enough to hold spares are provided, so that components are not distorted during storage. Air conditioned office space of about 1400 sq. ft is available to seat 15 plus staff belonging to Maintenance, Operations Quality, stores and admin department.


Office Space

Necessary general tools, special tools, Pressurization Unit equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 170sq.ft (approx.) for storing of parts / components etc.




6-12 seat conference / training / crew training facility with overhead projector are available for conducting induction / refresher training.

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PART - 1 - MANAGEMENT 1.8.5

BASE (Sub-base) MAINTENANCE FACILITY – JAMMU

Jammu – Line / Base Maintenance Facility Address : Nehru Helipad, Rajbhavan, Jammu Telephone : +91- 1991-234378/79 Fax : +91-1991-234379 Email – [email protected]


Area is provided by Govt. of J&K under mutual agreement. Manpower is positioned as and when required basis at this location to carryout the work.




Maintenance facility has a hangar space area of approximately 2000 sq. feet, capable of accommodating three to four helicopters. Hangar is closed from all sides, enabling the maintenance personnel to carryout their functions during rain.




Day’s room temperature varies from 10°C to 30°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Ten overhead fixed halogen lights and 5 Tube lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, etc.

Access

Area

Temp. Line & Base Maintenance facility at Jammu

Lighting
Equipment



Stores

Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 500 sq.ft (approx.)




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 1000 sq. ft is available to seat staff belonging to Maintenance.

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PART - 1 - MANAGEMENT 1.8.6

BASE (Sub-base) MAINTENANCE FACILITY – SURAT

Surat – Line / Base Maintenance Facility Address: Cairn Energy Site, Lakshmi Onshore Terminal, Survey No.-232, Reliance Jetty Road, Suvali Village, Post: Suvali, Taluka: Chourasiya, Dist: Surat-394510, Gujarat, India. .Telephone: +91- 9227901168/69. Fax : +0261-2862790/93 Email – [email protected] ; [email protected] ; [email protected]
Access
Area

Area is property of cairn Energy India ltd, provided to the organization for use, as the organization also provides Helicopter service for Cairn India Limited. Area includes Helipad, Hangar, Bonded Store & Quarantine Stores, and Engg. Office & Ops Office Surat facility has a hangar space area of approximately 4500 sq. feet, capable of accommodating three two-blade helicopters with one of its rotor blade tied down over the tail boom. The maintenance hanger is enclosed from three side to facilitate maintenance personnel to carryout their functions during rain




Day’s room temperature varies from 20°C to 30°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Nine overhead fixed halogen lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, stand for stacking rotor blades etc.

Temp. Line & Base Maintenance facility at Surat

Lighting
Equipment



Stores

Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of (16ftX15ft) 240 sq.ft (approx.) for storing of parts / components etc. Quarantine / Repair / Scrap stores are located in a segregated area of 80 Sq. ft.




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 145 sq. ft is available to seat 6 plus staff belonging to Maintenance, Tech-services, and logistics department

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PART - 1 - MANAGEMENT 1.8.7

BASE (Sub-base) MAINTENANCE FACILITY – RAIGARH

Raigarh – Line / Base / Maintenance Facility Address: Aviation Department, Jindal Steel & Power Limited, Kharsia Road, Post Box-16, Raigarh-496001, (C.G.), INDIA. Telephone: +91- 7762-304300 extn: 2111, 2112, 5129. Fax : +91-7762-304332 E-mail – [email protected]
Area is provided by Jindal Steel & Power Limited to the organization. All structures including hangar / office area are built by Jindal Steel & Power Access Limited.
Raigarh facility has a hangar space area of approximately 50m X 30m X 6.83m, capable of accommodating four to five fixed wing aircraft or helicopters. Hangar Area is closed from all sides, enabling the maintenance personnel to carryout their functions during rain.


Day’s room temperature varies from 20°C to 30°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Thirteen overhead fixed halogen lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, 230V power supply, 28V ground battery power supply, pneumatic air source.

Temp.

Line & Base Maintenance facility at Raigarh

Lighting
Equipment



Stores

Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 300 sq.ft (approx.) for storing of parts / components etc. Receipt and Dispatch section is located in an area of 150 sq.ft (approx). Quarantine / Repair / Scrap stores are located in a segregated area of 150 Sq. ft.




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 600 sq. ft is available to seat 08 plus staff belonging to Maintenance, Tech-services department.

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PART - 1 - MANAGEMENT 1.8.8

BASE (Sub-base) MAINTENANCE FACILITY – KOLKATA

Kolkata – Line Maintenance Facility Address : Room No.209,Hangar No.19,NSCBI Airport, Kolkata-700 052 Telephone : +91- 9432217928,9433196396 Fax : +91-332-511-2022 Email – [email protected]


Room and hangar at Hangar No.19 and Hangar No.6 respectively are leased by AAI, Kolkata to scheduled airline division of our organization, who has allowed us to use the same




Kolkata facility has a hangar space area of approximately 3000 sq. feet, capable of accommodating two ATR72 aero planes. Hangar is closed from two sides, enabling the maintenance personnel to carryout their functions during rain.




Day’s room temperature varies from 20°C to 30°C, hence environment control of hangar is not necessary.




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.




Noise pollution is prevalent in the area, as the hangar is situated inside the airport and hence all maintenance personnel take proper precautions during carrying out maintenance




Eight overhead fixed halogen lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, hydraulic power trolley etc.

Access

Area

Temp. Line & Base Maintenance facility at Kolkata

Dust Pollution Noise Pollution Lighting


Equipment



Stores

Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 80 sq.ft (approx.) for storing of parts / components etc. Quarantine / Repair / Scrap stores are located in a segregated area.




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 300 sq. ft is available to seat 06 staff belonging to Maintenance, Tech-services department.

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PART - 1 - MANAGEMENT 1.8.9

BASE (Sub-base) MAINTENANCE FACILITY – BHUBANESHWAR

Bhubaneswar – Line Maintenance Facility Address : East Air hangar, Bhubaneswar - 751014, India Telephone : +91- 674-243-3537 Fax : +91-674-243-5464 Email – [email protected], [email protected]


Area is leased by Capt. Ajay Kumar Mishra to the organization. All structures including hangar / office area are built by Capt. Ajay Kumar Mishra.




Bhubaneswar facility has a hangar space area of approximately 2000 sq. feet, capable of accommodating one helicopter with its rotor blades installed. Hangar is closed from three sides (Front Face is open), enabling the maintenance personnel to carryout their functions during rain.




Day’s room temperature varies from 20°C to 35°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Three overhead fixed halogen lights are available to provide sufficient lighting in the working area in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, stand for stacking rotor blades etc.

Access

Area

Temp. Line & Base Maintenance facility at Bhubaneshwar

Lighting
Equipment



Stores

Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 150 sq.ft (approx.) for storing of parts / components etc. Receipt and Dispatch section is located in same area. Quarantine / Repair / Scrap stores are located in an area of 300 Sq. ft. on the first floor.




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 150 sq. ft is available to seat 05 plus staff belonging to Maintenance, Tech-services, Quality, logistics department.

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PART - 1 - MANAGEMENT 1.8.10

BASE (Sub-base) MAINTENANCE FACILITY – HYDERABAD

HYDERABAD – Line / Base Maintenance Facility Address: C/O A.P. Aviation Academy. Begumpet, old Airport, Hyderabad, India. Telephone : +91- 04064581326 Email – [email protected],
Access
Area

Hangar belongs A.P.Aviation Academy in which our organization is permitted to park its helicopter and carry out maintenance activities for both helicopter and CJ1+ Fixed wing Aircraft. All structures including hangar / office area are rented to the organization by A.P. Aviation Academy Hyderabad facility has a hangar space area of approximately 5000 sq. feet, out of which approx 1200 sq feet hangar space is allotted for helicopter parking. And the rest of the space can be utilized on need basis.




Hangar is closed from all sides, enabling the maintenance personnel to carryout their functions during rain.




Day’s room temperature varies from 20°C to 35°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Thirty overhead fixed fluorescent lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner. Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, stand for stacking rotor blades etc.

Temp. Line & Base Maintenance facility at Hyderabad

Lighting
Equipment



Stores

Office Space

Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar. Environmentally controlled bonded store is located in area of 50 sq.ft (approx.) for storing of parts / components etc. Receipt and Dispatch section is located in an area of 50 sq.ft (approx). Quarantine / Repair / Scrap stores are located in area of 50 Sq.ft




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 100 sq. ft is available to seat 5 staff belonging to Maintenance, Tech-services, Quality, logistics department.

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PART - 1 - MANAGEMENT 1.8.11

LINE MAINTENANCE STATION – CHENNAI

CHENNAI – Line Maintenance Address: E-312, TVH Park Villa, Vinayaka Nagar, Thoraipakkam, Chennai – 600096 India. Telephone : +91- 44-24565312, +91-99406-35721 Email – [email protected]

Line Maintenance at Chennai

Access




Aircraft is parked at Chennai International airport. All line maintenance activities are carried out at parking bay.

Area




Parking bay allotted by airport authority of India.

Temp.




Day’s temperature varies from 20°C to 40°C.

Dust Pollution




Dust and airborne contamination is less in the airport area




Noise pollution is acceptable in the parking bay area, where the aircraft is parked and hence doesn’t affect / distract personnel from carrying out the intended task.

Lighting




Maintenance activities are carried out during day time only. No maintenance activities are carried out in the night

Equipment




Necessary general tools, water wash equipment required to carryout line maintenance are available and is carried to the airport, as and when required.




No parts are stored on routine basis. Required parts are transported from Bangalore as per requirement. Consumables & Parts intended for day to day use are held in appropriate manner for line maintenance consumption.




Air conditioned office space is available to seat 3 staff belonging to Maintenance / Operation at the address mentioned above.

Noise Pollution

Stores

Office Space

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PART - 1 - MANAGEMENT

1.8.12

LINE MAINTENANCE STATION – KOPPAL

KOPPAL – Line Maintenance Address : Baldota Koppal Aerodrome, Koppal, Karnataka Telephone : 08539-286570 Email – [email protected]

Line Maintenance at KOPPAL

Access




Aircraft is parked at MSPL airport at Koppal. All line maintenance activities are carried out at parking bay.

Area




Koppal is a private airport built by MSPL Limited.

Temp.




Day’s temperature varies from 20°C to 40°C.

Dust Pollution




Dust and airborne contamination is less in the airport area

Noise Pollution




Noise pollution is less / non-existent in the airport, where the aircraft is parked and hence doesn’t affect / distract personnel from carrying out the intended task.

Lighting




Maintenance activities are carried out during day time only. No maintenance activities are carried out in the night

Equipment




Necessary general tools, water wash equipment required to carryout line maintenance are available and is carried to the airport, as and when required.




No parts are stored on routine basis. Required parts are transported from Bangalore as per requirement. Consumables & Parts intended for day to day use are held in appropriate manner for line maintenance consumption.




Office space is available to seat 3 staff belonging to Maintenance at the address mentioned above.

Stores

Office Space

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PART - 1 - MANAGEMENT

1.8.13

LINE MAINTENANCE STATION – TORNAGALLU

TORNAGALLU – Line Maintenance Address: Jindal Vidyanagar Airport, Bellary Dist, Karnataka, India. Telephone: 08395-240499, +91-974-003-2075 Email – [email protected]

Line Maintenance at TORNAGALLU

Access




Aircraft is parked at Vidyanagar airport. All line maintenance activities are carried out at parking bay.

Area




Vidyanagar airport is a private airport built by Jindal Steel Works.

Temp.




Day’s temperature varies from 20°C to 40°C.

Dust Pollution




Dust and airborne contamination is less in the airport area

Noise Pollution




Noise pollution is acceptable in the parking bay area, where the aircraft is parked and hence doesn’t affect / distract personnel from carrying out the intended task.

Lighting




Maintenance activities are carried out during day time only. No maintenance activities are carried out in the night

Equipment




Necessary general tools, water wash equipment required to carryout line maintenance are available and are carried to the airport, as and when required.




No parts are stored on routine basis. Required parts are transported from Bangalore as per requirement. Consumables & Parts intended for day to day use are held in appropriate manner for line maintenance consumption.




Office space is available to seat 3 staff belonging to maintenance at the address mentioned above.

Stores

Office Space

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PART - 1 - MANAGEMENT 1.8.14

LINE MAINTENANCE STATION – VIZAG

VIZAG – Line Maintenance Address : 201, J.L.Nair Complex, Above Megna Megamart, Guchirajepalayam, Vizag , India. Telephone : 0891-3065568 Email – [email protected]

Line Maintenance at VIZAG

Access




Aircraft is parked at Vizag airport. All line maintenance activities are carried out at parking bay.

Area




Parking bay allotted by airport authority of India.

Temp.




Day’s temperature varies from 20°C to 45°C.

Dust Pollution




Dust and airborne contamination is less in the airport area




Noise pollution is acceptable in the parking bay area, where the aircraft is parked and hence doesn’t affect / distract personnel from carrying out the intended task.

Lighting




Maintenance activities are carried out during day time only. No maintenance activities are carried out in the night

Equipment




Necessary general tools, water wash equipment required to carryout line maintenance are available and are carried to the airport, as and when required.




No parts are stored on routine basis. Required parts are transported from Bangalore as per requirement. Consumables & Parts intended for day to day use are held in appropriate manner for line maintenance consumption.




Air conditioned office space is available to seat 3 staff belonging to Maintenance at the address mentioned above.

Noise Pollution

Stores

Office Space

*******************

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.8.15

LINE MAINTENANCE FACILITY – KATRA

Katra – Line Maintenance Facility Address : Katra Helipad, Katra Udhampur road, Katra, Distt-Udhampur-182301(J&k), India Telephone : +91- 1991-234378/79 Fax : +91-1991-234379 Email – [email protected], [email protected]




Area is leased by Sree Mata Veshno Devi Shrine board to the organization.




Katra facility has a hangar space area of approximately 4000 sq. feet, capable of accommodating four to five helicopters with its rotor blades removed. Hangar is closed from all sides, enabling the maintenance personnel to carryout their functions during rain. Hangar is also used by another operator.




Day’s room temperature varies from 10°C to 30°C, hence environment control of hangar is not necessary.

Dust Pollution




Dust and airborne contamination is less and the hangar is kept clean by routine cleaning of all area in and around hangar.

Noise Pollution




Noise pollution is less in the area, where the hangar is situated and hence doesn’t affect distract personnel from carrying out the intended task.




Five overhead fixed halogen lights and 10 Tube lights are available to provide sufficient lighting in the hangar, so that any maintenance activity can be carried out in an efficient manner.




Hangar is equipped with sufficient trestles, ladders, workshop benches, temporary storage racks, overhead gantry, 230V power supply, 28V ground battery power supply, pneumatic air source, etc.




Necessary general tools, special tools, equipment required to carryout maintenance as per scope of approval granted are available at the hangar.




Environmentally controlled bonded store is located in area of 800 sq.ft (approx.)




Storage facilities are maintained clean and non-air conditioned areas are well ventilated.




Storage racks strong enough to hold large components are provided, so that components are not distorted during storage.




Air conditioned office space of about 500 sq. ft is available to seat 6 plus staff belonging to Maintenance, logistics, and commercial department.

Access

Area

Temp.

Line Maintenance facility at Katra

Lighting

Equipment

Stores

Office Space

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PART - 1 - MANAGEMENT

1.9

ORGANIZATION’S ACTIVITIES / SCOPE OF WORK (Ref: AMC-145.A.10 & CAR 145.A.20)

a).

b).

Organization is an established AMO capable of and approved by DGCA to carrying out the following: 1.

Line Maintenance

2.

Base Maintenance

3.

Component Maintenance

4.

Specialized Activities

Line Maintenance is defined as any maintenance that is carried out before flight to ensure that the aircraft is fit for the intended flight. Line maintenance includes;

1.

Trouble shooting

2.

Defect Rectification

3.

Component replacement with use of external test equipment if required.

4.

Component replacement may include components such as engines and propellers.

5.

Scheduled maintenance and / or checks including visual inspections that will detect obvious unsatisfactory conditions / discrepancies but do not require extensive in depth inspection. It may also include internal structure, systems and power plant items which are visible through quick opening access panels/ doors.

6.

Minor repairs and modifications which do not require extensive disassembly and can be accomplished by simple means.

c).

For temporary or occasional cases (AD’s, SB’s), the Quality Manager may accept base maintenance tasks to be performed at line maintenance station provided all requirements are fulfilled.

d).

Maintenance tasks falling outside the above criteria are considered to be Base maintenance

PAGE NO : 40

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PART - 1 - MANAGEMENT

e).

Aircraft wise line / base maintenance classification is given below

Sl. No

Type of aircraft, engine and propeller

Classification of Scheduled Maintenance activity as Line Maintenance Base Maintenance

1

Bell 206B3 fitted with RR 250-C20 engines Bell 206L3 fitted with RR 250-C30P engine Bell206L4 fitted with RR 250-C30P engine Bell 407 fitted with RR 250-C47B engine AS 355F1 / F2 fitted with RR 250-C20F engine Bell 212 fitted with PT6T-3B engine Bell 412 fitted with PT6T-3B engine Schweizer 330SP fitted with RR 250C20W engine Agusta 109E fitted with PW 206C engine EC-145 fitted with Arriel 1E2 engine Bell 230 fitted with RR 250-C30G/2 engine PC-12, 12/45 & 12/47) fitted with PT6A67B engine Citation CJ1+ fitted with Williams FJ441AP engine Citation CJ2 fitted with Williams FJ442AC engine Caravan 208B fitted with PT6A-114A engine P68C fitted with Lycoming IO-230 A1B6 engine King Air B200 fitted with PT6A-42 engine King Air C90A fitted with PT6A-21 engine

Inspection below 300hrs

300Hrs inspection and above

Inspection below 300hrs

300Hrs inspection and above

Inspection below 300hrs

300Hrs inspection and above

Inspection below 300hrs Inspection below 300hrs

300Hrs inspection and above 300Hrs inspection and above

Inspection below 300hrs Inspection below 300hrs Inspection below Annual

300Hrs inspection and above 300Hrs inspection and above Annual inspection and above

Inspection below 400hrs Inspection below 600hrs Inspection below 300hrs

400Hrs inspection and above 600Hrs inspection and above 300Hrs inspection and above

Inspection below Annual

Annual inspection and above

Inspection below 300hrs

300Hrs inspection and above

Inspection below 300hrs

300Hrs inspection and above

Inspection below 400hrs

400Hrs inspection and above

Inspection below 200hrs

200Hrs inspection and above

Inspection below Phase-II

Phase-II inspection and above

Inspection below Phase-II

Phase-II inspection and above

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PAGE NO : 41

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PART - 1 - MANAGEMENT 1.9.1

ORGANIZATION’S APPROVED SCOPE OF WORK & TERMS OF APPROVAL a.

Scope of work, deemed to be constituting approval of DGCA is listed below in Table 1.9.1.A to 1.9.1.E. (CAR 145.A.20 refers).

TABLE -1.9.1.A CLASS

AIRCRAFT

RATING

A2 Aero plane below 5700 kg AUW

LIMITATIONS PC-12, 12/45 & 12/47) fitted with PT6A67B engine PC-12/45 fitted with PT6A-67B engine

Location

LINE

BASE

Delhi

X

X

Bangalore Mumbai

X X

X X

Citation CJ1+ fitted with Williams FJ441AP engine

Delhi Hyderabad

X X

--X

Caravan 208B fitted with PT6A-114A engine

Delhi Bangalore Raigarh

X X X

X X X

King Air B200 fitted with PT6A-42 engine

Mumbai

X

X

King Air C90A fitted with PT6A-21 engine

Bangalore Delhi

X X

X ---

P68C fitted with Lycoming IO-230 A1B6 engine

Bangalore

X

X

Citation CJ2 fitted with Williams FJ442AC engine

Kolkata

X

X

Terms of Approval at Line Station PC-12, 12/45 & 12/47) fitted with PT6A-67B engine

Up to Annual Inspection

Citation CJ1+ fitted with Williams FJ44-1AP engine

Up to 150Hrs Inspection

Caravan 208B fitted with PT6A-114A engine

Up to 400Hrs Inspection

King Air C90A fitted with PT6A-21 engine

Up to Phase-I inspection

PC-12/45 fitted with PT6A-67B engine

Up to Annual Inspection

King Air B200 fitted with PT6A-42 engine

Up to Phase IV Inspection

PC-12/45 fitted with PT6A-67B engine

Up to Annual Inspection

King Air C90A fitted with PT6A-21 engine

Up to Phase IV Inspection

P68C fitted with Lycoming IO-230 A1B6 engine

Up to 200Hrs / 1 Yr Inspection

Caravan 208B fitted with PT6A-114A engine

Up to 1000Hrs / 1Yr Inspection

Raigarh

Caravan 208B fitted with PT6A-114A engine

Up to 400Hrs Inspection

Hyderabad

Citation CJ1+ fitted with Williams FJ44-1AP engine

Up to 300Hrs Inspection

Kolkata

Citation CJ2 fitted with Williams FJ44-2AC engine

Up to 150Hrs Inspection

Delhi

Mumbai

Bangalore

PAGE NO : 42

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PART - 1 - MANAGEMENT

TABLE -1.9.1.B CLASS

RATING

LIMITATIONS

Location Bangalore Delhi Mumbai

LINE X X X

BASE X X X

Bell 206L3 fitted with RR 250-C30P engine

Bangalore Delhi Hyderabad Jammu

X X X X

X X X X

Bell206L4 fitted with RR 250-C30P engine

Bangalore Delhi Hyderabad

X X X

X X X

Bell 206L series fitted with RR 250C30P engine

Mumbai

X

X

Bell 407 fitted with RR 250-C47B engine

Bangalore Delhi Mumbai Hyderabad Jammu Bhubaneswar

X X X X X X

X X X X X X

Bell 212 fitted with PT6T-3B engine

Bangalore Surat

X X

--X

Bell 412 fitted with PT6T-3B engine

Mumbai

X

X

Bell 230 fitted with RR 250-C30G/2 engine

Delhi

X

X

AS 355F1 / F2 fitted with RR 250-C20F engine

Bangalore Mumbai

X X

X X

Schweizer 330SP fitted with RR 250C20W engine

Bangalore

X

X

Agusta 109E fitted with PW 206C engine

Jammu Delhi

X X

X ---

EC-145 fitted with Arriel 1E2 engine

Delhi

X

X

Bell 206B3 fitted with RR 250-C20 engines

AIRCRAFT

Bangalore

A3 Helicopters

Limitations / Terms of Approval at Line or Base Station Bell 206B3 fitted with RR 250-C20 engines Up to 1200hrs Inspection Bell 206L3 fitted with RR 250-C30P engine Up to 1200hrs Inspection Bell206L4 fitted with RR 250-C30P engine Up to 300hrs Inspection Bell 407 fitted with RR 250-C47B engine Up to 300hrs Inspection

PAGE NO : 43

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

Hyderabad

Mumbai

Delhi

Surat Jammu Bhubaneswar

AS 355F1 / F2 fitted with RR 250-C20F engine Bell 212 fitted with PT6T-3B engine Schweizer 330SP fitted with RR 250-C20W engine Bell 206L3 fitted with RR 250-C30P engine Bell206L4 fitted with RR 250-C30P engine Bell 407 fitted with RR 250-C47B engine AS 355F1 / F2 fitted with RR 250-C20F engine Bell 412 fitted with PT6T-3B engine Bell 206L series fitted with RR 250-C30P engine Bell 407 fitted with RR 250-C47B engine Bell 206B3 fitted with RR 250-C20 engines Bell 206B3 fitted with RR 250-C20 engines Bell 206L3 fitted with RR 250-C30P engine Bell206L4 fitted with RR 250-C30P engine Bell 407 fitted with RR 250-C47B engine Agusta 109E fitted with PW 206C engine EC-145 fitted with Arriel 1E2 engine Bell 230 fitted with RR 250-C30G/2 engine Bell 212 fitted with PT6T-3B engine Bell 407 fitted with RR 250-C47B engine Agusta 109E fitted with PW 206C engine Bell 206L3 fitted with RR 250-C30P engine Bell 407 fitted with RR 250-C47B engine

CLASS Engines

RATING B-1 Turbine

CLASS

RATING C-5 Electrical Power C-10 Helicopter Rotors C-11 Helicopter – Trans

Components

C-14 Landing Gear

TABLE -1.9.1.C LIMITATIONS Location RR Model 250 Bangalore Engines

TABLE -1.9.1.D LIMITATIONS Location Ni-cad Battery Bangalore

Bell 206L Series, Bell 206B3 and Bell 407 Bell 206L Series, Bell 206B3 and Bell 407 ATR42 Series, ATR 72 Series, Airbus A-320 ATP Aircraft

Up to 5000hrs/12yrs Inspection Up to 150hrs Inspection Up to 100hrs Inspection Up to 300hrs Inspection Up to 300hrs Inspection Up to 300Hrs / 12 Months Inspection Up to 500 Hrs / 2 Yr Inspection Up to 600 Hrs / 12 Months Inspection Up to 300 Hrs Inspection Up to 300 Hrs / 12 Months Inspection Up to 300 Hrs Inspection Up to 1200hrs Inspection Up to 1200hrs Inspection Up to 300hrs Inspection Up to 1200hrs / 24months Inspection Up to 100hrs / 6months Inspection Up to 100hrs Inspection Up to 600hrs / 12months Inspection Up to 3000hrs / 5years Inspection Up to 300Hrs / 12Months Up to 400hrs Inspection Up to 300hrs Inspection Up to 300Hrs / 12Months

Scope of work Module Change

ATA Chapters 24

Bangalore

62, 64

Bangalore

63, 65

Bangalore

32

Bangalore

32

PAGE NO : 44

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

CLASS Specialized Services

RATING D1 – Non Destructive Testing

TABLE -1.9.1.E LIMITATIONS Location Bangalore NIL

Scope of work FPI, MPI, Ultrasonic and Eddy Current Inspection.

PAGE NO : 45

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

PART - 1 - MANAGEMENT 1.9.2

CAPABILITY LIST - ENGINE

TABLE -1.9.1.F CLASS Engines

Sl.No. 1 2 3

1.9.3

RATING B-1 Turbine

LIMITATIONS RR Model 250 Engines

Location Bangalore

Scope of work Module Change

CAPABILITY LIST DESCRIPTION RR 250-C 20 Series Engines RR 250-C 30 Series Engines RR 250-C47B engine

PART No. All All All

CAPABILITY LIST - BATTERY

TABLE -1.9.1.G CLASS Engines

Sl.No. 1

RATING C-5 Electrical Power

LIMITATIONS Ni-cad Battery

PART No. 2758

2

1756

3

23491

4

1658-6

5

1656

6

1606-1

7

4078-2 40678-2

8

4071-1

/

Location Bangalore

ATA CHAPTERS 24

CAPABILITY LIST DESCRIPTION Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul

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PART - 1 - MANAGEMENT 9

NCSPB 40060 A

-

10

AD40678-2

11 12

NC001/NC115 4076-15

13

40179

14 15 16

2778-1 32824-001 40576

17

61-0478-9 & 11

Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul ATR Main Battery – Aero Design Electrical Test for new battery from stores. Electrical Test for battery from aircraft. General Overhaul. Initial commissioning / Capacity check Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Capacity Test & Charging General Overhaul Capacity Test Marathon Battery Reconditioning & Capacity Testing Periodical Check (Charging) Regular Check (Capacity Testing & Charging) General Overhaul Battery Pack Assembly Capacity check

18 19 20 21 22 23 24 25 26

61-3800-1 AD301-3017 301-1151 301-3017 Amdt A&B 3214-30 3214-31 405 CH 505 CH NCSP-B23060LM 39563-001

Emergency battery pack test procedure Emergency battery pack capacity test Emergency battery pack testing Emergency lighting power supply recharging Emergency battery pack capacity test Airbus 330 Battery – Recharging, Capacity Test, General overhaul. Airbus 340 Battery – Recharging, Capacity Test, General overhaul. Airbus Battery (Indigenized) – Re-charging, Capacity Testing & General overhaul Battery Pack – Capacity test

PAGE NO : 47

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

PART - 1 - MANAGEMENT 1.9.4

CAPABILITY LIST - HELICOPTER COMPONENTS

TABLE -1.9.1.I CLASS Components

Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

RATING C-11 Helicopter – Trans

LIMITATIONS Bell 206L Series, Bell 206B3 and Bell 407

Location Bangalore

ATA CHAPTERS 63, 65

PART No. ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

CAPABILITY LIST DESCRIPTION 206L Series – Main Rotor Head 206L Series – Tail Rotor Head 206L Series – Main Rotor Gearbox 206L Series – Tail Rotor Gearbox 206L Series – Freewheeling Assembly 206L Series – Swashplate & Support Assembly 206L Series – Main Rotor Drive Shaft 206B3 – Main Rotor Head 206B3 – Tail Rotor Head 206B3 – Main Rotor Gearbox 206B3 – Tail Rotor Gearbox 206B3 – Freewheeling Assembly 206B3– Swashplate & Support Assembly 206B3 – Main Rotor Drive Shaft Bell 407 – Main Rotor Head Bell 407 – Tail Rotor Head Bell 407 – Main Rotor Gearbox Bell 407 – Tail Rotor Gearbox Bell 407 – Freewheeling Assembly Bell 407– Swashplate & Support Assembly

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PART - 1 - MANAGEMENT 1.9.5

CAPABILITY LIST - WHEELS & BRAKE

TABLE -1.9.1.I CLASS

RATING

Components

C-14 Landing Gear

Sl.No 1

LIMITATIONS ATR42 Series, ATR 72 Series, Airbus A-320 ATP Aircraft

PART No. 5006856,-1,-2,-3,-4,-5

2

5006858,-1,-2

3 4 5

5006857,-1,-2 5012609 C 20195162

6

3-1531,-1,-2,-3, 3-1470 series C 20225310, C 20225410 series, C 20225508 / 9 / 10 series AHA 1752, AHA 1890 AH54452, AH54474 AHA 1653 AHA 2122 AH54422

7

8 9 10 11 12

Location Bangalore

ATA CHAPTERS 32

CAPABILITY LIST DESCRIPTION Tire Change and Overhaul of Main Wheel assembly fitted on ATR 42320/500 aircraft Tire Change and Overhaul of Nose Wheel assembly fitted on ATR 42320/500 aircraft. Overhaul of Brake Assembly fitted on ATR 42-320 aircraft. Overhaul of Brake Assembly fitted on ATR 42-320/500 aircraft. Tire Change and Overhaul of Main Wheel assembly fitted on Airbus A-320 aircraft. Tire Change and Overhaul of Nose Wheel assembly fitted on Airbus A-320 aircraft Overhaul of Brake Assembly fitted on Airbus A-320 aircraft. Tire Change and Overhaul of Main Wheel assembly fitted on ATR 72-500 aircraft. Tire Change and Overhaul of Nose Wheel assembly fitted on ATR 72-500 aircraft. Overhaul of Brake Assembly fitted on ATR 72-500 aircraft. Tire Change and Overhaul of Main Wheel assembly fitted on ATP aircraft. Tire Change and Overhaul of Nose Wheel assembly fitted on ATP aircraft.

********************

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT 1.10

NOTIFICATION PROCEDURE TO DGCA REGARDING CHANGES TO ORGANISATION’S ACTIVITIES / APPROVALS / LOCATION / PERSONNEL. (Ref: CAR 145.85, EPM Section-1, Chapter-16) a).

Quality Manager will notify DGCA of any proposal to carryout any of the following changes before such changes takes place to enable DGCA to determine continued compliance with the CAR-145 and to amend, if necessary, the approval certificate, except that in case of proposed changes in personnel not known to the management beforehand, these changes will be notified to DGCA at the earliest opportunity. 1 2 3 4 5

1.10.1

CHANGES TO NAME / MAIN LOCATIONS / ADDITIONAL LOCATIONS

a).

1.10.2

Quality manager will inform the Regional Airworthiness Office, Bangalore in writing of a proposed change of the organization name, main location or additional locations, giving reasons along with an amendment to the relevant parts of this exposition. This will be carried out in a timely manner thus allowing the exposition amendment to be considered and accepted/rejected before the new location is used.

ACCOUNTABLE MANAGER

a).

1.10.3

Name of the organization Main location of the organization Additional location of the organization Any of the persons nominated under 145.A.30.b (Chief Engineer and Quality Manager) Variation in support / certifying manpower (more than 25%) or change in scope of work or terms of approval that could affect the approval.

An intended change of the “Accountable Manager” will be carried out under written proposal to the Regional Airworthiness Office, Bangalore, by the Managing Director. On receipt of acceptance letter from the Regional Airworthiness Office, Bangalore, Quality Manager will organize to issue an amendment to Part 1.1 and Part 1.5 of this exposition. This exposition amendment will state the corporate commitment signed by the new accountable manager.

NOMINATED PERSONNEL (CHIEF ENGINEER & QUALITY MANAGER)

a).

An intended change of the “Chief Engineer” / “Quality Manager” will be carried out under written proposal l (using FORM-4) to the Regional Airworthiness Office, Bangalore, by the Accountable Manager. Advance information will be given to the Director of Airworthiness for enabling him to consider the application and accept / reject the nominee. On receipt of approval from the Regional Airworthiness Office, Bangalore, Quality Manager will issue an amendment to Part 1.1 and Part 1.5 of this exposition.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT 1.10.4

1.10.5

CHANGES IN THE COMPANY ACTIVITIES (SCOPE OF APPROVAL, CAPABILITY Etc...) a).

Quality Manager will intimate the Regional Airworthiness Office, Bangalore in writing of changes in the company activities such as facilities, equipment, tools, materials, procedures, work scope or certifying staff that could affect the existing approval. QM will intimate the Regional Airworthiness Office, Bangalore of the reduction in the number of personnel when it falls by more than 25 % of the requirement based on man hour plan Vs organization’s activity.

b).

In case of addition of scope approval / capability, the Quality Manager will submit the proposed changes along with audit reports of the facilities requesting for addition of scope of approval / capability. Once the scope of approval / capability is granted, necessary amendments to the relevant parts of MOE will be submitted for approval, by the Quality Manager

PROCEDURE FOR ESTBALISHING A NEW SUB-BASE MAINTENANCE FACILITY a).

Quality Manager will send a proposal to the Regional Airworthiness Office, Bangalore in writing for establishing a new permanent sub-base maintenance facility to commensurate with the operational / customer requirements. Quality Manager will ensure that the facility is established as detailed in EPM, Section-1, Chapter-15.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT 1.11

1.11.1

1.11.2

EXPOSITION ISSUE / AMENDMENT PROCEDURE (Ref: EPM Section -3, Chapter 14)

a).

Maintenance Organization Exposition (MOE) is a document(s) that contain the material specifying the scope of work deemed to constitute approval and showing how the organization intends to comply with the CAR-145 requirements.

b).

MOE will be prepared & submitted by the Quality Manager to the office of Regional Airworthiness Office, Bangalore, on behalf of the Accountable Manager and amended based on revisions to Aircraft Rules, CAR 145 or based on any other regulatory / procedure requirement. (CAR 145.A.70.a refers).

PERSON RESPONSIBLE FOR AMENDING THE EXPOSITION

a).

Quality Manager will ensure that the exposition is amended as necessary to remain an up-to-date with the regulatory requirements. MOE issue / amendment will be submitted to the Regional Airworthiness Office, Bangalore for approval.(CAR 145.A.70.b refers)

b).

Changes to this MOE will be initiated by quality manager. The reasons for revision will be provided in Revision transmittal sheet. Changes will be issued in the form of amendments to the applicable sheets. The corresponding amended pages will have a higher revision number. The changes made in the document will be identified by vertical lines at the left margin of the affected paragraph. Controlled copy holders, on receipt of amendments will amend the MOE and enter in the amendment record.

c).

When ever an additional sheet is required to be inserted in between a two adjacent pages to accommodate additional information, the corresponding sheet will be identified with an alphabet suffixed to the previous page number. The revision status of all the amended sheets will be indicated on the list of effective pages available in the beginning of this document.

d).

Amendments requiring approval (Refer – MOE 1.11.3) will be forwarded to Regional Airworthiness Office and implemented only after obtaining approval. Approved amendments will be issued to all the control copy holders as per distribution list.

e).

The quality manager will review this document once every six months for adequacy and continued suitability and issue required amendments. The record of such revisions will be documented in the record of revision sheet of this MOE.

SOURCES OF PROPOSED AMENDMENTS WITHIN THE ORGANISATION a).

MOE will be revised whenever necessary as a result of change in Company Policy, Organization Structure, Scope of approval, address, etc.

b).

MOE will also be revised whenever there is a change in CAR-145 requirements, or issue of airworthiness advisory circulars, which affect the organization’s policy, procedure and maintenance practices.

c).

Generally it will be reviewed twice a year - in the month of June and December.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.11.3

d).

The quality manager and chief engineer will review the MOE, including associated procedure manuals in conjunction with other post holders / senior maintenance personnel and prepare any proposed amendments for submission to Regional Airworthiness Office, Bangalore.

e).

On receipt of the approved amendments from the Regional Airworthiness Office, Bangalore the quality manager will ensure distribution of approved revisions to all controlled copy holders thru Manager –Technical services. Manual holders, on receipt of amendments, will incorporate the revisions in their copies of the manual in accordance with the revision instructions issued. The acknowledgement slip of accomplishment will be returned to the Technical Officer - Library

f).

Quality Manager’s MOE copy is designated as Master MOE. All superseded / amended copies of the Master MOE will be retained by Quality Manager in a separate file for reference.

g).

Any minor changes to the MOE will be issued as Revisions. If changes to the MOE are more than 50%, then the MOE will be re-issued and the issue number will be identified on the first page.

h).

Any observed errors or omissions must be brought to the attention of the quality manager.

DESIGNATION OF PARTS OF EXPOSITION THAT CAN BE AMENDED WITHOUT THE PRIOR APPROVAL OF DGCA.

a).

1.11.4

Part of the MOE which contains the list of man power, grammar mistakes will be amended without the prior approval of DGCA. Such amended parts will be submitted to the Regional Airworthiness Office, Bangalore for approval during subsequent revisions.

SUMMARY OF DOCUMENTS, INCLUDING "LOWER ORDER" DOCUMENTS, CONSTITUTING THE TOTAL EXPOSITION (Ref: EPM Section – 3, Chapter – 21) a).

The following updated documents will be available for reference and use and are called as the ‘Lower order” documents, constituting the Total Exposition. 1.

Engineering Procedures Manual (EPM)

2.

Logistics Procedure Manual (LPM)

3.

Shop Procedure Manual (SPM)

4.

Training Manual

5.

Forms Manual

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION

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PART - 1 - MANAGEMENT

1.11.5

PROCEDURES FOR THE CONTROL AND AMENDMENT OF CAPABILITY LIST

a).

The Quality Manager will seek the acceptance / approval for enhancement of capability of the organization along with supporting documents, whenever the capability of the shop / organisation is required to be amended to include / extend the scope of approval for maintenance of aircraft and/or components capable of being serviced / repaired / overhauled.

b).

Quality Manager will submit the documentary proof supporting the availability of literature, tools & equipment, manpower, facility etc to the Regional Airworthiness Office, Bangalore. On receipt of acceptance / approval, the Quality Manager will amend the capability list.

*******************

PAGE NO : 1

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.1

2.1.1

: 01

DATE

: Aug 2008

SUPPLIER EVALUATION AND CONTRACTOR /SUBCONTRACTOR CONTROL PROCEDURE (Ref: LPM Chapter-2 & 14) a).

This chapter defines the policies and procedures of evaluation & approval of suppliers (source) of aircraft goods & contractors (approved maintenance organization) so as to assure the airworthiness standards and quality of aircraft components and materials purchased / work outsourced.

b).

Detailed procedures for evaluation of suppliers / contractors are provided in LPM chapter -2 and 14 respectively.

COMPANY POLICY a).

All materials used on Deccan Aviation owned or customer aircraft will be obtained directly or indirectly (through business partners / facilitators) from the following sources along with proper release documents. Such sources will be enlisted as Company approved suppliers. i. ii. iii. iv. v.

2.1.2

MAINTENANCE PROCEDURES

REV NO

Manufacturer of aircraft / engine / components / consumables / raw material (OEM), Manufacturer’s approved sources, Parts distributors approved by aviation authority of the country, where the parts distributor is located, Parts Manufacturer Approval (PMA) holders, approved by FAA, JAA, Transport Canada (TC)) etc FAA /EASA-145 / approved maintenance organization, with authorized release certificate / FAA Form 8130-3 or equivalent.

b).

All maintenance activities beyond the scope of approval of Deccan Aviation will only be outsourced for repair, overhaul, testing to manufacturer, manufacturer approved /authorized maintenance agencies, FAA / EASA-145 / approved maintenance agencies. Such agencies will be enlisted as Company approved Contractor’s.

c).

Any maintenance activities to be outsourced to Non-EASA / TC /FAA -145 approved agencies will be carried out only after specific clearance from the Regional Airworthiness Office, Bangalore.

COMPANY APPROVED SUPPLIERS / CONTRACTORS a).

All aircraft materials such as Life limited / On-condition parts, rotables, hardwares, consumables, raw materials etc for use on aircraft will be purchased from organization listed in MOE 2.1.1.a only. All such parts supplier’s will be evaluated by Head-Logistics and approved by Quality Manager as Company approved Suppliers.

b).

Logistics - Head will maintain list of all such Company approved suppliers / contractors and the same will be listed as annexure in Chapter-2, Logistics Procedure Manual.

c).

Criteria for evaluation of SUPPLIERS are listed below; i.

Company information such as Name, company incorporation details, registered address, contact phone, mail id, website details etc

ii.

Approval information related to FAA/EASA/Transport Canada (TC) etc.

manufacturing

/

distribution

issued

by

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

d).

e).

2.1.3

MAINTENANCE PROCEDURES

PAGE NO : 2 REV NO

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Criteria for evaluation of CONTRACTORS are listed below; i.

Company information such as Name, company incorporation details, registered address, contact phone, mail id, website details etc.

ii.

Scope, Capability and Validity of Approval issued by FAA / EASA / TC related to the maintenance, repair, overhaul intended to be outsourced.

Criteria for evaluation of Parts Manufacturer Approval Holder’s are listed below; i.

Company information such as Name, company incorporation details, registered address, contact phone, mail id, website details etc.

ii.

Head-Logistics will ensure that the holder’s approval is current and it covers the specific parts which are to be procured. Copies of approvals with limitations will be obtained for records.

iii.

Head-Logistics will satisfy him (her) self that the PMA holder has established credibility and good reputation as a manufacturer and has been supplying such parts to various airlines/operators of repute.

iv.

Head-Logistics will ensure that FAA/JAA/CAA is subjecting the PMA holder’s organisation to regular surveillance with satisfactory results.

v.

Head-Logistics will satisfy him (her) self that the parts manufactured by the PMA holder do not have a history of repeated failures and have achieved a satisfactory service life.

vi.

Head-logistics will satisfy that the new component will be accompanied by a release document issued by the manufacturer or Production Certificate holder. The release document should clearly state that it is issued under the approval of the relevant national airworthiness authority under whose regulatory control the manufacturer or Production Certificate holder works.

f).

Procedures for evaluation and approval of suppliers are provided in Logistics Procedure Manual, Chapter - 2

g).

Procedures for evaluation and approval of contractors are provided in Logistics Procedure Manual, Chapter - 14

PROCUREMENT THRU IN-DIRECT SUPPLIERS a).

At times, due to different countries, language, commercial compulsion such as advance payment before delivery, credit card payment only etc, Deccan will procure parts thru its business contacts, who in turn will procure parts from sources listed in MOE 2.1.1.a.

b).

In all cases, Head-Logistics will ensure that the authorized release certificate such as FAA Form 8130, EASA / CA Form ONE or the appropriate release / conformity Certificates listed in Annexure3.3 & 3.4, Chapter-3 of Logistics Procedure Manual accompanies the material procured

c).

Before procurement of spares thru in-direct mode, supplier evaluation procedure will be followed and Company approved Supplier Code will be allotted for the original supplier / manufacturer.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.1.4

2.1.5

MAINTENANCE PROCEDURES

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MONITORING OR CONTROL OF SUPPLIERS / CONTRACTORS (Refer Para 3.0, Chapter-2, Logistics Procedure Manual) a).

Parts, Components, Consumables, Raw materials will be procured directly / indirectly from Company approved suppliers only. Maintenance services will be outsourced to agencies (contractors) approved by manufacturer, or under FAA/ TC /EASA-145 system.

b).

Criteria for monitoring or control of suppliers (including PMA holders) / contractors are given below; 1.

Previous experience of the supplier / contractor in supplying parts or providing maintenance services.

2.

Parts manufactured / supplied or maintenance services provided by the supplier /contractor do not have a history of repeated failures and have achieved a satisfactory service life.

3.

Previously demonstrated performance in terms of quality work, turn around time, industry feedback, cost etc.

4.

If the supplier provided parts or contractor provided maintenance services failed to meet the company requirement, the supplier / contractor will be intimated of the short comings.

5.

Repeated failures i.e. more than two times will be considered as Maximum limit and procurement of parts or availing of maintenance services will be dis-continued with the respective supplier / contractor and the organization will be de-listed from the company approved supplier /contractor list.

c).

Continuous validity of approval’s issued by the manufacturer or authority of the country, where the supplier /contractor is located will be monitored by the Head-Logistics, vide Company approved supplier’s / contractor’s code list.

d).

Parts obtained from sources mentioned in 2.1.2 / 2.1.3 above will be inspected on receipt by store inspector and during installation by certifying person to ensure that satisfactory levels of quality and airworthiness of the parts are achieved.

e).

Supplier’s and Contractors approved by manufacturer or under FAA / TC /EASA-145 will be assessed as per procedure given in Para 3.0, Chapter -14 of Logistics Procedure Manual

SYSTEM OF PLACING ORDERS (Refer Para 4.0, Chapter-2 Logistics Procedure Manual) a).

Procurement of materials (Parts, consumables, raw materials etc) for maintenance, outsourcing of maintenance services etc will be done under serially numbered purchase (or repair) orders, respectively.

b).

Purchase(or repair) order will clearly spell out the following minimum information ; i. ii. iii.

Name, contact details (address, mail id, and telephone /fax no.) of the organization on which the purchase order is raised. Description of the material to be supplied / maintenance service requested to be accomplished. Part number, Serial Number (in case of repair order)

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

iv. v. vi. vii. viii. ix. x. xi.

2.1.6

MAINTENANCE PROCEDURES

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Expected modification / bulletins / directives status on the part or modification / bulletins / directives required to be carried out (if applicable) Minimum expected shelf life / service life on delivery (if applicable) Acceptable release documentations to accompany the material supplied or for the work carried out. Copy of Material Safety Data sheet (if applicable). Specific handling & storage condition. Acceptable lead time for delivery of material / completion of maintenance activities and return of components. Warranty clause on material & workmanship. Details of parts used during maintenance / repair / overhaul and its release documentation.

c).

All orders will be placed by Head-Logistics or person authorized by Head-Logistics only.

d).

All purchase orders / repair orders will be placed with company approved suppliers / contractors only.

CONTROL OF SUBCONTRACTORS

a). Deccan Aviation doesn’t sub-contract any of the maintenance activities. Procedures for sub-contracting will be specified in this chapter, if requirement arises.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.2

: 01

DATE

: Aug 2008

This section details the policy requirements to be met for accepting parts into the stores system. It defines the policies for carrying out segregation and inspection of the aircraft components and materials received from; 1. 2. 3. 4. 5.

b).

2.2.2

REV NO

ACCEPTANCE / INSPECTION OF AIRCRAFT COMPONENTS & MATERIALS. (Ref: CAR 145.A.42a & d, LPM Chapter-3) a).

2.2.1

MAINTENANCE PROCEDURES

PAGE NO : 5

Company approved suppliers / contractors, Internal sources such as various line / base stations, Removed from aircraft as Serviceable unit, Received on loan or purchase from other CAR-145 organization, Operator etc. Customer for fitment on their aircraft / component.

Detail procedure for acceptance inspection of aircraft components and material are provided in Logistics Procedure Manual chapter-3

COMPANY POLICY. a.

All components and materials received into the company stores will be inspected for origin, serviceability status, proper documentation etc.

b.

All components received will be classified into various categories such as Acceptable, Serviceable, Qurantainable, Unserviceable, Repairable, Scrap etc.

c.

Classified items will be appropriately segregated and stored at different locations such as Bonded store, Quarantine store, POL store, commercial store, Repairable store, scrap store etc.

d.

All component will be inspected for suitability before installation on the aircraft / component

COMPONENT / MATERIAL CLASSIFICATION & SEGREGATION CRITERIA

a).

All components will be classified and appropriately segregated into the following categories: 1.

Acceptable Components – Components obtained by the organization, released on CA Form-1 / EASA Form-1 / FAA Form-8130-3 or 4 or equivalent authorized release certificate (Equivalent means a release document issued by an organization acceptable to DGCA or by an organization approved under the terms of a DGCA maintenance bilateral agreement), inspected by stores inspector for satisfactory condition as per the acceptance criteria ( MOE 2.2.3) and issued with parts acceptance tag for storage in Bonded stores are called Acceptable ( airworthy)components.

2.

Serviceable Components: Components removed from the aircraft by the support / certifying staff in airworthy condition and tagged with Serviceable tag, with relevant details as required in serviceable tag are called serviceable components

3.

Unserviceable Components: Components which are declared / doubted to be unserviceable by the maintenance personnel or found damaged during incoming inspection by stores personnel are called Unserviceable components.

4.

Unsalvageable Components : Components which have reached their certified life limit or contain a non-repairable defect, or assessed to be beyond economical repair are classified as Unsalvageable (Scrap) and will not be permitted to re-enter the component supply system unless the manufacturer has extended the service life limits or repair solution is found and approved by the manufacturer (CAR 145.A.42.d refers)

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5.

Standard Parts used on aircraft, engine, propeller or other aircraft component when specified in the manufacturer’s /vendor’s illustrated parts catalogue and /or the maintenance data (Technical publications) and supported by proper release documents such as Certificate of conformity, Form One / FAA 8130-3 or equivalent.

6.

Material both raw and consumable used in the course of maintenance when it is satisfied that the material meets the required specification and has appropriate traceability. All material procured will be accompanied by documentation (appropriate documentation such as certificate of conformity, test certificate, etc) clearly relating to the particular material and containing a conformity to specification statement plus both the manufacturing and supplier source.(CAR 145.A.42.a.5 refers)

b).

Serviceable Components and Materials segregated as explained above will be subjected to acceptance inspection before storing them in the bonded stores.

c).

Detailed procedures for receipt and acceptance of parts /material are provided in LPM Chapter-3

COMPONENT / MATERIAL INSPECTION & ACCEPTANCE CRITERIA

a).

All Aircraft components / material received from various company approved suppliers / contractors will be inspected by the stores inspector to check whether it meets the airworthiness and company requirements.

b).

Criteria for inspection and acceptance are given below; i.

Components / Materials are received from company approved Suppliers / Contractor’s, Internal sources such as other line / base stations, Removed serviceable from aircraft or Received from other CAR-145 operator’s on loan / sale basis and accompanied with proper records.

ii.

Proper packing, Proper condition of the part, any transit damage etc.

iii.

Part Number, Description, quantity, status (new, overhauled, repaired, as is), maintenance work carried out etc matches with the purchase (repair) order requirement.

iv.

Part number, serial number, Mod status (if shown in data plate) matches with, between the purchase order, part and the release document.

v.

Proper release documents as listed in Annexure 3.3 and 3.4, Chapter-3 of Logistics Procedure Manual for various types of components / materials are available.

vi.

Availability of Strip report / Investigation report for the prematurely failed components, which was sent for repair / overhaul / test etc.

c).

Those components / material which don’t comply with the requirement will be quarantined initially and clarification sought from the supplier. If supplier is unable to provide the required documentation, the item will be rejected and necessary action initiated to return the materials as Rejected material to the supplier. Components and materials meeting the requirement will be stored in Bonded Stores.

d).

Detailed procedures for incoming inspection and acceptance procedures are provided in LPM Chap.-3.

PAGE NO : 7

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2.2.5

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ACCEPTANCE OF COMPONENTS FROM INTERNAL SOURCES a).

When parts are received from various line / base station of the company the same will be checked by stores inspector for transit damage, supporting airworthiness related documents and subjected to inspection for condition.

b).

Items found serviceable with proper documents will be stored in bonded stores or released for use on other aircraft / component.

c).

Detailed procedures for acceptance of components from internal sources are provided in LPM Chapter-3

COMPONENTS REMOVED AS SERVICEABLE FROM AIRCRAFT

a). All aircraft components, which are removed as serviceable from an aircraft, will be attached with a serviceable tag by the certifying /support staff, who removed the component. b). Certifying / support staff will hand over such parts / components to stores for storing in Bonded stores / issue to other aircraft, after the acceptance inspection of stores inspector. c). Detailed procedures for acceptance of parts / components removed as serviceable from aircraft are provided in LPM chapter-3

2.2.6

2.2.7

COMPONENTS / MATERIALS ORGANIZATION / OPERATOR.

RECEIVED

FROM

ANOTHER

CAR-145

APPROVED

a)

Parts / Components may be received from other CAR-145 organization or Operator, on loan /sale basis, for installation on aircraft maintained by Deccan Aviation.

b)

Such parts /components will be subjected to acceptance inspection as per MOE 2.2.2 by stores inspector.

c)

Detailed procedures for acceptance of parts / components received from other CAR-145 organization are provided in LPM Chapter-3

COMPONENTS RECEIVED FROM CUSTOMERS FOR REPAIR / OVERHAUL ETC.

a).

When a component is received from customers for repair and / or overhaul, the stores inspector will inspect for condition, damage and for accompanying documents such as customer’s overhaul / repair request, history card of the component for proper entries and repairable tag duly signed by authorized person.

b).

On satisfying the above, the component will be routed to the Component overhaul Workshop / Manufacturer’s approved facility / CAR or EASA Part 145 approved repair station for overhaul / repair.

c).

Detailed procedures for inspection of such components and its records are provided in shop procedure manual.

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COMPONENT / MATERIAL RECEIVED FROM CUSTOMER / OPERATOR FOR FITMENT ON THEIR AIRCRAFT / COMPONENT.

a).

When a component / material is received from operator /customers for installation on their aircraft or components, the same will be subjected to inspection as per MOE 2.2.2 by stores inspector and accepted items will be stored in appropriate store.

b).

Operators / Customers parts will be taken into bonded stores and accounted while issue to their aircraft.

c).

Operator / customer, if requires to keep the component / material supplied by them separately, then those component / material will be stored separately and the same issued to their aircraft / component only. These requirements will be incorporated into the maintenance contract with the operator / customer.

PARTS FABRICATED INTERNALLY BY THE ORGANIZATION

a).

Fabricated Parts – are those internally fabricated by the organization with acceptance from DGCA, after procuring engineering drawing and fabrication process information from TC / STC holder. Such parts will be certified with Fabricated Parts Tag.

b).

Pars fabricated i.a.w MOE 2.3.10 will be checked for condition, damage and any abnormalities and for the duly signed Fabricated Parts Tag, by person approved by Quality Manager.

c).

Accepted parts will be credited to bonded stores, after entering relevant data in FLYPAL / Bin card and stored in bonded stores in a separate area, specifically identified as Internally Fabricated Parts.

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2.3

2.3.1

2.3.2

2.3.3

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TAGGING, STORAGE AND RELEASE OF AIRCRAFT COMPONENTS AND MATERIAL TO AIRCRAFT MAINTENANCE ( Ref : LPM Chapter-4, 5, 6, 7 & 8)

a).

This section details the policy requirements to be followed for tagging, storage, and release of aircraft components and material to aircraft maintenance.

b).

Stores inspector will carryout the following procedures at the Base station at Bangalore and stores in-charge / Engg in-charge will carryout the procedures at other base station or operating line station respectively.

c).

Detailed procedure for Identification and Traceability, Material handling & storage condition, Control of shelf life and modification standard, Control of flammable / hazardous / dangerous goods and control of release of aircraft parts & materials to aircraft maintenance are provided in Logistics Procedure Manual Chapter 4, 5, 6, 7 & 8 respectively.

COMPANY POLICY

a).

All components and materials will be handled carefully, be well protected and stored properly till used.

b).

Deccan Aviation will provide adequate space and other facilities for storage of aircraft items in clean and temperature controlled rooms.

c).

All components accepted into the stores will be properly tagged which will reflect the status of the material /component and stored as per manufacturer recommended procedures before release to aircraft maintenance.

PROCEDURE FOR PROPER HANDLING OF COMPONENTS / MATERIAL

a).

General handling instructions provided in the package will be followed during receipt, transfer, storage or issue of components / materials to avoid damage to material.

b).

All components / material will be retained in the original packing or in manufacturer recommended packing conditions.

c).

Heavy / bulky components or materials will not be dragged on the floor or on the shelf, which may damage the components /materials.

d).

Heavy / bulky components will not be stacked one above the other, which may cause damage due to its weight.

e).

ESDS material will be handled as per specific procedures for handling ESDS material, to avoid component damage due to static electricity.

TAGGING / LABELLING SYSTEM

a).

Stores inspector will allot GRN Number (Goods Receipt Note Number) to each of the consignment of parts / consumables purchased and received in the stores.

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b).

Stores inspector will allot BRN Number (Base Receipt Note Number) to each of the consignment of parts / consumables received from any of the station / loaned from any of the operator.

b).

Store inspector receiving the incoming parts will attach a parts acceptance tag after inspection and acceptance, reflecting the status of the parts such as New, Overhauled, Repaired, Serviceable (as removed), etc. Stores inspector will attach the Unserviceable / Rejected tag, if the item didn’t pass the incoming inspection and acceptance criteria.

c).

d).

Item owned by the organization / loaned from other organization, if rejected will be tagged with Unserviceable tag and scrapped / returned accordingly.

e).

Item purchased by the organization, if rejected will be tagged with rejected tag, issued with Rejection note and returned to the supplier, thru Head-Logistics.

f).

Stores inspector will ensure that all components / parts / Materials entering or exiting the stores (Bonded, Quarantine, Repair, Scrap, POL) are accompanied with proper tag providing the following information; 1. 2. 3. 4. 5.

2.3.4

MAINTENANCE PROCEDURES

PAGE NO : 10

Part Number, Description Quantity Serial No. Status of the component (New, Repaired, Overhauled, Serviceable, Unserviceable, Scrap etc)

g).

Support / certifying staff removing the part from the aircraft / component will attach respective status tag reflecting the status of the parts such as Unserviceable, Repairable, and Unsalvageable etc. and handover the item to the store inspector.

h).

Detailed procedures for issue of various tags are provided in Logistics Procedures Manual chapter No. 4.

UPDATION OF STORES RECORDS ( CREDITING TO BONDED STORES) a).

Incoming components passing the acceptance criteria and issued with parts acceptance tag will be handed over by stores inspector to stores assistant for crediting / accounting into the bonded stores by entering the information about the parts in the FLYPAL inventory software and in the respective part bin card.

b).

At the time of entry into the FLYPAL inventory software / bin card, the following minimum information will be entered by the stores inspector; 1. 2. 3. 4. 5. 6. 7. 8.

Part Number. Description Quantity Authorised Release Note Number & Date Cure date (if applicable) Expiry date or Inspection /servicing due date. GRN / BRN Number Remarks (for ex.; Details of partial lifed item.)

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PROCEDURES FOR MAINTAINING SATISFACTORY STORAGE CONDITIONS

a).

All storage areas will be maintained clean, temperature controlled (for Bonded stores) as per industry standards.

b).

Proper handling procedures will be established and followed to avoid damage to the components / material, while handling at Deccan stores.

c).

Proper segregation of aircraft components, materials, equipment and tools will be made and stored in appropriate locations.

d).

Manufacturer’s storage instructions for storage of specified components / materials such as Rotables, temperature sensitive consumables, flammable materials, engines, and bulky assemblies will be followed to prevent deterioration and damage of stored items.

e).

If material / parts received & accepted weren’t received in proper packing, stores personnel will ensure that proper packing is done and then stored at appropriate location.

f).

Batch numbers provided in the release documents will be affixed on the parts and in the respective parts acceptance tag, to enable identification of specific item vis-à-vis its release documentations.

g).

Access to the storage facilities will be restricted to authorized personnel only.

h).

Detailed storage procedures for rotables, hard wares, rubberized items, flammable fluids etc are provided in Logistics Procedures Manual Chapter No. 5, 6 & 7.

SYSTEM FOR CONTROL OF SHELF LIFE AND MODIFICATION STANDARD

a).

Shelf life (expiry date / inspection or servicing due date) is entered by the stores assistant at the time of crediting the parts in the FLYPAL inventory software and in the shelf life register.

b).

Store inspector will monitor shelf lives of components on monthly basis and remove life expired items from stores.

c).

Further, the same will be destroyed or sent for servicing /testing and re-certification as the case may be.

d).

Stores in-charge / inspector will ensure rotation of stock to prevent the expiry of shelf life (when stored) using First-In, First-Out process.

e).

Manufacturer of a part / component may issue instruction to verify the modification standard of stored parts and take necessary action such as repair / test / up-gradation etc. Manager – Technical services who receive all technical publication (including verification of modification standard of stored parts) will intimate stores in-charge / inspector to take necessary action such as sending it to repair / overhaul shop for carrying out the modification. Stores Inspector, will intimate the HeadLogistics, who in turn will initiate action for incorporating the modification at a company approved contractor’s facility.

f).

Detailed procedures for control of shelf life and modification standard are provided in LPM, Chapter 6

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2.3.8

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INSPECTION REQUIREMENT DURING STORAGE a).

Store inspector will monitor any routine inspection / servicing to be carried out on the component, while in storage, on monthly basis.

b).

Any routine inspection /action to be carried out on parts or components may be reflected in the release document of the parts / components or form a standard storage procedure (such as rotation of tires on routine basis).

c).

Such routine inspection / action to be taken will be reflected in the shelf life register or in the inventory software, while crediting the item into the bonded stores i.e. at the time of data entry.

d).

Stores inspector will advise the respective personnel for carrying out routine inspection /action, due on the stored parts; 1.

Head-Logistics for organizing to carryout the routine inspection, if the item is required to be sent to the company approved contractor’s facility.

2.

Base engineering manager / Engg. In-charge to depute qualified certifying person to carryout routine maintenance / inspection, if it is with in the purview of the internal certifying staff.

3.

Stores assistant to re-position the part (such as rotation of tires on routine basis)

ISSUE OF COMPONENTS TO THE MAINTENANCE PROCESS

a).

Issue of parts / components to the maintenance process will be carried out based on parts requisition from the support / certifying staff.

b).

Parts requisition form (No. 016) will contain at least the following information; 1. 2. 3. 4. 5. 6.

Name of the support /certifying staff requesting the part, Aircraft registration marks / serial number on which the parts are required to be used, Location of the store, where the parts are requested for Part number, description and quantity, Illustrated parts catalogue reference no, Reason for request (Life expiry, Defect rectification etc)

c).

No parts will be issued to maintenance process without a requisition or based on requisition from un-authorized (support /certifying) personnel.

d).

All parts requisition and issue will be traceable to specific work orders to ensure that the parts requested and issued were used on a specific aircraft.

e).

Support / Certifying staff receiving the parts from the stores will ensure that the particular component is eligible to be fitted on the aircraft (in line or base maintenance) / component (in shop maintenance) when different modification and / or airworthiness directive standards may be applicable for the component.(CAR 145.A.42.b refers).

f).

Detailed procedure of issue of parts / components to the maintenance process is provided in LPM Chapter No. 8

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2.3.10

MAINTENANCE PROCEDURES

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FREE ISSUE DISPENSING OF STANDARD PARTS ( CONTROL, IDENTIFICATION & SEGREGATION)

a).

Deccan Aviation doesn’t intend to follow the process of Free Issue or Dispensing of standard parts and its use on the aircraft.

b).

Any standard parts such as split pins, washers, nuts, bolts etc will be issued based on specific parts requisition from the authorized staff for use on specific aircraft.

FABRICATION OF PARTS FOR INTERNAL USE DURING OVERHAUL / MAINTENANCE / MODIFICATIONS / REPAIR OF AIRCRAFT / COMPONENTS (Ref: CAR 145.A.42.c & EPM Section-2, Chapter-8)

a).

Deccan Aviation may fabricate a restricted range of parts for use during overhaul, maintenance, modification, or repair of aircraft or components, undergoing work within the facility. Fabrication will be undertaken only if the fabrication /assembly, inspection and testing are clearly within the technical and procedural capability of the organization.

b).

All necessary data to fabricate the part will be submitted either to Type Certificate (TC) Holder or supplemental type certificate (STC) holder for approval. Any fabrication for internal use of such fabricated parts will be initiated after obtaining approval / permission from any of the above authority.

c).

Fabrication of parts will be undertaken after an engineering drawing (which includes any necessary fabrication processes) is procured from the TC / STC holder and acceptance to the same is obtained from Regional Airworthiness Office, Bangalore in writing.

d).

Chief engineer will designate two independent qualified and competent person to be responsible for the fabrication and inspection process respectively. Quality manager will conduct a competent assessment examination and if found competent, will issue approval for fabrication & inspection.

e).

Fabricated parts will be subjected to an inspection stage before, separately and preferably independently from, any inspection of its installation.

f).

Inspection procedure will be established in such a way that full compliance with the relevant manufacturing data and the part will be unambiguously identified as fit for use by stating conformity to the approved data.

g).

Adequate records will be maintained by the person nominated for fabrication about various fabrication processes such as heat treatment, machining etc. Similarly, the person nominated for inspection will keep records for various stages of inspection carried out on the fabricated part.

h).

Person nominated for fabrication will ensure that all parts, except those having not enough space, is etched / marked with part number that clearly relates it to the manufacturing / inspection data.

i).

Additional to the part number, the organization’s identity will be marked on the part for traceability purpose.

j).

Fabricated parts will be issued Fabricated Part Tag (Form No. 056) and the same will be signed by both person who were nominated for fabrication and inspection. Fabricated parts will not be issued with CA Form-1 or any form of CRS.

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k).

Fabricated parts will be routed to the stores for acceptance inspection (i.a.w MOE 2.2.3) with relevant document pertaining to fabrication. After acceptance of the part, by the stores inspector, the fabricated parts will be stored in bonded stores.

l).

Permission /approval to fabricate do not constitute approval for manufacture and supply externally and those parts will not qualify for certification on CA Form One. In case of bulk transfer of surplus inventory, such locally fabricated parts will be physically segregated and excluded from sale /delivery.

m).

Fabrication of parts, modification kits etc for onward supply and/or sale will not be undertaken.

n).

Detailed procedure for control of fabrication, inspection of parts and its use within the organization is provided in EPM Section-2, Chapter-8

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2.4

2.4.1

2.4.2

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ACCEPTANCE OF TOOLS AND EQUIPMENT & CONTROL OF INSPECTION / SERVICING REQUIREMENTS INCLUDING ALTERNATE TOOLS & EQUIPMENT (Ref : LPM Chapter-9 & 10)

a).

This section defines the policy requirements to be followed for controlling the tools and equipments necessary for performing the approved scope of work in terms of ensuring its serviceability and accuracy.

b).

This section also provides the procedures for control of inspection & servicing requirements of tools and equipment.

c).

Detailed procedures for receipt and acceptance are provided in Logistics Procedure Manual chapter3.

COMPANY POLICY a).

General Tools and equipment will be procured from the reputed general industry tools and equipment suppliers.

b).

Special tools and equipment will be procured from the original equipment / tool manufacturer.

c).

New tools and equipment will be subjected to condition inspection before accepting

d).

All tools and equipment will be identified with an identification number for tool tracking purpose.

e).

Tools and equipment requiring calibration will be subjected to calibration, unless accompanied by a production test / calibration certificate, when procured new.

f).

Tools and equipment fabricated by the organization based on approved drawing, sample tools are called as Alternate tools and it will be controlled for its quality, while fabrication and during routine use.

g).

Precision measuring equipments and highly complicated tools will not be locally fabricated.

h).

Tools and equipments inspection / servicing periodicities will be established and monitored for compliance.

i).

Use of personal general tool kit will be encouraged and quality of tool in personal tool kit will be controlled by the organization.

PROCESS FOR ACCEPTANCE INCLUDING ALTERNATE TOOLS

-

(IDENTIFICATION,

CERTIFICATION,

CONTROL)

a).

General tools and equipments required for maintenance will be purchased from the general industrial suppliers by Head-Logistics, based on requisition from maintenance personnel.

b).

Special tools and equipments required for maintenance will be purchased from the original equipment (aircraft, engine or component) manufacturer or from the specialized tool manufacturers, by Head-Logistics, based on requisition from maintenance personnel.

c).

On receipt of tools and equipments, the tools & equipment in-charge will subject them to condition inspection and ensure that those tools and equipment requiring periodic calibration are supplied with production test / calibration certificate. If production test / calibration certificate is not available, those tools and equipments will be sent for calibration before putting them for use.

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d).

Tools & equipment which doesn’t have identification part numbers allotted by its manufacturer, will be provided with a unique traceable part number

e).

On satisfactory condition inspection, tools and equipment in-charge will identify those tools & equipment by means of permanent engraving of its part number, if permanent marking of part numbers are not available.

f).

Tools and equipment in-charge will then enter the details of the tools & equipment such as (Part No. Description, Source procured etc) into the Tools and Equipment Master List (Flypal software / Computer / Register) and create a history card in duplicate for each special tool & equipment.

g).

One history card will remain at the base in Bangalore and the second history card will move along with the tools & equipment for identification of the tool and its servicing requirement.

h).

History card will contain the history of the tool / equipment, its location, its movement (between various stations) details, periodic servicing / calibration requirements, last carried out and next due.

i).

History card specific to alternate tools / equipment will have the word “ALTERNATE“ rubber stamped on top RH side of the history card.

j).

Tools and equipment in-charge will maintain a separate list of various alternate tools manufactured by the organization for quick reference of the same.

k).

Tools & Equipment in-charge will be responsible for control of tools and equipments receipt, storage, transfer between various stations, periodic servicing, calibration and scrapping in case of damage.

PROCEDURE FOR CONTROL OF ALTERNATE TOOLS AND EQUIPMENT a).

Occasions may arise to fabricate tools & equipment to carryout the maintenance of aircraft due following reasons; 1) 2) 3) 4)

Based on drawing provided by manufacturer for fabrication. Based on experience gained in maintenance. Based on sample tool available with the company, so that fabricated copy of the tool can be made use of at various locations. Based on sample tool available with other operator.

b).

Such requirement for fabrication will be initiated by the Base Engineering Manager / Chief Engineer with details such as reason for fabrication, along with the manufacturer provided tool engineering drawing mentioning the material and dimensional specification.

c).

If tool or equipment engineering drawing is not provided by the manufacturer and the tool required to be fabricated is based on experience gained in maintenance or based on sample tool then a tool engineering drawing process will be initiated by the Base engineering manager / chief engineer.

d).

Tool or equipment engineering drawing will be done with the help of general engineering industry professional and the drawing will be allotted a unique serial number by tool & equipment incharge for traceability.

e).

Based on the tool or equipment engineering drawing, fabrication will be initiated.

f).

After fabrication, the sample tool or equipment, its drawing and the fabricated tool will be subjected to verification by Base engineering manager / chief engineer and approved by Quality Manager.

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g).

After a tool is approved, tool & equipment in-charge will allot a unique part number and serial number both starting with prefix – A.

h).

Both part number and serial number having prefix-A, will explicitly identify that the tool is fabricated by the organization and termed as Alternate tools.

i).

All such alternate tools & equipment will be controlled by the Tools & Equipment in-charge as per procedure explained in MOE 2.4.2 for manufacturer supplied tools.

j).

Detailed procedure for fabrication and control of alternate tools & equipment are provided in LPM Chapter 9.

CONTROL OF PERIODIC INSPECTION / SERVICING OF TOOLS AND EQUIPMENTS INCLUDING ALTERNATE TOOLS & EQUIPMENTS

a).

Periodic inspection / servicing of various tools and equipment will be proposed by the Chief Engineer and approved by Quality Manager based on the following; 1. 2. 3. 4.

2.4.5

MAINTENANCE PROCEDURES

PAGE NO : 17

Recommendation provided by the instrument / tool / equipment manufacturer, Extent or Degree of utilization – More the utilization, lesser the calibration frequency. Organization previous experience, Industry standard calibration periodicity.

b).

List of various tools and equipment and its inspection or servicing requirements and periodicities are provided as Annexure 10.1 in Logistics Procedure Manual, Chapter-10

c).

Tools and equipment at Bangalore and Stores in-charge at other base station will monitor the history card of the individual tool / equipment and hand over the history card of the tool /equipment falling due for inspection /servicing to the Base engineering manager.

d).

Base engineering manager will allot the work to the foreman or senior technician, available to carryout the inspection / servicing and update the history cards accordingly.

e).

Foreman / senior technician will carryout the work, as per the history card and update the history card about the work carried out and return the card to the tools & equipment in-charge.

f).

Monitoring of Inspection / servicing periodicity of tools and equipment will be done by stores in charge at other base stations and by Engg. In-charge at operating line station.

g).

Above inspection and servicing procedure will also be applicable for tools fabricated internally and designated as alternate tools, where as the alternate tool / equipment will also be subjected to verification by Base engineering manager / chief engineer, once a year.

PROCEDURE FOR CONTROL OF PERSONAL GENERAL TOOL KIT

a).

Support staff performing maintenance activities will be encouraged to use their personal general tool kit and the tool kit will be controlled as per procedure given below; 1.

Personal tool kit should be submitted to the tool & equipment in-charge at Bangalore and stores in-charge at other base station for allotment of serial number and taking inventory of the tool kit.

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2.

Tools & Equipment / Stores in-charge will inspect all tools for condition, damage etc.

3.

Tools & Equipment / Stores in-charge will issue a tool kit inspection certificate, valid for a period of one year from the date of issue.

4.

Tool kit inspection certificate (laminated copy) is required to be displayed in the interior (inside) of the tool kit for audit purpose.

5.

Tool kit without valid inspection certificate will not permitted to be used, till the same is certified and in effect, certificate is issued.

6.

Support staff will ensure that all tools are kept in a specified place, preferably on cushions cut to specific size to fit the tool.

7.

Tool inventory list certified by the tool & equipment / store in charge will remain part of the tool kit, to enable verify the inventory for any reasons.

8.

When a support staff intends to take the tool kit outside the company premises on nonreturn basis, the certificate should be surrendered back to the tool & equipment incharge, so that the serial number could be allotted for another staff.

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2.5.1

2.5.2

MAINTENANCE PROCEDURES

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CALIBRATION OF TOOLS AND EQUIPMENT (Ref: CAR 145.A.40.b & LPM Chapter-10) a).

This section defines the requirements to be followed for controlling the calibration of tools and equipments necessary for performing the approved scope of work, including establishment of inspection, servicing & calibration time period, monitoring of servicing /calibration due dates etc.

b).

Detailed procedures are control of calibration / inspection / servicing of tools and equipments including ground support equipments are provided in Logistics Procedure Manual Chapter-10

COMPANY POLICY a).

All instruments, tools and equipment requiring routine (periodic) calibration will be identified and subjected to calibration control programme.

b).

Periodic calibration schedule (calibration control programme) will be decided as per recommendation from the manufacturer, based on the extent of utilization or industry standards.

c).

Calibration will be carried out internally within the organization at the calibration shop for those instruments / tools / equipment calibration facility is established.

d).

Calibration shop will be subjected to process of accreditation by NABL (National Accreditation Board for Testing laboratories)

e).

Testers / Calibrators used in the calibration shop will be traceable to national standards.

f).

If calibration facility is not available in-house, then such equipments will be sent to calibration agencies, whose standards are traceable to national standards.

g).

All maintenance personnel will be encouraged to provide immediate feedback about the quality of a tool, erratic reading, mis-handling of a specific tool by other personnel etc.

ESTABLISHMENT OF INSPECTION, SERVICING AND CALIBRATION TIME PERIODS AND FREQUENCIES b).

Calibration periodicity will be proposed by the Manager – Technical services based on the following; 1. 2. 3. 4.

Recommendation provided by the instrument / tool / equipment manufacturer, Extent or Degree of utilization – More the utilization, lesser the calibration frequency. Organization previous experience, Industry standard calibration periodicity

c).

Calibration requirement and periodicity for all instruments, tools & equipment are listed in a table in Annexure 10.1 of Chapter-10 of Logistics procedure manual

d).

Calibration periodicity listing proposed by the Manager – Technical services, will be verified by Chief engineer and approved by Quality Manager.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.5.3

REV NO

: 01

DATE

: Aug 2008

CALIBRATION PROGRAMME / EQUIPMENT REGISTER

a).

Calibration data pertaining to instruments, tools (including alternate tools) and equipment will be maintained in the FLYPAL inventory software / computer / register, by the tools & equipment incharge for all the tools available in Bangalore and all other bases. Such data includes the following minimum information; 1. 2. 3. 4. 5. 6.

b).

2.5.4

MAINTENANCE PROCEDURES

PAGE NO : 20

Part number provided by manufacturer / allotted by tools & equipment in-charge. Serial number provided by manufacturer / allotted by tools & equipment in-charge. Inspection / Servicing / Calibration time period. Current location of the tool Last carried out and Next due date. Calibration agency Name & Location.

Tools and equipment in-charge will liaison with various station stores in-charge / engineer incharge to update master list which contains the details of various instruments / tools / equipment requiring calibration.

IDENTIFICATION OF CALIBRATION DUE DATES

a).

Tools & Equipment In-charge will monitor the master list of instruments, tools & equipment held by the company at various locations. Each tool and equipment will be identified with a serial number and its history card.

b).

Master list will contain the details of all the tools & equipment such as part number, serial number, location, calibration last carried out and next due.

c).

Tools and Equipment in-charge will scrutinize the master list and send those instruments requiring calibration for carrying out the same. For those items kept at line / base stations, he will issue call outs on 15th of every month, for the forth coming month to outstation store in-charge or engineer incharge, where the tools and equipments are located.

d).

The tool holder will positively dispatch the affected item to the tools & equipment in-charge or directly to the calibration agency as advised by the tools & equipment in-charge in the call out. Format of the call out is reflected in Logistics Procedure Manual Chapter 10.

e).

On receipt of items after calibration, tools & equipment in-charge will update the master list and the history card at Base and advise the station engineer to update the history card in station.

f).

Standard color (Yellow) coded Sticker reflecting the last carried out and next due date will be affixed by the approved person at the calibration shop.

g).

In case of items calibrated at outside facility, tools and equipment in-charge will ensure that standard color coded (yellow) stickers depicting the last carried out and next due date is affixed firmly on the instrument / tool / equipment. He will make available such stickers at all stations, where the stores in-charge / engineer in-charge will affix the sticker based on the calibration certificate.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.5.5

MAINTENANCE PROCEDURES

PAGE NO : 21 REV NO

: 01

DATE

: Aug 2008

IN-HOUSE CALIBRATION FACILITY

a).

Calibration shop is established to carryout calibration of torque wrenches, precision measuring instruments, multi-meter, pressure gauges, voltmeter, ammeter etc., used for carrying out maintenance or in /as ground equipments at any of the Deccan’s or Customer’s facility.

b).

Calibration shop will be subjected to accreditation process by National Accreditation Board of Testing Laboratories (NABL).

c).

Master equipments / Calibrators, owned by Deccan and used for carrying out the calibration will be calibrated at Central Government approved labs, which will be traceable to National Standards (Primary Standards). Such Master equipments / Calibrators will be called as Secondary Standard equipments. All gauges / measuring equipments will be calibrated against the secondary standard equipment.

d).

Calibration of the secondary standard equipment will be carried out once in a year.

e).

Approved person for calibration will prepare calibration schedule. Calibration procedure will be drawn from the test manuals / requirements provided by the instrument / tool / equipment manufacturer. For standard instruments / tools / equipment, standard testing procedure will be used

f).

2% error or as dictated by NPL / IS standards will be acceptable while calibration and certified correction card will be provided for all equipment showing applied and observed readings. Correction card will contain the following minimum information; 1. 2. 3. 4. 5. 6. 7. 8. 9.

Part Number of the instrument / tool / equipment. Serial number. Applied value. Observed value. Percentage of error in different range of values. Date of calibration. Next due date ( with reference to calibration programme in Chapter-10, LPM) Signature of approved person. Approval number.

g).

Date of inspection and next due will be reflected in a color coded sticker (yellow), and the same will be firmly affixed on the instrument / tool / equipment by the approved person at the calibration shop.

h).

Quality Manager will assess the competence of the person, in terms of qualification, previous experience and issue an approval for calibration, after conducting an oral examination.

i).

Detailed procedure for control (shop facility, master equipment calibration, issue of approval for personnel, issue of calibration tag etc) of calibration shop for calibration of tools / gauges / equipments used by Deccan Maintenance staff or other maintenance organization is provided in Shop Procedure Manual.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.5.6

MAINTENANCE PROCEDURES

PAGE NO : 22 REV NO

: 01

DATE

: Aug 2008

FEEDBACK ABOUT THE TOOL / EQUIPMENT QUALITY a).

All maintenance personnel will report about the quality of tool / equipment, erratic reading or any mis-handling of a tool / equipment by any personnel, using Tool Damage form (Form No….)

b).

Tool Damage form booklet will be kept at the tools & equipment issue window and can be used by support staff to report any damage, erratic or non functioning or mis-use of tool.

c).

Such report will be provided to tools & equipment in-charge who in turn will take suitable action to correct the anomaly.

d).

If a person is found to be mis-handling the tool, the same will be reported by the person observing the same using Quality Deficiency & Hazard Reporting Form (Form No.009) to the base engineering manager.

e).

Base engineering manager will organize to provide additional training to use the tool / equipment rightly, without damaging the tool or disturbing the calibration settings.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.6

2.6.1

2.6.2

MAINTENANCE PROCEDURES

PAGE NO : 23 REV NO

: 01

DATE

: Aug 2008

USE OF TOOLS & EQUIPMENT BY STAFF (INCLUDING ALTERNATE TOOLS) (Ref; CAR 145.A.40.a & LPM Chapter-11)

a.

This section outlines the requirements to be followed for use and control of tools and equipment available in the organization for maintenance activities.

b.

Detailed procedure for control of issue, use and return of tools & equipments for maintenance are provided in Logistics Procedure Manual Chapter-11

COMPANY POLICY

a).

General tools of good standard will be used for aircraft maintenance.

b).

Manufacturer specified tools / equipment will be used for carrying out maintenance work, unless, the alternate tools are fabricated as per procedures given in MOE 2.4.3. (CAR 145.A.40.a.1 refers)

c).

General and Special tools and equipment will be permanently made available, except in the case of any tool or equipment that is so infrequently used that its permanent availability is not necessary. (CAR 145.A.40.a.2 refers).

d).

Tools and equipments will be issued and retrieved in a controlled manner

e).

Maintenance personnel will be trained to handle the tools and equipment in a careful manner and they will be encouraged to report any damage, malfunctioning or mishandling of tools or equipment

ISSUE & RETURN OF TOOLS – (RECORD OF USER AND LOCATION)

a).

General tools of good standard and special tools approved / recommended by manufacturer will only be procured and used in the aircraft / component maintenance.

b).

Master list of tools maintained by tools & equipment in-charge at bangalore and stores in-charge / engineer in-charge at base / line station and the individual tool history card will provide the detail of the tool and its current location at any point of time.

c).

Proper record of day-to-day issue of tools and equipment will be maintained in “Issue Register” by tool & equipment or stores in-charge, so that the user and location of the tools can be identified.

d).

Tool issue register will contain the following minimum information; 1. 2. 3. 4. 5. 6. 7. 8.

Date of issue. Part no. or Description of tool / equipment issued. Name of the person to which tool /equipment is issued. Signature of acceptance of tool / equipment in good condition. Date & Time of return. Signature of person who returned the tool / equipment. Signature of tool & equipment / stores in-charge who received the tool back in good condition. Remarks – Information about possible late return of tool / equipment

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.6.3

2.6.4

REV NO

: 01

DATE

: Aug 2008

e).

If the tool issued for maintenance is not returned back to stores at the end of the day, the person who received the tool, will return to the store and make an entry of the expected date of return in the remarks column of the register and sign against the same.

f).

If a tool is not traceable at the end of the day, a verbal communication will be initiated by the person who had received the tool from the store, to all maintenance personnel working in the aircraft / hangar / shop to search at all possible location to retrieve the tool. This will ensure that no tool is left in the aircraft, which could result in flight safety issues.

g).

If the tool is still not traceable, an alert warning will be issued by tools & equipment / stores / shop in-charge, by giving a watch out notice on the notice board, till the tool is traced back.

DETERMINING SERVICEABILITY OF TOOLS PRIOR TO ISSUE a).

Before any such tools are issued & accepted, the maintenance personnel will ensure that the tools / equipment bears a valid calibration label and physically examine the item to ensure its satisfactory condition. Maintenance personnel will use the correct and serviceable tools and equipment as per instructions and maintain the tools in good condition.

b).

Tools & Equipment In-charge and/ or maintenance personnel will attach an unserviceable tag whenever the condition of any tool/ equipment is identified to be Unserviceable.

c).

Maintenance personnel observing a tool/ equipment as unserviceable will inform tool & equipment in-charge, by writing the comments on the remarks column of the tools/ equipment issue register and attach an unserviceable tag.

d).

Under no circumstance an unserviceable tool/ equipment will be issued to maintenance or used for carrying out any maintenance.

e).

Tools and equipment / Stores in-charge will verify the condition of the tools /equipment, when they are returned back to stores after use by maintenance personnel and affix their signature confirming acceptance of the tools / equipment back in to the stores in good condition

TRAINING AND CONTROL OF PERSONNEL IN THE USE OF TOOLS AND EQUIPMENT (RECORDS OF TRAINING).

a).

2.6.5

MAINTENANCE PROCEDURES

PAGE NO : 24

All maintenance personnel including certifying staff will be trained for use of tools and equipments as per procedure and intervals given in Training Manual, Para 6. Training records will be maintained by Training Manager.

PERSONAL (OWN) INSTRUMENT / TOOL CONTROL. a).

Aviation industry practice demands the certifying staff to own and use their personal set of general tools while carrying out maintenance on the aircraft.

b).

Deccan Aviation will also insist on certifying personnel to have their own general tool kit. It will be the responsibility of the individual to have the tool box equipped with cushions having specific slots for keeping each and every individual tool.

c).

Tool box owner will ensure that tool is placed back in its specific slotted location at the end of the day. This will ensure that no tool is left behind in the aircraft or lost, at the time of closing of work.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.6.6

2.6.7

MAINTENANCE PROCEDURES

PAGE NO : 25 REV NO

: 01

DATE

: Aug 2008

d).

In case of a requirement to use maintenance personnel’s personal (own) special or precision tools on the aircraft, the same will be routed through the tools & equipment in-charge / line station stores incharge for listing in the company’s LOAN MASTER REGISTER.

e).

After ensuring that the tool is inspected / serviced / calibrated (as required for the type of the tool), the same will be issued for use on the aircraft, by the tools & equipment in-charge / station stores incharge.

f).

On return of such tools, back to the owner of the tool, the listing on the LOAN MASTER REGISTER will be cancelled by obtaining a signature from the tool owner for having received the tools / equipment. Defacing of the entry by striking out the row, will not permitted, on return of the tool back to the owner.

LOAN TOOL CONTROL AND AUDIT a).

It may be necessary to loan tools from another organization for use on Deccan fleet of aircraft. Similarly it may be necessary to lend Deccan’s tool to other organization. Such loaning will be effected based on instruction from the Chief engineer / Base engineering manager.

b).

Loaned tools will be subjected to acceptance inspection i.a.w procedures as given in MOE 2.4.2. Accepted tools will be entered into the LOAN MASTER REGISTER.

c).

Inspection, Servicing and Calibration requirements will be ensured by tools & equipment in-charge / station stores in-charge before issue of such tools for maintenance.

d).

Details of inspection, servicing, calibration carried out and its utilization information will be maintained by Tools & Equipment in-charge at Bangalore and stores in-charge at other base station.

CONTROL OF ALTERNATE TOOLS a).

An alternate tool fabricated will be identified by using A in bracket (A) as suffix to the part number assigned to distinguish the alternate tool.

b).

All alternate tool will be listed in the master list and controlled for applicable periodic inspection / servicing / calibration, as per procedure given in MOE 2.5.3

c).

An alternate tool fabricated as per procedures given in MOE 2.4.3 will be inspected / verified once in a year for the following and the same will be certified by a base engineering manager / chief engineer on the tool history card. 1. 2. 3.

Proper Dimensions. No damage or wear and tear Proper functioning.

b).

Any tool found not in compliance with the above will be rejected by the base engineering manager / chief engineer and the same will be scrapped by the tools & equipment in-charge / station stores-incharge after deleting the item in the ALTERNATE TOOLS REGISTER.

c).

Tool history card will be stroked, without defacing the entries and mentioning the reason for rejection.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.7

2.7.1

2.7.2

2.7.3

MAINTENANCE PROCEDURES

PAGE NO : 26 REV NO

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DATE

: Aug 2008

CLEANLINESS STANDARDS OF MAINTENANCE FACILITIES (Ref: CAR 145:25 & EPM Section-2, Chapter-2)

a).

This section outlines the company requirements with regard to the cleanliness of the maintenance facilities and the associated good maintenance practices.

b).

Detailed procedure for control of cleanliness standards of maintenance facilities are provided in EPM Section-2, Chapter-2.

COMPANY POLICY

a).

Management will inculcate an awareness of the need for cleanliness on the part of all staff and ensure that discipline in housekeeping and cleanliness is enforced.

b).

All line / base / shop facilities and the surrounding areas will be maintained clean.

c).

Solid / Fluid wastages will be disposed off without causing environmental pollution.

"FOREIGN OBJECT" EXCLUSION PROGRAMME a).

All Base / Line / Shop facility of Deccan Aviation will run Foreign Object Exclusion activities (observation / walk) on daily basis.

b).

Engineering Manager / In-charge of the line station and the shop in-charge of the component shop will be responsible for conducting the foreign object exclusion programme (foreign object search process).

c).

Detailed procedure of foreign object exclusion programme is provided in EPM, Section-2, Chapter2

CLEANING PROGRAMME - INDIVIDUAL RESPONSIBILITIES - TIMESCALES a).

Hangar will be inspected for Foreign Object and swept on a daily basis. Mopping will be done once in a week.

b).

Hangar floors, work benches, equipment racks will be inspected by the foreman (Hangar in-charge) on a weekly basis to ensure that the facilities and its surrounding areas are clean.

c).

All individuals will observe company standards and procedures for cleanliness, in their respective areas of work at all times.

d).

All materials and components that need to be cleaned will be kept in a separate area to avoid hangar / workspace contamination.

e).

Fluid / Grease containers will always be kept closed to avoid spillage and deterioration of the working environment.

f).

Fluid draining from the aircraft will be done using a drain container and fluids will not be allowed to drip in the hangar floors. When the aircraft is parked in the hangar, required amount and suitable size of drain pans will be kept under the aircraft for collecting the dripping fluids.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

g).

h).

i).

2.7.4

MAINTENANCE PROCEDURES

PAGE NO : 27 REV NO

: 01

DATE

: Aug 2008

Support & Certifying staff will ensure that acceptable levels of tidiness and cleanliness are maintained at work places. In the maintenance area, Base engineering manager / in-charge ensure that tools and equipment are stored in their assigned location and that removed components are kept properly and all working areas are free of debris. Base Engineering Manager / in-charge of base or line station will ensure that all debris and litter, such as paper, tins, locking wire, plastic bags, etc. are retrieved and disposed off correctly. Oil and fuel spills will be cleaned and neutralized. If the fuel and oil spillage is in large quantity, airport authorities will be contacted for their assistance.

WASTE MATERIAL DISPOSAL

a).

Container for accumulating various types of waste such as solid (paper, metal, fabric etc) and fluid (oil, grease, solvents etc) will be kept in the hangar / workshop at designated locations. Each bin will be marked to identify the type of waste to be put into it.

b).

All waste material generated during maintenance activity in line / hangar / shop maintenance areas will be identified as solid or fluid, isolated and disposed off in respective containers, by the person who generates such waste material.

c).

All such waste will be disposed off, without polluting the environment. Fluid waste will be collected in barrels till the required quantity of fluid is consolidated for environmental friendly waste disposal as per the local regulations.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.8

MAINTENANCE PROCEDURES

PAGE NO : 28 REV NO

: 01

DATE

: Aug 2008

MAINTENANCE DATA / INSTRUCTIONS & RELATIONSHIP TO AIRCRAFT / AIRCRAFT COMPONENT MANUFACTURERS’ INSTRUCTIONS INCLUDING UPDATING & AVAILABILITY TO STAFF. ( Ref : CAR 145.A.45 & EPM Section -1, Chapter-8 )

a).

b).

Maintenance Data is defined as (CAR 145.A.45.b refers): 1.

Any applicable requirement, procedure, operational directive or information issued by the DGCA.

2.

Any applicable airworthiness directive issued by the DGCA.

3.

Instructions for continuing airworthiness, issued by the type certificate (TC) holders, STC holders, any other organization required to publish such data by CAR-21 and in the case of aircraft or components from outside countries the airworthiness data mandated by DGCA.

4.

Any applicable standard, such as but not limited to, standard maintenance practices recognized by DGCA as good standard for maintenance.

5.

Any applicable data issued by the organization as Modified Maintenance Instructions as per CAR 145.A.45.d

Maintenance instruction is defined as various documents prepared by the organization as a guidance material for carrying out maintenance activity with in the scope of approval granted under CAR-145 procedures. Maintenance instruction includes the following; 1.

Aircraft Maintenance Programme developed by the maintenance agency with reference to the manufacturer supplied Maintenance Data and approved by Regional Airworthiness Office, Bangalore.

2.

Any applicable inspection / overhaul / replacement time limit,

3.

Routine, Special, Corrosion prevention, Storage inspection schedule,

4.

Procedure sheet, developed by the organization in accordance with the Maintenance Data

c).

This section provides the requirements of the organization for obtaining, processing and applying the maintenance data to carryout inspection / overhaul / replacement / repair of aircraft or component in line / base / shop maintenance area.

d).

Detailed procedure for control of Maintenance Data, Preparation of Maintenance instructions and making available of the same to staff are provided in EPM Section-1, Chapter-8.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.8.1

2.8.2

MAINTENANCE PROCEDURES

PAGE NO : 29 REV NO

: 01

DATE

: Aug 2008

COMPANY POLICY a).

All applicable maintenance data to carryout the maintenance work within the granted scope of approval will be readily available for use when required by maintenance personnel. (CAR 145.A.45.f refers).

b).

Company Approved updated Maintenance instructions will be circulated to all maintenance personnel for carrying out the work on the aircraft or component.

c).

Good maintenance practices will be inculcated into the minds of each and every maintenance personnel, which will help them to carryout the work meticulously and in a more professional manner.

d).

Human factors principles and limitations will be applied to all maintenance activities, to avoid any maintenance activity being carried out, under stress, which could directly hazard the safety of the flight.

CONTROL OF INFORMATION – TECHNICAL LIBRARY (INFORMATION HELD, CONTROL, ISSUE) ( Ref : CAR 145.A.45.f & EPM Section-4, Chapter-28)

2.8.2.1

SUBSCRIPTION & RECEIPT

a).

A Master list of various aircraft / engine / propeller / component on which the organization is capable of carrying out maintenance activity will be maintained by Manager – Tech services, thru Technical Officer (Library). The list will also contain the various publications (aircraft / engine / propeller / component wise) required to be maintained by the organization in the Technical library (at various stations).

b).

Manager – Tech services will subscribe for obtaining initial / revision issue of all publications for the aircraft owned by Deccan Aviation to receive continuous updates.

c).

In case of aircraft under maintenance contract, owned by a customer, conditions for provision of all maintenance publication pertaining to the aircraft will form a part of the contract. Contract will specify whether the customer will pay for the subscription directly and provide the proof of subscription to the Manager – Technical services or will allow Deccan to obtain the subscription for their aircraft / engine / propeller.

d).

Contract will also specify whether the publications will be handed over to the Technical Officer(Library) and obtain acknowledgement for the same or provide Deccan Aviation address as address for receiving the publication

2.8.2.2

DOCUMENT SAFEKEEP

a).

A technical library will be established in the organization and the same will be handled Tech. Officer (Library). Technical Library will be equipped with technical literatures of Airframe, Engines, Propeller and other components of all aircraft being maintained by the organization, under CAR-145 approval

b).

Technical Officer (library) will allot a controlled copy number to each of the manual required to be held as per the master list of publications at Bangalore and at all stations.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

MAINTENANCE PROCEDURES

PAGE NO : 30 REV NO

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c).

The manager - technical services will ensure that the technical library at Bangalore and all base / line station is maintained and all relevant technical publications (Maintenance data) required for maintenance of aircraft /engine / propeller / component at respective station are updated and are made available for reference at all times. (CAR 145.A.45.g refers)

d).

All the incoming technical literature (paper format / CD / DVD format) will be entered in an aircraft /component wise register kept in the technical library. This register will have details of literature received from, date of receipt and the publication evaluation form reference number for tracking action taken.

e).

Publications those which are available on-line will be accessed by the Technical Officer (library) every month and any new issue / revision will be downloaded, printed, entered in the register and folder amended.

2.8.2.3

DISPATCH TO OTHER STATIONS / ISSUE TO MAINTENANCE PERSONNEL

a).

All incoming literatures (Hard copy / CD /DVD /Downloaded) will be entered in the aircraft /component wise register and circulated to other controlled copy holders of respective manuals.

b).

Technical publications (paper / CD / DVD format) kept in the library (Main base / base or line stations) will be issued to maintenance personnel by the Technical officer (library) after making an entry in the publication issue register.

c).

Publication issue register will contain the following minimum information; 1. 2. 3. 4. 5. 6.

Date of issue. Description / Part number of the manual or folder. Condition of the manual at the time of issue. Signature of the person receiving the manual. Condition of the manual at the time of return. Signature of the person returning the manual and countersignature of Tech. Officer(library)

d).

Maintenance personnel will return the publications to the Technical officer (library) after use and affix their signature confirming the return of the manual in good condition, which will be countersigned by the Technical Officer (library).

2.8.2.4

MAINTENANCE DATA EVALUATION AND ACTION FOR COMPLIANCE

a).

All incoming literatures (Hard copy / CD /DVD /Downloaded) including regulatory documents such as Rules / CAR / Advisory circulars etc will be evaluated by Manager –Technical services using publication evaluation form (Form no. 022).

b).

Minimum Evaluation criteria for publication received is given below; 1. 2. 3. 4. 5. 6. 7. 8.

Description, Subject of the publication. Aircraft / Engine / Propeller /Component affected. Due information – Hrs / Calendar periods / landings / Cycles / others Applicability w.r.t company’s fleet of aircraft under maintenance and work order No. issued to carryout the same. Any work under progress is affected by the received publication? Details of Updation of master copy. Details of Dispatch of copy of literature to controlled copy holders. Details of Maintenance Programme amendment, if required

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

9. 10. 11. 12. 13. 14. 15.

2.8.3

MAINTENANCE PROCEDURES

PAGE NO : 31 REV NO

: 01

DATE

: Aug 2008

Details of Inspection schedule amendment, if required. Details of procedure sheet amendment, if required. Details of any material to be procured. Details of warranty claim, if any? Details of Technical circular to be issued for dissemination of information. Details of compliance of those, which are optional in nature. (if intended to be complied) Details of circulation to technical personnel thru Read & Sign file

c).

On completion of evaluation, Manager – Technical services will raise an Inter office communication (IOC) form (Form no. -051) providing specific instruction to various personnel to carryout specific functions.

d).

Publication evaluation form will be submitted to the Chief engineer for acceptance of evaluation procedure at this stage.

e).

Manager – Technical services will follow up, within 15days, with those personnel to whom the Inter office communication is issued for completion of compliance action and update the publication evaluation form.

f).

On completion of all actions by concerned personnel and recording of all action taken information on the form, Manager –Technical services will put up the form to the Chief engineer for signature towards the acceptance of all compliance action.

2.8.2.5

MAINTENANCE DATA EVALUATION AND ACTION FOR COMPLIANCE – BASE / LINE STATION.

a).

All incoming publication at the base/ line station will be received by the Technical Officer / Engg. In-charge respectively.

b).

Incoming publication evaluation will be done by Base Engineering Manager / Engg. In-charge of base / line station i.a.w applicable criteria listed in MOE 2.8.2.4 using publication evaluation form (Form No. 022)

c).

On completion of evaluation, Base engineering manager will raise an Inter office communication (IOC Form No. 057) providing instructions to various personnel to carryout certain functions to complete the compliance action.

d).

Base engineering manager will follow up, within 15days, with those personnel to whom the Inter office communication is issued for completion of compliance action and update the publication evaluation form.

REVISION / AMENDMENT PROCEDURE (MANUALS – SERVICE SIL Etc.))

INFORMATION (AD – SB –

a).

The Manager - Technical Services will ensure that Deccan Aviation is on the mailing lists of the manufacturers of all Aircraft, Engine, and Propellers, maintained by Deccan Aviation by paying subscription for revision services in respect of all literatures held, in order to receive regular updates of relevant revision documents.

b).

Technical Officer (Library) will ensure that the technical literatures are updated with in one week from the date of receipt of the amendments at the Library and copy of the same sent to other stations, where similar manuals / folders are maintained.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.8.4

2.8.5

MAINTENANCE PROCEDURES

PAGE NO : 32 REV NO

: 01

DATE

: Aug 2008

c).

Latest revision status index for all aircraft / engine / component manuals will be maintained to reflect the latest revision of all the technical literatures.

d).

Every month, during the first week, a visit to all available websites will be done and revisions to the publications / revision status downloaded. Record of such visits will be maintained.

e).

The revision status of all the manuals will be verified once a month with respect to latest revision index.

f).

If the revisions service is based on paid subscription, the manager - technical services will ensure subscription payment is made in time. He will maintain a record of all subscription data.

g).

In case of a revision, the superseded documents will be removed and destroyed. They will never find a place where valid documents are kept.

h).

Any manuals kept in Technical Library / issued to other stations will be allotted with unique traceable serial number (Controlled Copy). All revisions to such controlled manuals / service bulletins / airworthiness directives will be issued under a publication dispatch form (Form No. 014), with returnable acknowledgement slip.

i).

List of manuals kept in all stations will be maintained at the library with a traceable serial number, so that revisions to all such manuals could be sent accordingly.

j).

Details of technical literature to be maintained at each base / line / shop station location will be provided in EPM Section-1, Chapter-8 and the Technical Officer – Base station / Engg. Incharge of line station / Shop in-charge will update such publications.

UNCONTROLLED / UNSUBSCRIBED COPIES OF MANUALS a).

All uncontrolled copies will be listed by the Tech. officer (Library), by providing a unique serial numbers, starting with alphabet UC.

b).

At base station, Tech. Officer will ensure that uncontrolled copies are stored in a separate cupboard and are identified with alphabet UC.

c).

Uncontrolled copies of manuals will not be used for carrying out maintenance and will be kept in different location in library. Uncontrolled copies will be used as study material or for reference to know the previous procedures before revisions.

d).

Maintenance data printed out by maintenance personnel from current revision status CD /DVD / Online web access publications will be considered as an effective maintenance data for carrying out the maintenance work in the base / line / shop station at that moment and not for retention. Any printed and retained data for future use will be considered as uncontrolled and superseded copies.

COMPANY TECHNICAL PROCEDURES / INSTRUCTIONS

a).

Technical circulars will be issued to make the technical personnel aware of certain new / modified technical procedures. Source of information for technical circulars may be derived from the Manufacturer’s Technical publications, Directives issued by airworthiness authorities,

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Operational & Maintenance experience, defects, incidents, accidents etc. These circulars will be issued by Chief Engineer.

2.8.6

2.8.7

b).

Technical circulars will be given an index number and kept in technical library. Manager Technical services will circulate these circulars to all stations. Hard copies will be sent later to all line / base stations and the dispatch record will be maintained in a register.

c).

In line station / base stations, Circulars will be kept in a folder with a “read and sign” page consisting the names of the personnel who has read and understood the contents. Each personnel will affix the signature against the name for having read and understood the contents.

AWARENESS OF INFORMATIONS

TECHNICAL

PUBLICATIONS,

INSTRUCTIONS

&

SERVICE

a).

Awareness of the status of the Technical publications, instructions, service information’s will be ensured by sending out Technical Publication Status Information Circular to all line / base stations to enable the Base engineering manager / engineer-in charge of the station to update the station publications.

b).

Technical publication status information circular will contain the following information; 1.

List of Maintenance Data (Publications issued by manufacturer) and its revision status, with reference to controlled copy numbers.

2.

List of Maintenance programme approved by DGCA, its revision status with reference to revision status of Maintenance data, from which the maintenance programme is derived.

3.

List of inspection schedules for each aircraft / component and its revision status.

4.

List of procedure sheets for each aircraft and its revision status

c).

Technical Publication Status Information Circular will be sent out at the end of every quarter of the year i.e. on last day of March, June, Sept & December.

d).

Detailed procedure for issue of technical publication status information circular is provided in EPM Section-2, Chapter-4.

MAINTENANCE INSTRUCTION - (PREPARATION, APPROVAL & AMENDMENT CONTROL)

a).

Maintenance instruction is defined in MOE 2.8.b of this MOE.

b).

Aircraft Maintenance Programme and inspection schedules will be prepared with reference to the MPD, Chapter 4, 5 & 12 of, Airframe, engine and propeller maintenance manuals, service bulletins, service instructions, service letters issued by manufacturer, ADs and modifications issued by regulating authorities. Inspection requirements called for by Optional equipment manufacturer will also be included.

c).

Maintenance programme developed by Deccan Aviation for maintenance of aircraft will include details about:

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Service Life Limit / Time Between Overhaul limit of parts or components List of Periodic Inspections List of Out of phase inspection. List of Special Inspection. List of Lubrication Servicing Schedule. List of Corrosion Control Inspection. List of Conditional Inspection. List of aircraft / engine Storage Inspection (Preservation). Brief details of inspection as Per DGCA's Directives. List of Directives issued by the Airworthiness Authority of the Country of Manufacturer. List of Directives issued by the manufacturer ( ASB, SB, SL, CEB etc) Optional equipments fitted and its continuous airworthiness inspection requirements.

d).

Maintenance Programme will have the revision status (No. & Date) of the various reference document, based on which it has been prepared.

e).

Aircraft Maintenance Programme for each type of aircraft will be prepared by Tech Officer (AMP/Schedules) and type trained / qualified Engineer and verified by the Regional Engineering Manager / Chief Engineer and Quality Manager. Maintenance programme will have statement of scrutiny signed by the Regional Engg. Manager / Chief engineer and Quality Manager.

f).

After Chief engineer’s and Quality Manager’s verification, maintenance programme will be submitted to the Regional Airworthiness Office at Bangalore for approval.

g).

Latest amendments/ updation to Maintenance Publications will be incorporated in the Aircraft Maintenance Programme within 15 days of their receipt and submitted to Regional Airworthiness Office for approval.

h).

Any amendment for technical publication / directive issued by the manufacturer or airworthiness authority will be implemented on the aircraft / engine / component immediately, without time delay / waiting for DGCA approval.

i).

Inspection schedules will be prepared by the Tech Officer (AMP/Schedules) and type trained / qualified Engineer and approved by the Manager – Technical services.

j). Header

Inspection schedule will contain at least the following information’s; 1. Form No. allotted for the specific schedule. 2. Organization Name Aircraft / Engine / Propeller / Component Model 3. 4. Type of inspection schedule 5. Periodicity of the inspection schedule 6. Schedule Approval status (Rev. No & Date) 7. Page No. ( x of y format ) Section -1 1. General instructions to the maintenance personnel. 2. Aircraft / Engine / Component – Type, Model, Regn, Part No, Sl.No. 3. Status of Aircraft / Engine / Component – TSN / TSO / Cycles / Landings. Date & Time of inspection – Starting / Completion 4. 5. Details of tools, equipments, spares, consumables to be used. 6. Provision for recording the name’s of persons involved in maintenance work. 7. Provision to record the details of additional sheets used. 8. Part of work order / work package no. Section -2 1. Clear detail of the inspection to be carried out with reference to task card or maintenance manual chapter-paragraph-sub-paragraph numbers.

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k).

2.8.8

2.8.9

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Provision for recording physical measurements made during maintenance work. Provision for recording any observations. Provision to record additional work carried out. Provision for certification by the personnel for affixing stamp and signature. Description of reference document, Document number, Revision No & date Signature of person prepared (& his licence number) / approved the inspection schedule.

Revised aircraft maintenance programme and schedules will be distributed to all (applicable) stations by Manager -Technical Services with a proper record. All superseded schedules will be destroyed at respective stations by the base engineering manager / engineering in-charge.

DGCA ACCEPTANCE OF ORGANISATION’S TRANSFER OF AIRWORTHINESS DATA

a).

Any manuals kept in Technical Library / issued to other stations will be allotted with unique traceable serial number (Controlled Copy).

b).

List of manuals kept in all stations will be maintained by the Tech. Officer (library) with a traceable serial number, so that revisions to all such manuals could be sent accordingly.

c).

All revisions to such manuals / service bulletins / airworthiness directives will also be issued under a publication dispatch form (Form No. 014), with returnable acknowledgement slip, by Tech. Officer (Library).

d).

Tech. Officer at base / line stations will receive the publications sent from main base, circulate one copy of the publication for evaluation to the Base Engineering Manager / Engg. In-charge and update the received copy in the respective folders of the controlled copy of the manual.

e).

Tech. Officer at base / line station will fill up the acknowledgement slip attached with the publication dispatch form and return it to the Tech. Officer (library) for records.

REVIEW AND LITERATURE

IDENTIFICATION

OF

AMENDMENT

STATUS

OF

MAINTENANCE

a).

Revision status of all maintenance publications will be reviewed by the Manager – Technical services every quarter.

b).

A continuous record will be maintained, which will provide the revision status of all technical literature. Also refer MOE 2.8.5 for circulation procedures.

DISTRIBUTION OF AIRWORTHINESS DATA - ACCESS BY MAINTENANCE PERSONNEL a).

All the technical literature containing airworthiness data will be kept in technical library at each line / base station and in the shop for access to maintenance personnel. List of publications required to be held in each station will be published in EPM Section-4, Chapter-27.

b).

Maintenance personnel can obtain the literature, use it for reference or carrying out maintenance activity and then return the same to the library.

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c).

A register will be kept in the library, where in the person taking the maintenance data (publication) will write his name and description and controlled copy number of the manual being taken from the library.

d).

On return of the manual, the person will sign the register for recording the return of the manual and the entry will be countersigned by the Technical officer (library) or his assistant.

e).

Airworthiness Data such as service bulletins / airworthiness directives / mandatory modifications will be kept in the Read & Sign file for a period of one month from the date of receipt of the data, to enable the maintenance personnel to read, understand and acknowledge the same. Read and Sign document will have statement that the “signature on this form by maintenance personnel represents that they have read the contents of said airworthiness data and undertake to comply with the requirements”

f).

2.8.11

MAINTENANCE PROCEDURES

PAGE NO : 36

VERIFICATION AND VALIDATION OF NEW PROCEDURES WHERE APPLICABLE. a).

New procedures in maintenance activities may have to be adapted by the organisation due to various reasons such as product improvement, process improvement etc.

b).

In such cases, the procedures will be initiated by the Chief Engineer. Such procedures will be assessed and evaluated by the quality manager. On verification and validation by the Quality Manager, new procedures will be circulated in the form of Technical circulars to all concerned.

INCORPORATION OF BEST PRACTICE AND HUMAN FACTORS PRINCIPLE (Ref: CAR& AMC 145.30(e), MOE 3.13 & EPM Section-3, Chapter -24)

a).

Deccan Aviation will strive to incorporate Good Maintenance Practices and Human factors principles in the working culture of the organisation.

b).

All employees will be provided with an induction training, during which good maintenance practices will be stressed upon.

c).

All support / certifying personnel will be provided with refresher training every two years, during which importance of awareness and use of standard practices given by manufacturer will be stressed upon.

d).

Detailed procedure for human factors training is provided in EPM Section-3, Chapter-24.

e).

Importance of Human factors principles and the negative effect on the individual and the organisation, if the same is not followed will also be stressed upon during all training process.

f).

Details of good maintenance practices and human factors principle are provided in the EPM Section-1, Chapter 19 & 23.

CONTROL OF CUSTOMER SUPPLIED MAINTENANCE DATA a).

As a policy all owner / operator will be advised to be on the mailing list of manufacturer for the publication related to aircraft / engine / propeller. This instruction will form part of the maintenance contract as owner’s / operator’s responsibility

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b).

Contract terms will be clearly spelt out, whether the owner will provide the Deccan Aviation address (Bangalore) or owner’s address for shipping address for receipt of all publications.

c).

If Deccan Aviation address is provided as shipping address, all received publication will be routed to the Technical Officer (Library) for recording of incoming publication and necessary compliance action taken as per publication evaluation form.

d).

If Aircraft owner /operator’s address is provided as shipping address, contract terms will be specified that all documents received should be handed over / couriered to Technical Officer (Library) with in seven days of receipt.

e).

Technical officer (library) will update the customer’s manual & company manual on receipt of revision / amendment to publication.

f).

Manager – Technical services will advise all aircraft owners / nodal officer’s to be on the mailing list of the manufacturer of aircraft / engine / propeller for continuous amendment of the manuals and ensure the same by monitoring the expiry date and advising them, a month before expiry date.

MODIFICATION OF MAINTENANCE INSTRUCTIONS (Ref ; CAR 145.A.45.d & EPM Section-3, Chapter-33)

a).

Maintenance organization personnel may find a procedure alternate to the manufacturer’s instructions providing similar or better maintenance standards. In such cases, the chief engineer will be responsible to demonstrate to the quality manager that the modified maintenance instructions result in equivalent or improved standards.

b).

If acceptable, Quality Manager will approve and then intimate the TC/ STC Holder and the Regional Airworthiness Office, Bangalore about the modified maintenance instructions.

c).

Any feedback received from the TC / STC holder will be implemented as advised.

d).

Maintenance instructions for the purpose of the above paragraph mean instructions on how to carryout the particular maintenance task and they exclude the engineering design of repairs and modifications.

e).

Detailed procedure to be followed for control of modification of maintenance instruction is given in EPM Section-3, Chapter-33

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REPAIR (Ref: EPM Section-2, Chapter: 1)

a).

2.9.1

MAINTENANCE PROCEDURES

PAGE NO : 38

This section provides the policies & requirements of the organization for carrying out repair on aircraft under maintenance with Deccan Aviation.

COMPANY POLICY a).

Repairs will be carried out and certified by appropriately approved support / certifying staff as per the repair scheme provided in the Maintenance Data or by the TC / STC holder.

b).

Repairs that are not covered in the Maintenance Data will be referred to the TC / STC holder for obtaining specific repair scheme.

REPAIR – ASSESSMENT – SCOPE OF WORK & STAFF APPROVAL - ACCOMPLISHMENT

a).

Whenever a defect / damage is noticed by operation / maintenance personnel, documentation of the same will be first made in the tech. logbook of the aircraft.

b).

Minor repairs will be carried out after raising a work order by the support / certifying staff under the purview of their license and appropriate company approval issued by Quality Manager.

c).

When a major repair is required to be carried out, Regional engineering manager / Chief Engineer will analyze the recorded damage or carryout detailed damage assessment.

d).

Scope of Repair for major damages will be initiated in consultation with the manufacturer.

e).

Repair scheme for major Repair, which affects the primary load carrying member of the aircraft will be submitted to DGCA (Aircraft Engineering Division) for approval.

f).

Repair scheme as approved by DGCA (Aircraft Engineering Division) will be issued as work order. Additional procedure sheet detailing the instruction to carryout the repair will be developed based on the standard repair practices manual (AC 43-13) / manufacturer provided maintenance data.

g).

Scope of repair work will be clearly spelt out in the work order issued by the Regional Engg. Manager / Chief engineer with limitations / conditions if any.

h).

Regional Engg. Manager / Chief Engineer will propose a support /certifying staff who has received adequate training on applicable structural repair procedures after assessing his qualification, knowledge & competence level and prior experience for carrying out the work.

i).

Quality Manager / auditor will examine the candidate and issue a company approval to the support / certifying staff to carryout and certify the repair work. Any limitations will be clearly indicated on the approval.

j).

Approved Support / certifying staff will carryout the work using the approved repair scheme and standard practices and certify the work in the relevant logbook with the details of work done, cross reference to the repair scheme ( & its approval) and current maintenance data (Rev. No. and date)

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

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After completion of repair work and certification in the logbook, Certificate of Release to Service will be issued by the authorized certifying staff referring to the repair work and work order number.

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AIRCRAFT MAINTENANCE PROGRAMME COMPLIANCE (Ref: EPM Section -2, Chapter-3 and Section-3, Chapter-26)

a.

2.10.1

MAINTENANCE PROCEDURES

PAGE NO : 40

This section provides the policies & requirements of the organization for control of compliance of various maintenance activities called for in the aircraft maintenance programme.

COMPANY POLICY

a.

All maintenance work carried out on aircraft, engine or components will be carried out in accordance with manufacturer’s requirements / recommendations.

b.

Every maintenance work undertaken by the organization, will be thru a clear work order system.

c.

Maintenance work will be carried out by qualified, competent, approved personnel using approved facility, material, tools & equipment and current technical literature.

d.

Maintenance work will be carried out by adapting good maintenance practices.

GENERATION AND COMPLIANCE OF WORK ORDERS

a.

In order to ensure continued airworthiness of the aircraft, various maintenance actions called for in the aircraft maintenance programme are required to be carried out at specified intervals. All such maintenance work will be carried out after generating a clear work order mentioning the specific work to be carried out.

b.

Maintenance work required to be carried out to keep the aircraft in the continuous airworthy state are provided in various Maintenance Data. Such maintenance data is customized for compliance as Maintenance Instructions (Maintenance Programme and Inspection schedules).

c.

List of maintenance activities given in the aircraft maintenance programme will be entered into the Master list of FLYPAL, (a web based software for monitoring maintenance activities) for each aircraft model / serial number, by the Tech. Officer (software).

d.

Data entered into the master list for monitoring will be verified by Manager – Technical Service and a record of data entry and its verification will be maintained by the Tech. Officer (Records)

e.

FLYPAL will calculate the various periodicities as entered and provide impending maintenance activities as due reports (or call outs) for carrying out the maintenance work.

f.

Due report for every month will be generated by Tech. Officer (software) and sent to concerned base engineering manager where aircraft is maintained, concerned support / certifying staff responsible for the aircraft, logistics personnel and Nodal officer or customer’s representative.

g.

Tech. Officer (Planning) will convert the due report into Planning Advisory (Form No. 060) and circulated to concerned base engineering manager where aircraft is maintained, concerned support / certifying staff responsible for the aircraft, logistics personnel and Nodal officer or customer’s representative, with the following information; 1. 2. 3.

Maintenance action (Inspection / Replacement / Testing etc) due. Parts, Tools & Consumables required for scheduled inspection as per inspection schedule. Due information ( Flying hrs / cycles / landings / calendar period etc)

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h.

Access to view information on FLYPAL will also be granted to all support / certifying staff for generating due reports, pertaining to the aircraft, on which they are working.

i.

Due report will be considered to be a call out from the Manager – Technical Services to carry out the work.

j.

Work order will be generated by the support / certifying staff on two occasions i.e. for carrying out scheduled maintenance based on the due report or for carrying out unscheduled maintenance such as defect rectification or repair due to damage.

k.

Support / certifying staff will raise the work order for Scheduled maintenance (servicing / inspection / replacement / calibration etc) based on the due report. These work order will be identified as scheduled maintenance work order.

l.

Support / certifying staff will raise the work order for unscheduled maintenance based on the defect / damage entry made by the operation / maintenance personnel in the tech. logbook. These work order will be identified as unscheduled maintenance work order.

m.

All defects including minor defects will be rectified only after creating an unscheduled maintenance work order. No defect will be closed with an entry in the tech. logbook alone.

n.

Every defect entered in the tech logbook will be related to the work order for detailed information of the rectification action and the work order number will be cross referred in the rectification action taken columns of the tech. logbook.

o.

Work order will be generated by using a pre-printed format as explained below. Registration and Serial No. column will be pre-printed and issued as a booklet to each aircraft by Manager – Technical services. This will ensure that no work order is misplaced. Registration DAX

Year 2008

Month 01

Date 10

Sl.No Pre-printed

p.

Work order booklet will be in printed in duplicate and issued under controlled documentation by Manager – Tech services.

q.

On completion of the scheduled or unscheduled maintenance work, support / certifying staff will carryout entries in all the following documents as per sample entries given below; Type of entries to be made for Scheduled Maintenance Work

In Tech. Logbook

In Work order

In Working Copy of Logbook Starter generator sl. No. xxxx, TSN - 1999:00Hrs, TSO 999:00Hrs removed as due for overhaul.

Starter Generator replaced due for overhaul – Refer work order No. DAX-2008-01-10

Support / certifying staff will write the following – in work In action taken required column column Replace starter Starter generator as generator due for replaced. overhaul Electrical system tested. Found satisfactory

New / Overhauled starter generator sl. No. yyyy, TSN – 1000:00 hrs, TSO- 0:00 Hrs installed on engine serial no. CAE-845678. as per MM Rev. No.3 dt 21st May-07, Chapter. 72-30-60

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Type of entries to be made for Un-Scheduled Maintenance Work In Tech. Logbook

In Work order

Snag reported – Impending fuel Filter bypass found extended

Action Taken – Filter cleaned or replaced. System purged. Ground run found satisfactory. Aircraft cleared for flight. Refer work order no; DAX-2008-01-10 r.

Support / certifying staff will write the following – in work In action taken required column column Filter cleaned or replaced. Impending fuel System purged. filter bypass Ground run found found extended. -satisfactory. Rectify Aircraft cleared for flight.

In Working Copy of Logbook

Fuel filter removed and cleaned (or replaced) and installed, System purged as per EMM Rev.No.5 dated 15th Sept. 08, Chapt. 73-3020. Ground run found satisfactory.

First copy of the work order will be removed from the booklet, attached with the following supporting documents and sent to Technical Officer (Records) at Bangalore for scrutiny and safe keeping. 1.

Copy of the due report, based on which the work order was created and work carried out. This will enable Tech. officer (planning) & (records) to carry out a cross verification that all maintenance activities due on a specific date / hrs was carried out without fail.

2.

Duly completed inspection schedule / procedure sheets used to carryout the work.

3.

Additional inspection sheets / off-job sheets used (if any)

4.

List of spares used for carrying out the work and copy of authorized release certificate / parts acceptance tag.

5.

Dimension Recording Sheets used for recording physical observations / measurements. (if any)

s.

Second copy of the work order will remain with the book. In case, the first copy of the work order is lost in transit, the second copy of work order retained in the book will provide the necessary information.

t.

Support / certifying staff or Tech. Officer (base station) will update the FLYPAL on real time basis (as soon as the tech. log book / work order / working logbook entries are done) about the work done on the aircraft. This will enable the Tech. officer (planning) to carryout proper monitoring of completion of work as per Planning advisory / due report.

u.

In case, support / certifying staff or Tech. officer (base station) is unable to update the FLYPAL, then they will intimate the Tech. Officer (Planning) via sms / email about the completion of the work carried out on an aircraft, before sending the hard copy of the work order to the Tech. Officer (records) for scrutiny and retention.

v.

Technical officer (Records) will scrutinize the completed work order and its attachments received at Bangalore and intimate any discrepancy to the Manager – Technical service and to the concerned support / certifying staff for corrective action.

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w.

Technical officer (Planning) will refer the completed work order file and the work completed entries in FLYPAL and update about the compliance action taken on the planning advisory / due report

x.

Any work order / schedule having discrepancies will be brought to the notice of the support / certifying staff with the specific aircraft for taking appropriate compliance action.

y.

If no discrepancy is found, Technical officer (Records) will scan the work order and the attached documentation and send to the soft copy to the concerned base / line station for records.

z.

Technical officers at line stations will update the web based FLYPAL software, with all flight logs, maintenance log details such as Inspections carried out, SLL / TBO components replaced, Directives (ADs, Mandatory Modifications and Service Bulletins) carried out etc. Those who don’t have access to internet / difficulties in having continuous access will provide a weekly aircraft status vide Weekly Report form (Form No. 023) to the Tech. Officer (software). Tech. Officer (software) will enter the details received thru the weekly report form into the FLYPAL data base.

aa.

Any wrong data entered in to the software is required to be intimated to the Tech. Officer (software) in writing by e-mail or fax.

bb.

Tech. Officer (software) will be the only person to have editing rights in the software. Tech. Officer (software) will edit software data based on the request from the individual and will retain the request in the related aircraft Flypal data file.

cc.

Quality auditors will carryout audit of completed work orders. If any deficiency is observed, the same will be recorded as Non-compliance and brought to the notice of the concerned support / certifying staff and chief engineer for correction of the observed discrepancy.

dd.

Tech. Officer (Planning) will also monitor the compliance action recording / updation of various maintenance activities in the work order / FLYPAL. Based on this monitoring, he will send a last day call by e-mail / telephone, to the Base engineering manager / station engg. In-charge about the pending scheduled work on a particular aircraft.

ee.

If the work is already carried out / planned for the last due date / flying hours, base engineering manager / station in-charge will disregard the information. If the work is not carried out previously or planned for the last due date / flying hrs, then the base engineering manager / station engg. Incharge will ground the aircraft due non-compliance of scheduled maintenance activity.

ff.

If the work order sheet becomes invalid due to wrong entries, such work order will not be disposed off. All invalid work order will be crossed across the sheets and first copy will be sent to Tech. Officer (Records) at Bangalore. Second copy will remain in the book.

gg.

If a work order booklet is missing / misplaced, immediate information will be sent to Manager – Tech services by the concerned support / certifying staff. Manager – Tech. services will document the same and issue another work order booklet, with continuing serial numbers.

MAINTENANCE PROGRAMME ONE TIME VARIATIONS (Refer EPM Section-3, Chapter-26) a).

Aircraft Maintenance Programme preparation and approval procedure is explained in MOE 2.8.7.

b).

If any one time variation is required to be introduced, Chief engineer will propose the same to the Quality Manager for acceptance. On acceptance from the quality manager, chief engineer will forward the one time variation request to respective Regional / Sub-Regional Airworthiness Office for approval.

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c).

If variation is provided in the Maintenance Manual or other manufacturer’s instruction for ease of maintenance scheduling, then the variation request will be sent to Regional Airworthiness Office, with a copy of the allowances provided by the manufacturer.

d).

If the variation required is beyond the variation limit provided in the manuals, then the manufacturer will be approached to obtain a NTO (No Technical Objection) for applying the variation for the specific aircraft. In such case, the NTO from manufacturer will be submitted to the Regional Airworthiness office along with the variation request proposal.

CONTROL OF PROGRAMME AND AMENDMENTS a).

Any amendment to the maintenance programme will be initiated by the Tech. Officer (MPD/schedules) and verified by the Chief Engineer & Quality Manager before submitting to the Regional Airworthiness Office, Bangalore for approval.

b).

Approved amendments will be distributed by manager - technical services as per distribution list for effecting the amendments in to the copies of Aircraft Maintenance Programme.

c). d).

Record of all amendments to Aircraft Maintenance Programme will be maintained in technical All station technical officers’ will destroy the superseded copies and insert the new amendments into the Aircraft Maintenance Programme folder.

RELIABILITY MONITORING AND REPORTING

a).

2.10.6

MAINTENANCE PROCEDURES

PAGE NO : 44

CAR Section-2, Series-C, Part-V, requires Maintenance control by Reliability method for all scheduled airlines having sizable fleet of aircraft in operation. Presently Deccan Aviation is involved in maintenance of non-scheduled operations aircraft only. Hence reliability monitoring as per the CAR will be undertaken as and when scheduled operations are initiated.

CORROSION CONTROL PROGRAMME REPORTING.

a).

All airframe / engine manufacturer provides corrosion prevention and corrosion control inspection programme in the maintenance manual.

b).

Periodicity of corrosion control inspection varies from 100hrs / 90days to 1 year, 2 year etc. Inspections as recommended by the manufacturer will be included in the Aircraft Maintenance Programme and the same will be followed.

c).

If severe corrosion is found in any of the aircraft, then the same will be reported to the manufacturer and DGCA. Actions recommended by manufacturer for control of corrosion and preventive action will be undertaken to avoid spreading of corrosion in the same or another aircraft of similar type.

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MAINTENANCE PROGRAMME INSPECTION STANDARDS

a).

Inspection as per maintenance programme will be carried out as per Aeronautical Standards. Support and certifying staff will ensure that the work carried out by them meets the standards explained below ; Work area is clean, sufficient to carryout the intended inspection. Proper Tools & equipments duly calibrated are available for carrying out the intended the maintenance. 3. Updated maintenance data (Literature) and Maintenance instruction (schedules) are available for carrying out the maintenance 4. Serviceable parts and consumables are available for carrying out the maintenance. 5. Appropriately qualified, experienced, skilled and competent personnel are available for carrying out the maintenance 6. Observance of safety precautions during all phases of maintenance and operation. 7. Tools are accounted before and after carrying out the inspection. 8. Work is certified progressively, as they are completed. 9. Proper mixing of adhesives / compounds, as recommended by the manufacturer in terms of measure. 10. Use of calibrated precision measuring instruments for recording precision measurements. 11. Multiple measurements and recording of all measurements taken to find average readings. 1. 2.

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2.11.2

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AIRWORTHINESS DIRECTIVES / DGCA MANDATORY MODIFICATION / ALERT SERVICE BULLETIN – CONTROL PROCEDURE (Ref: EPM, Section-1, Chapter-7)

a).

This section outlines the policies and requirements for compliance and control of all the airworthiness directives received from airworthiness authorities of the country of origin, alert service bulletins issued by the TC holder and the Mandatory Modifications issued by DGCA. The entire procedure will also be applicable for the miscellaneous modifications issued by the DGCA.

b).

Word “Directive” in this and related chapters of MOE / EPM will denote Airworthiness Directives, Alert Service Bulletins or Mandatory Modifications.

c).

Detailed procedure for control and compliance of AD / ASB / Mandatory Modifications are provided in EPM Section-1, Chapter-7.

COMPANY POLICY a).

All maintenance activities, that are made mandatory in the form of Airworthiness Directives, by the Airworthiness authority of the country of Origin (Civil Aviation Authority of the country, which has issued the Type Certificate for the aircraft, engine, propeller or component), will be carried out within the time frame given in the AD.

b).

Service Bulletins issued by Manufacture of aircraft, engine, propeller or component and classified as Alert or Mandatory will also be carried out with in the time frame given in the compliance requirement column of the bulletin.

c).

Mandatory Modifications issued by DGCA specific to particular airframe, engine, propeller or miscellaneous component will be complied within the specified time limits on the aircraft / aircraft component maintained by Deccan Aviation.

d).

No aircraft/aircraft component will be operated beyond the specified limit, without the compliance of the AD, Alert / Mandatory Service Bulletins or Mandatory modifications.

e).

Compliance status of all directives in respect of airframe, engine, propeller and miscellaneous components will be maintained for those aircraft which are under the maintenance of the organization.

AIRWORTHINESS PROCEDURE.

DIRECTIVE

/

DGCA

MANDATORY

MODIFICATION

RESPONSE

a).

Airworthiness Directives and DGCA Mandatory modifications are listed in the respective authorities’ website.

b).

Technical Officer (Directives / Occurrences ) will visit the website of the authorities publishing the Directives (including mandatory modifications), every 15days and download the contents, and update separate registers / lists maintained for each type of airframe, engine, propeller etc.

c).

Manager – Technical services & Chief Engineer will evaluate all AD’s / Mod’s using publication evaluation / review form (Form No. 22) and document the required action to be taken by various individuals for following action;

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Any aircraft / engine /component under maintenance affected by the AD. Up-dation of the master folders of the AD / Mod’s for various airframe / engine / component etc Circulation of AD / Mod’s to various bases, where such airframe /engine / propeller are being maintained under CAR-145 approval. Amendment of maintenance programme / inspection schedule / procedure sheet etc. Updation of FLYPAL master data for one time / repeat compliance of AD / Mod’s. Logistics procedure such as procurement of spares / warranty claim etc Requirement to issue technical circular to disseminate information to maintenance / operation personnel Any other action to be taken for ensuring continuous airworthiness

d).

Manager – Technical service will monitor compliance of all actions to be taken, till such time all actions are completed and then forward the publication evaluation / review form to Chief engineer for verification of satisfactory compliance of the requirements of AD / Mod’s.

e).

Detailed procedure of receipt of AD and its compliance procedures are listed in EPM Section-1, Chapter-7

REPETITIVE DIRECTIVE’S REQUIREMENTS - (INSPECTION CONTROL)

a).

b).

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PAGE NO : 47

Manager – Technical services & Chief Engineer evaluating an AD / Mods / ASBs using Publication Evaluation Form (form No. 022) will initiate following action, if the AD / Mods / SB’s is found to be of repetitive in nature; 1.

Raise inter office communication form (Form no. 057) to Tech. Officer (AMP/Schedules) to include the repetitive inspection requirement AD / Mods / SBs in maintenance programme and/or inspection schedule.

2.

Raise inter office communication form (form no. 057) to Tech. Officer (software) to include the AD / Mods / SBs in the master list of monitoring for the specific aircraft for repetitive monitoring.

Detailed procedure of inclusion of repetitive inspection requirements of AD / Mod’s in aircraft maintenance programme / FLYPAL software for continuous monitoring is provided in EPM Section-1, Chapter-7

COMPLIANCE STATUS OF AIRWORTHINESS DIRECTIVES / MANDATORY MODS. a).

Technical Officer (Directives & Occurrences) will maintain a master list and related reference document of Airworthiness Directives and Mandatory Modifications for each type of airframe, engine and propeller being maintained by the organization under the granted scope of approval.

b).

Service bulletins issued by few manufacturers are considered as Mandatory as they are issued under the title of ALERT SERVICE BULLETINS. Some of the manufacturer issues under the title SERVICE BULLETIN and declare some of those bulletins as Mandatory in compliance requirement column. Since Service Bulletins are declared as a Controlled copy and the folders are allotted a controlled copy number, all service bulletins will be maintained in Technical Library at Bangalore and at all base or operating line stations.

c).

Technical officer (Directives) will maintain ADs / Mandatory Modification history card (Form No. 012) for each type of aircraft, engine and propeller, which will provide a bird eye view of the compliance status of the all the ADs and Mods

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d).

Miscellaneous modification for each aircraft will also be maintained in the form of history card.

e).

Compliance requirement of all directives (AD / Mod / ASB) will be fed in the “Directives Module” of FLYPAL software by Technical Officer on receipt of Inter office communication (Form No. 051) from Manager –Technical Services.

f).

FLYPAL will provide one time or periodic call out for compliance of the repetitive ADs / Mods / ASBs.

g).

On receipt of one time / periodic call out generated by FLYPAL for compliance of ADs / Mods / ASBs, the support / certifying staff will generate a work order, carryout the work and certify the same in the Tech. logbook, work order and the working copy logbook.

h).

Support / certifying staff or Tech. Officer at base station will update the Directive module of the FLYPAL from their location on completion of the maintenance activity as called for in AD / Mod / ASB.

i).

Directive module of FLYPAL will also provide a compliance status of all effective Directives (AD / Mod / ASB) in ascending order.

j).

On receipt of the completed work order at Bangalore, the Technical Officer (Records) will update the original logbooks of the airframe, engine or propeller and Technical Officer (Directives & Occurrences) will update the respective AD / Mod / ASB history cards.

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2.12.1

2.12.2

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OPTIONAL MODIFICATION PROCEDURE (Ref: EPM Section-1, Chapter-9) a).

This section provides the policies and requirements for control & compliance of all the optional service directives / modifications issued by the aircraft, engine, propeller or component manufacturer.

b).

Detailed procedure for control of optional modification is provided in EPM Section-1, Chapter-9.

COMPANY POLICY a).

Service Bulletins / Letters / Instructions / Modifications issued by the aircraft, engine, propeller or component manufacturer as Optional will be evaluated for its effect on operational, maintenance, comfort characteristics of the aircraft.

b).

Any bulletins / letters / instructions / modifying improving operational, maintenance or comfort features of the aircraft will be carried out on the aircraft after case to case evaluation and decision taken.

c).

Detailed policy of evaluation and method of embodiment is explained in EPM Section-1, Chapter-9.

CONTROL OF OPTIONAL MODIFICATIONS (ASSESSMENT PROCEDURE & COMPLIANCE) a).

Manager – Technical services & Chief engineer evaluating an SB / SL / SI using Publication Form (form No. 022) will initiate following action, if the service bulletins / letters / instructions are optional in nature; 1. 2. 3. 4. 5. 6. 7.

Up-dation of the master folders of the service bulletins / letters / instructions for various airframe / engine / component etc Circulation of the publication to various bases, where affected airframe /engine / propeller are being maintained under CAR-145 approval. Amendment of maintenance programme / inspection schedule / procedure sheet etc. Updation of FLYPAL master data for one time / repeat compliance of optional SB/SL etc. Logistics procedure such as procurement of spares / warranty claim etc Requirement to issue technical circular to disseminate information to maintenance / operation personnel Any other action to be taken for ensuring continuous airworthiness

b).

Manager – Technical services and Chief engineer will decide, whether to comply with an optional service bulletin / service letter / service instruction after weighing the pro’s and con’s of compliance, such as cost of compliance, aircraft grounding time, improvement in operational or maintenance characteristics, increase in passenger comfort level etc.

c).

Evaluation and decision making process of whether to comply the bulletin or not will be completed within a period of one month from the date of receipt of the bulletin.

d).

While taking the decision, Chief engineer will consider repeated premature failures, defects, ease of maintenance, improved operational characteristics or performance of the aircraft and decide whether to comply or not.

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e).

Chief engineer will record the reason for the decision to comply or not to comply in action taken information column of the publication evaluation form.

f).

Manager – Technical service will monitor compliance of all actions to be taken, till such time all actions are completed and then forward the publication evaluation / review form to Chief engineer for verification of satisfactory compliance of the requirements of SB / SL / SI etc.

. g).

Detailed procedure of receipt of optional modification and its compliance procedures are listed in EPM Section-1, Chapter-9.

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2.13

2.13.1

2.13.2

MAINTENANCE PROCEDURES

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MAINTENANCE DOCUMENTATION IN USE AND COMPLETION OF THE SAME (Refer: CAR 145.A.45e & EPM Section – 1, Chapter -8 & Section-3, Chapter -18)

a).

This section outlines the policies, requirements and brief procedures regarding various maintenance documentations to be used for the purpose of documenting various maintenance and related activities.

b).

Detailed procedure to be followed by various personnel for documentation of maintenance work carried out and completion of the same is provided in EPM Section-1, Chapter-8 and Section-3, Chapter-18.

COMPANY POLICY

a).

All maintenance work carried out on the aircraft, engine, propeller or component will be documented properly, so that the continued airworthiness is ensured and history of maintenance activity is traceable during the life time of the component.

b).

All maintenance personnel will be trained and advised to document maintenance activities performed, by them.

c).

Procedures will be created to provide a common system (Inspection Schedules & Work orders) to be used throughout the organization (Line, Base, Component shops etc).

d).

Instructions provided in manufacturer’s maintenance data (CAR 145.A.45.b / MOE 2.8) or the modified maintenance instructions ( CAR 145.A.45.d / MOE 2.8.13) will be transcribed to inspection schedules or procedure sheets to enable the maintenance personnel to carryout the required maintenance work in right manner.

e).

Complex maintenance tasks will be transcribed onto the Inspection schedules or procedure sheets and sub-divided into clear stages to ensure a record of the accomplishment of the complete maintenance task. (CAR 145.A.45e refers).

f).

If the aircraft operator (customer) requires their approved inspection programme / schedule to be carried out on their aircraft / component, then the same will be used for carrying out maintenance on their aircraft / engine / component. (CAR 145.A.45.e refers).

VARIOUS MAINTENANCE DOCUMENTS IN USE a).

Various maintenance documents in use are listed and defined below; 1.

Work Package consists of compilation of various work orders required to be complied on aircraft, engine or on component, under base or shop maintenance, respectively.

2.

Work order - A document issued by Regional / Base Engineering Manager or station engineering in-charge or prepared by the support / certifying staff, highlighting the scheduled work (inspection /replacement) to be carried out as listed in due report or unscheduled work such as damage or defects to be repaired / rectified.

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3.

Inspection schedule consists of various items of inspection drawn from Maintenance Data to be complied on the aircraft, engine, propeller or component.

4.

Due Report – Report generated by the maintenance software “FLYPAL”, providing details of inspection, replacement to be carried out the aircraft, engine or propeller.

5.

Procedure sheet - consists of step by step by procedure for carrying out a maintenance task or activity, prepared in accordance with manufacturer’s recommended or standard procedure to ensure that the maintenance activity is performed in a sequential manner.

6.

Off-Job sheet – is a document raised by support /certifying staff to carryout and certify minor work on the aircraft while performing a line / base / shop maintenance activity on an aircraft, engine, propeller or a component under a work order. Any off-job sheet raised during base / shop maintenance activity will be attached with the relevant work order or work package.

7.

Repair scheme: Repair instruction, inclusive of repair drawing / process information etc provided in the relevant updated maintenance data for carrying out repair on the aircraft or on a component is defined as Repair scheme.

8.

Repair procedure sheet: Schedule of items containing step by step procedure of instructions to comply a repair on the aircraft or on a component, prepared based on relevant updated maintenance data and approved by the chief engineer or person authorized by him is called as Repair Procedure Sheet.

9.

Dimension Recording sheet (Form No. 008) is a document to enter the observed dimension and compare with the required dimensions given in the maintenance data. All dimensions recording sheet will be attached with the respective inspection schedule to which it refers to.

10.

Working copy logbook: Aircraft / Engine / Propeller logbooks, maintained in operating line station / base station for the purpose of support staff to document the work carried out with in the time frame of 48hrs provided by DGCA. These logbooks will have similar appearance as that of original logbook, but have “working copy” printed on each of the sheets. Working copy logbook will enable the representatives of local airworthiness office to get a glimpse of maintenance activities undertaken on the aircraft as all forms of original aircraft documentation is maintained and updated at the centralized location (Bangalore – Approved main base) under CAR-145 approval. Retaining the working copy will also satisfy the 2year retention requirement of copy of records, in case maintenance contract ceases to be valid.

11.

Original Logbook – Aircraft / Engine / Propeller logbooks maintained at Bangalore (Approved main base under CAR-145 approval) by Technical Officer (Records) is referred as Original Logbooks. Entries in this logbook will be made by Tech. Officer (Records) and signed by Manager – Technical services under his/her stamp and signature. This logbook will allow representative of the Regional Airworthiness Office, Bangalore to audit and get a glimpse of maintenance activities undertaken on the aircraft, though the aircraft may be operating at an operating line station or based at any other base station for maintenance and operation.

WORKORDER FOR NON-ROUTINE TASKS a).

Non-routine tasks are required to be carried out if any defects are observed or any damage occurs to the aircraft.

b).

If defect / damage is minor in nature and within the scope of line maintenance activity, support / certifying staff will raise the work order on their own as per the format explained in MOE 2.10.2

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

c).

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If defect / damage is classified as major, then the work package will be decided in consultation with the manufacturer / DGCA, as per repair policies and procedure given in MOE 2.9

ASSEMBLY OF WORK PACKAGES FOR ISSUE TO MAINTENANCE ACTIVITY

a).

Maintenance activity required to be carried out will be reflected in the due report generated from the FLYPAL software.

b).

All activities which are due at in terms of flying hours, calendar period, landings, cycles or RINS are required to be carried out on Mandatory basis, by the support / certifying staff after creating a work order.

c).

Any other work, which may fall due within the near future, could be clubbed (assembled) together to avoid frequent grounding of the aircraft. Support / Certifying staff will consult the chief engineer for the same and chief engineer will advise based on following considerations; 1. 2. 3.

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Need to avoid frequent grounding and ensure optimum operational utilization of the aircraft. Need to avoid frequent removal / installation of components. Need to ensure efficient utilization of available manpower.

WORKORDER / INSPECTION SCHEDULE COMPLETION – MAINTENANCE SIGN – OFF

a).

Tech Officer (software) will provide a monthly due report to Base Engineering Manager and the concerned support / certifying staff about the scheduled maintenance activity falling due within next 30days / 100flying hours / 250 landings / 500cycles.

b).

Tech. Officer (Planning) will provide a Planning Advisory to Base Engineering Manager and the concerned support / certifying staff, based on the due reports, which will provide the required tools, equipments, consumables required to carryout the scheduled maintenance activity.

c).

Base engineering Manager or the concerned support / certifying staff will ensure that the following are available before initiating maintenance activity (under work order and inspection schedule); 1. 2. 3. 4. 5. 6.

Availability of Up to date Maintenance data for the maintenance of aircraft / engine / component, including standard practice manual. Duly accepted and issued parts, consumables etc. Properly calibrated and controlled tools & equipment. Qualified and competent manpower to carryout and certify the work. Appropriate scope of approval and capability to carryout the work. Adherence of any limitation on the scope of approval /capability or on the support /certifying staff.

d).

Base engineering manager / operating line station engg. In-charge / shop in-charge will ensure that the facility is clean and FOD eliminating procedures are followed as given in MOE 2.7.2

e).

Base engineering manager / operating line station engg. In-charge / shop in-charge will ensure that any observations received thru the Quality Deficiency & Hazard Reporting System procedure is adequately addressed so that no untoward occurrences occur due to deficiency in maintenance standards.

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f).

Base engineering manager / shop in-charge will ensure that all Support staff progressively signs off every inspection item as it is completed in inspection schedule or on the procedure sheets, with the mentioning of date & time along with signature and the approval stamp.

g).

Similarly, every inspection schedule listed on a work order will be signed off, as the inspection schedule is completed and closed, with the mentioning of date & time by the respective support staff.

h).

Habit of signing off all inspection items on a schedule or all inspections on a work order at one time will not be practiced by any of the support staff, as this may lead to signing of an item of inspection without actually carrying out the work.

SCRUTINY OF WORK COMPLETION & CERTIFICATION a).

Support staff carrying out the maintenance activity on line / base / shop maintenance location will sign off all inspection items on the schedule and scrutinize to ensure that no item is left out, without action taken for compliance or unsigned, after compliance.

b).

Certifying staff authorized to release the aircraft / component for service will scrutinize to ensure the following that ; 1.

Maintenance Work ordered has been properly carried out by the support staff in accordance with the procedures given in the MOE / EPM and the relevant updated maintenance data.

2.

Availability and use of the relevant updated maintenance data for carrying out the maintenance work is proven beyond doubt, by way of evidences

3.

There are no non-compliances which are known that may hazard seriously the flight safety.

c).

After detailed scrutiny and satisfactory results, certifying staff will issue appropriate certificate of release to service for the aircraft under line / base maintenance or the component under shop maintenance.

d).

If new defects or incomplete maintenance work orders are identified during the scrutiny of maintenance work completion on the aircraft, the same will be brought to notice of the owner / operator for the specific purpose of obtaining his consent to rectify such defects or completing the missing elements of the maintenance work order.

e).

In case, if the operator declines to have such maintenance carried out, certifying staff may issue a certificate of release to service within the approved aircraft limitations. Certifying staff will enter such fact in the aircraft certificate of release to service, before the issue of such certificate.

UPDATION OF LOGBOOKS, WORK ORDERS AND COMPUTER SOFTWARE

a).

Support staff carrying out the work on the aircraft at operating line station / base station will certify the following documents without fail, before the certifying staff carries out the scrutiny for issue of CRS;

1.

Tech. Logbook

:

Very brief reference to the work carried out pertaining to the scheduled (any inspection or component replacement) or nonscheduled maintenance work (any observation, defect (minor / major), damage, incident or accident) and reference of the related work order no.

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Work order

MAINTENANCE PROCEDURES

:

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Brief detail of scheduled work to be done / snag reported and the detailed action taken for scheduled or unscheduled maintenance work carried out, including the details of parts removed and installed (such as part number, serial number, life completed in terms of flying hours, calendar periods, cycles, landings, RINS etc.), RNN as read from the parts acceptance tag in the appropriate columns. Entries for duplicate inspection is also required to be entered in the work order in appropriate columns

3

2.13.8

2.13.10

:

b).

Support staff / certifying staff carrying out the work / releasing the aircraft or the Technical Officer at base station will update the web based FLYPAL about the details of all scheduled and unscheduled maintenance activities carried out. This updation will be ensured for completion by the base engineering manager, by establishing a standard procedure detailed in EPM Section-4, Chapter-29.

c).

In case of difficulty in updating the web based software due to broad band connectivity issues, then the established alternate procedure of sending reports in weekly report format will be followed immediately. Tech. Officer (software) will update the maintenance information received from line / base station on to the web based software.

ASSEMBLY OF COMPLETED WORK PACKAGES FOR CERTIFICATION

a).

2.13.9

Working copy logbook

Detailed explanation of action taken for scheduled or unscheduled maintenance work carried out on the aircraft / engine / component in respective logbook, with the detail of relevant updated maintenance data (Description of the manual used, current revision number and date)

Multiple inspection schedules / work orders can be combined as single work package and one CRS issued with clear cross reference to all work order nos.

RECORDING OF TEST RESULTS AND DIMENSIONS a).

Dimensional measurements, torque values measured and required to be documented will be recorded in Dimension Recording Sheet (Form No. 008)

b).

This sheet will be used as an annexure to the corresponding inspection schedule or work orders, so that dimensional information about any component is available at later date for reference.

c).

Such dimension recording sheet will have cross reference to the related inspection schedule / procedure sheet / work order and will remain attached with the relevant schedule / work orders.

CONTROL AND USE OF CUSTOMER SUPPLIED INSPECTION SCHEDULE / WORK ORDER

a).

As an approved CAR 145 maintenance organization, Deccan Aviation will carryout all maintenance tasks as per approved maintenance programme / inspection schedule.

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b).

However if an operator / maintenance organization supplies their maintenance programme / inspection schedule / work order / repair order for carrying out a specific maintenance action, the same will be carried out and certified.

c).

Deccan Aviation CRS will be issued for such work carried out on the customer aircraft following the customer provided maintenance programme / inspection schedule / work order or repair order.

SELF MONITORING / INTERNAL SPOT CHECK a).

Self monitoring of the quality of work carried out by various maintenance personnel including support staff will be carried out by the Quality engineers / auditors on random basis, whenever work is carried out on the aircraft / component.

b).

Such monitoring will otherwise be addressed as Internal Spot Check and objectionable observations will be recorded as Non-Conformance, after conducting audit i.a.w MOE 3.2 & 3.3

c).

Non-compliance recorded will be intimated to the concerned person, whose actions or the results of his action, found to be non-compliant, the base engineering manager / station engg. In-charge and the Quality Manager.

d).

On completion of corrective action, the person responsible will intimate the corrective action to the Quality Manager. Quality Manager will evaluate the action taken report and close the NonConformance.

e).

Accountable Manager will be briefed about the Non-conformance and corrective action during the quarterly review meeting between Accountable Manager, Chief Engineer and the Quality Manager.

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TECHNICAL (MAINTENANCE) RECORDS CONTROL (Ref; CAR 145.A.55 & EPM Section -3, Chapter – 17)

a).

Control of maintenance records (technical records) related to aircraft maintenance and its retention for a defined period is of utmost importance to prove the airworthiness status of the aircraft / component.

b).

This section outlines the policies, requirements and brief procedures regarding completed technical records control related to maintenance of aircraft and components.

c).

Detailed procedure for control of technical records is provided in EPM Section-3, Chapter-17.

2.14.1

COMPANY POLICY a).

A system will be maintained and compliance by the respective support / certifying personnel & technical services personnel will be monitored for recording of all details of maintenance work carried out in the appropriate document.

b).

As a minimum, the records necessary to prove that all requirements have been met for issuance of the certificate of release to service will be retained for a period of 2years from the date the aircraft or the component to which the work relates was released from the organization. (CAR 145.A.55.a refers)

c).

Copy of the certificate of release to service will be provided to the aircraft operator, together with a copy of any specific approved repair / modification data used for repairs /modifications carried out. For example: Flight Manual Supplement for modifications, Maintenance or Operational information, restriction, limitation for any repair activities carried out.

d).

A copy of all detailed maintenance records (work orders & inspection schedules) and any associated maintenance data will be retained for two years from the date the aircraft or component to which the work relates was released from the organization. (CAR 145.A.55.c refers). However, records of aircraft / engine / propeller such as manufacturer / Indian logbooks, component history cards will be maintained permanently, till the time the airframe / engine / propeller / component is in use

2.14.2

SYSTEM FOR CONTROL, STORAGE AND RETRIEVAL

a).

Technical records of aircraft exists in two means as given below; 1.

Soft copy – Web based software namely “FLYPAL”.

2.

Hard copy documents such as Tech. Logbook, aircraft, engine, propeller, avionics equipment logbook, history cards for life limited / TBO components, History card for AD’s SB’s, etc.

b).

Control of computer based maintenance record system is explained in MOE 2.21.

c).

Control of technical records in hard copies are explained below in table format, document wise;

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

No

Type of Record

a

Tech. Logbook (containing first sheets)

b

Second sheet of Tech. Logbook

c

Third sheet of Tech. Log book

MAINTENANCE PROCEDURES

Responsible person

Certifying staff attached with the aircraft is responsible for the control. If certifying staff doesn’t travel with the aircraft, technician attached to the aircraft is responsible for the control.

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System for control of Record 1. Tech. Logbook will generally remain with the aircraft. 2. Once completed, the logbook should be handed over to the Tech. Officer (sub-base) who will then sent it to the Tech. Officer (records). This sheet is will be Removed sheets should be removed after the last preserved and handed over flight of the day. to the Tech. Officer (subThis sheet is required to be base) at the earliest removed after pilot’s available opportunity. acceptance (considered as pilot’s acceptance Tech. Officer (sub-base) document for the aircraft) will send it to Tech. of the aircraft, but before Officer (records), once the first flight of the day. every three months. Work order booklet will remain with the aircraft.

d

Work order Booklet

Certifying person attached with the aircraft

Any time a certifying person intends to carryout any inspection other than BFF / Transit / ALF inspection, including rectification of minor defects, he will raise the work order, carryout the work and certify in the work order. Completed work order will be faxed for immediate information and then couriered from aircraft location or handed over to Tech. Officer (sub-base). Tech. officer (sub-base) will collect the work orders and send it to Tech Officer (records) on weekly basis.

e

f

g

Working copies of airframe, engine, propeller and radio equipment logbooks

Tech. Officers at subbase or Engineer incharge of line station is responsible for the control of the document. Support / Certifying staff carrying out the work will obtain the logbook from Tech. Officer (sub-base), make necessary entries and return the logbook

Original airframe, engine, propeller and radio equipment logbook

Tech. Officer (records) at Bangalore will be responsible for the control of the logbooks

History cards – SLL components, TBO components, ADs, Mandatory Mod’s and Service Bulletins.

Tech. Officer (records) at Bangalore will be responsible for the control of the history cards

All entries in this logbook will to be carried out by the support / certifying staff carrying out the work on the aircraft. Entry in the working copy will be considered to be the compliance of the regulatory requirement of completion of logbook entry within 48hrs of the completion of the logbook. Tech. officer (sub-base) will not make any entries in this logbook. Entries in this logbook for the aircraft, engine, propeller & radio equipment will be made by Tech. Officer (records) and verified by the Manager- Tech. services. Manager – Tech. services will affix his signature and stamp to validate the entry. Tech. Officer (Records) will make entries in the history cards, based on the work order received from the Tech. Officer (sub-base).

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d).

All technical records will be handled by the respective responsible persons (as explained in the table above) and unauthorized access / entries will be prevented by safe keeping of all documents, under lock and key.

e).

Tech. logbooks will remain with the aircraft, till exhaustion of the sheets and then returned by the certifying staff completing the last sheet to the Tech. Officer (sub-base/line station). Tech. Officer (sub-base/line station) will return the tech. logbook to the Tech. Officer (records) at Bangalore.

f).

Removed sheets (second /third) of tech. logbook will be returned to the Tech. Officer (sub-base /line station) on the same day or at the earliest by the certifying staff. Tech. officer (sub-base / line station) will send the aircraft wise removed sheets to Tech. Officer (records) once in three months.

g).

Work orders completed by the certifying staff will be handed over to the Tech. officer, if the aircraft is operating from the same location. If the aircraft is operating at different location, the same will be faxed to Tech. Officer (sub-base) for immediate information and then couriered to Tech. Officer (sub-base). Tech. Officer (sub-base) will collect the work orders and send to Tech. Officer (records) on weekly basis.

h).

Tech officer (records) will scan all the copies of the work order and attached documents and retain it in the aircraft wise folder in his system. Back up copy of the scanned work orders will be taken in portable hard disc, every 15days along with back up of the FLYPAL database.

i).

Working copy (in similar format of original logbook, but clearly printed as “Working Copy”) will be maintained at all stations, where the aircraft is operating. Support / Certifying staff will complete the work order and make entries in the working copy of the logbook. This copy will provide ample information to the maintenance personnel and to the officer’s of Regional / Sub-Regional office of Civil Aviation Department about the subject aircraft maintenance history.

j).

Working copy logbooks will remain in sub-base / line station where the aircraft is operating, so that the certifying staff can make the entries within the 48hrs after completion of the work.

k).

Original Logbooks pertaining to airframe / engine / propeller / radio will be retained at Technical Services section at Bangalore and will be handled by Tech Officer (Records).

l).

All original logbook entries will be made by Tech .Officer records, based on the work order received from line / sub-base stations.

m).

Logbook entries will have an annotation “XX hrs inspection carried out by AME No. XXXX under work order no. DAX/2007/01/01/09”. Same will be signed and stamped under the seal of the company, by Manager – Technical services.

n).

All entries will be made in indelible ink only. No whitener will be used to hide the wrong entries. In case of a wrong entry having been made, the same will be stroked by a single line and correct entry made thereafter.

o).

Whenever a SLL / TBO item is replaced on the aircraft, removal / installation entry of the component on the respective history card will be made by the Tech. Officer (Records), based on the removal / installation details provided in the work order.

p).

Technical officer (records) at main base and Tech. officer (sub-base) will follow the instructions and carryout as given below to enable proper storage and retrieval of records at all times; 1. 2.

All records at main base / sub-base will be stored in a safe manner so that data loss by means of theft, damage due to fire, flood could be averted. Each aircraft technical records will be kept in cupboards using the registration marks for location identification.

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Loose records as history cards will be kept in a folder with index providing the number of history cards in a folder.

4.

Each logbook / folder will be given a serial number (volume numbers, will be provided if more than one volume) uniquely identifiable with the aircraft registration as prefix. Index for the total number of logbook / folder will be maintained.

5.

Incoming / Outgoing (including transfer for any reason) records will be documented in a register containing following information, so that records can be traced, when transferred from one place to another; Description of the record. Dispatched to station (Name) Dispatch Mode and Date ( Hand carried / courier /Airfreight / postal) Dispatch details (courier waybill no. / AWB/Regd. Post acknowledgement). Detail of receipt acknowledgment from the person who received it.

q).

Back up hard disc will be stored in steel (fire proof cupboard) at a different location (building) other than the location, where all the hard copy documents are stored.

r).

Manager – Technical Services will be responsible for controlling the storage and retrieval of all technical records.

CONTROL OF ACCESS TO RECORDS

a).

All aircraft technical records will be kept in cupboards under lock and key. Two keys will be made, one will remain with the Tech. Officer (records) and another will remain with the Manager – Technical services.

b).

Access to the technical records cupboards will be limited to Tech. Officer (Records / software) and Manager-Technical services. Management personnel will have access to all records at any time.

RECORD – KEEPING SYSTEM – (ESSENTIAL RECORDS) a).

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3.

i). ii). iii). iv). v).

2.14.3

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Record keeping system for various essential records related to the airframe / engine / propeller / component are explained below in various sub-paragraphs.

LOG BOOKS / COMPONENT HISTORY CARD / SERVICEABLE OR PARTS ACCEPTANCE TAG

a).

Working copies of the logbooks will be available at sub-base / line station to enable the certifying staff to make entries in the logbook within 48hrs after completion of the work.

b).

Original copies of the logbook will be available at the main base (Bangalore) to enable the Technical officer (records) to make entries in the logbook, on receipt of the completed work order.

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c).

History cards of all components will be available at the main base (Bangalore) to enable the technical officer (records) to make entries on receipt of the completed work order.

d).

A part / component when issued to maintenance from stores will be issued with a Serviceable or Parts Acceptance Tag. After installation of the component on the aircraft or component support / certifying staff will attach the serviceable tag with the respective work order and return the work order to Tech. Officer (Records).

ENGINE MODULE RECORDS

a).

Lives of engine module are monitored as per approved SLL, TBO schedule in the computer based FLYPAL software. These requirements will be included in Aircraft Maintenance Programme.

b).

All entries in the ORIGINAL module records will be made by Technical officer – Records based on the following information provided by the certifying staff on the completed work order;

1.

Description, Part number and Serial number of the installed component.

2.

Life completed in terms of Hrs /Calendar period /RINS/cycles/landings etc of the installed component obtained from copy of the Authorized Release Certificate / parts acceptance tag, which are available with the component.

3.

Date and Hrs (airframe hrs /engine hrs /propeller hrs) at the time of installation, from the working copy of the logbook.

4.

Description, Part number and serial number of the removed component.

5.

Date and Hrs (airframe hrs / engine hrs /propeller hrs) at the time of removal, from the working copy of the logbook.

6.

Life completed in terms of Hrs / calendar period / RINS / cycles / landings etc of the removed component from the working copy (if installation entry is available).

Note: If the life of removed component is not available in the working copy of the logbook the same can be obtained from the Tech. Officer (software / records) by phone /mail or instruction can be provided in the work order to the Tech. Officer to (records) find out from the software or history card and update the work order.

c).

When an engine module is sent for repair / overhaul, original module records will be sent to the repair agency to make entries on the original module records.

d).

Photocopy of the engine module records will be retained by the Tech. Officer (records), when the component is sent for repair / overhaul.

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SHOP LEVEL HISTORY CARDS

a).

Components received at the shop (Battery / wheels & brake / helicopter components) for servicing, repair or overhaul will be allotted a shop component history card (Form No. 061) and work carried out on the item will be entered in it by the Tech. Officer (shop records).

b).

Shop component history card will have the following minimum information; 1. 2. 3. 4. 5. 6. 7. 8.

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PAGE NO : 62

Description, Part Number, Serial Number. Received from Customer / Aircraft / Date Life completed when received at shop. Work required to be carried out when received. Detail of work carried out. Work order reference number Due for next servicing / inspection /overhaul (if applicable) Dispatched on Date.

SCAN COPY OF TECHICAL RECORDS a).

Hard copy technical records pertaining to the aircraft maintained at various locations under the organization approval will be scanned at Bangalore base every month on routine basis as on last day of the month.

b).

Various types of documents to be scanned are listed below; 1. 2. 3. 4.

First sheet of Tech. Logbook. Work order with attachments (Including parts tag / release certificate, but excluding inspection schedules) Original logbooks (airframe, engine, propeller & radio equipments) Component history cards.

c).

Records of aircraft (including CRS) visiting any of the sub-base for one-off maintenance activity will be scanned and stored by the Tech. Officer (at sub-base) and a copy sent to Tech. Officer (records) once in three months on routine basis as on last day of March, June, September and December of the year.

d).

Records of components (including history cards and CRS) visiting the shop for maintenance activity (one-off or regular) will be scanned and stores by the Tech. Officer (shop) once in three months on routine basis as on last day of March, June, September and December of the year.

e).

Scanned copies of the technical records will be stored in the portable disc and safely kept at a different location than the location where the hard copies of technical records are stored.

f).

Scanned copies of the back up information will help to rebuild the records, if the technical records are lost in transit or due to fire or flood.

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DISPOSAL OF RECORDS ON TRANSFER OF AIRCRAFT a).

Hard copy Records of aircraft owned by Deccan Aviation Limited will be maintained till the time the aircraft is permanently withdrawn from use or will be handed over to the new owner on transfer of aircraft title.

b).

Scanned copy records will be maintained for a period of two years from the date the aircraft is permanently withdrawn from use or title transferred to the new owner.

c).

In case of customer aircraft being maintained by Deccan Aviation, all logbooks, history cards, release certificates, parts acceptance tags and other records of aircraft will be transferred to owner on termination / conclusion of maintenance contract.

d).

However scanned copy of all the technical records will be maintained by Deccan Aviation for a period of two years from the date conclusion of contract.

e).

Technical Services manager will ensure that proper record is kept for transfer of these records.

LOST OR DESTROYED RECORDS (RECONSTRUCTION - DGCA ACCEPTANCE)

a).

Reconstruction of lost or destroyed records is important to retain the aircraft / component in continuous service.

b).

Data will be collected from scanned copies (i.a.w MOE 2.14.4.4) of records to reconstruct the lost or destroyed records.

c).

Data from the software / back up copy will be printed out and used as reference to reconstruct the lost records.

d).

Manager – Technical service will initiate reconstruction of records using scanned back up records. On completion of re-construction, Manager – Technical service will put up the reconstruction records to Quality Manager for acceptance.

e).

Quality Manager will scrutinize the records and will stamp and affix the signature on the first and last page of the logbooks, history cards indicating the acceptance and submit it to respective regional airworthiness office for approval.

PROVISION OF RECORDS & CRS TO OPERATOR / CUSTOMER

a).

b).

For aircraft under maintenance contracts, following procedures will be followed; 1.

All technical records will be maintained as per MOE 2.14 and returned to the owner i.a.w MOE 2.14.4.5 (Disposal of records on transfer of aircraft).

2.

On completion of every scheduled or unscheduled maintenance activity (except BFF /Transit / ALF inspection), aircraft CRS will be issued. First copy of the CRS will be provided to operator (kept in the aircraft document bag at appropriate location).

For aircraft visiting the organization for one-off maintenance activity, all original technical records and the first copy of the CRS will be provided to the owner / customer on completion of the maintenance activity.

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c).

For components visiting the shop (one-off or routine), an internal history card will be created and updated whenever the particular serial number components visits the shop for maintenance. All original records and first copy of the CRS will be provided to the customer along with the component.

d).

One-off maintenance – all originals given – 2 scanned copy retained in CD/DVD format

RETENTION OF RECORDS (PERIODS – METHODS AND SECURITY) a).

Records and documents related to maintenance of aircraft, engines and systems will be preserved safely for the periods as required by DGCA and the same are elaborated in the EPM Section-3, Chapter -17

b).

All documents pertaining to each aircraft will be kept at the designated locations in the office of Technical Services section, under the control of Technical Officer (Records) and Manager – Technical Services.

c). d).

Access to documents will be restricted to authorized personnel only. All maintenance records will be stored in a safe way with regard to fire, floor and theft.

e).

Portable disc containing scanned copies of technical records and FLYPAL database will be stored in different location than the location where the hard copy documents are kept and in an environment that ensures they remain in good condition.

f).

All Maintenance records of the aircraft / component owned by organization will be retained till the time, the aircraft is owned by the organization.

g).

If an operator’s (customer) aircraft maintenance contract is terminated, all maintenance records of the aircraft will be returned to the operator (customer) of the aircraft. Scanned copy of records will be retained for a period of two years from the date of conclusion of the contract

h).

Maintenance records of the component (serviced by component shop) will be retained for a period of five years from the date of release and the scanned copy of the records will be retained for a period of 10years from the date of release.

i).

List of technical records and their retention periods are detailed in EPM Section-3, Chapter-17.

DESTRUCTION OF RECORDS a).

b).

All records which had been retained for the period listed in EPM section-3, chapter-17 will be destructed by Manager-Technical services after following the given procedure; 1.

Index of records required to be destroyed will be prepared by Manager – Technical services and submitted to Chief engineer for verification and acceptance to destroy.

2.

On receiving the acceptance from the chief engineer, the records will be put up to the Quality Manager for approval.

3.

On receipt of the approval from Quality Manager, all the technical records as per index will be destroyed by shredding only.

Records intended to be destroyed will never be trashed or thrown in to the dustbin.

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RECTIFICATION OF DEFECT ARISING DURING BASE / LINE MAINTENANCE (Ref: EPM Section-2, Chapter-6)

a).

This section outlines the policies, requirements and brief procedures regarding rectification of defects arising during base / line maintenance.

b).

Detailed procedure for defect recording, reporting and rectification is provided in EPM Section-2, chapter-6.

COMPANY POLICY a).

Defects noticed during operation or line maintenance of the aircraft by operation or maintenance personnel and action taken by certifying staff as per maintenance data, for rectification of the same will be recorded in the Tech. logbook.

b).

Defects noticed during base / shop maintenance and rectification taken as per maintenance data will be recorded in the additional work to be carried out column in the inspection / servicing schedule.

c).

No defect rectification will be carried out by any support / certifying staff based on verbal communication of defects.

RECORDING OF DEFECT ENCOUNTERED DURING LINE / BASE / SHOP MAINTENANCE. a).

Defect noticed by the operating crew or maintenance personnel during operation or line maintenance of the aircraft will first be recorded by the person observing the defect in the tech. logbook. Such recorded defects will be transferred to the work order for rectification action. Certifying staff will enter the work order number in the tech. logbook for quick cross reference.

b).

Defect noticed by the non-certifying / support / certifying staff during base or shop maintenance of the aircraft will be recorded as observation in the additional work to be carried out columns in the inspection schedule. Defect recorded in the additional work to be carried out will then be transferred to the work order for rectification action. Support / certifying staff will enter the work order number in the inspection schedule (in additional work carried out column) for quick cross reference

RECTIFICATION (SIGN-OFF) OF LINE / BASE / SHOP MAINTENANCE DEFECTS.

a).

Defects noticed during operation or line maintenance, first entered in tech. logbook, then transferred to work order will be rectified by the certifying staff using updated troubleshooting manual or other maintenance data.

b).

Defects noticed during base / shop maintenance, first entered in the additional work required to be carried out column in the inspection schedule, then transferred to the work order will be rectified by support / certifying staff using troubleshooting manual or other maintenance data

c).

Work order raised for defects found during line / base / shop maintenance will contain the nature of defect reported / observed.

d).

After defect rectification is completed, work order will be closed by the certifying staff concerned and CRS issued with reference to the nature of the defect and the work order number. CRS number will also be entered in the work order for cross reference.

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e).

Support / certifying staff rectifying the defect will enter the detail of the defect found and rectification action in the respective (airframe / engine / propeller / radio equipment) working copy logbooks available at the station, where the aircraft is operating.

f).

Major defects noticed & rectification action taken during shop maintenance of a component and transferred to the work order will also be reflected in the history card of the component, so that defect history of the component will be known to the shop maintenance staff during its next visit to the shop.

g).

Detailed procedure for recording and rectification of defect is explained in EPM Section-2, Chapter-6

CARRYING FORWARD DEFECTS TO FUTURE MAINTENANCE INSPECTION (CONTROL AND ACCOUNTABILITY).

a).

If defect covered under MEL is observed during line operation at outstation (not a usual night halt station), then MEL will be invoked by operating crew or certifying staff.

b).

If MEL is invoked by the certifying staff approved for BFF / Transit / ALF inspection and aircraft flown under MEL, certifying staff rectifying the defect will review the maintenance action taken by the certifying staff at outstation for invoking the MEL.

c).

No defects will be carried forward on the aircraft, if the defect is observed during base maintenance of aircraft owned by the organization as an operator. Similarly, no defects will be carried forward on aircraft under regular maintenance contract with the organization. Aircraft will be grounded till the time the defect is rectified and then released to service.

d).

If new defect or previously release incomplete maintenance work is identified during the base maintenance of aircraft under one-off maintenance activity, the defect will be brought to the attention of the owner / operator for the specific purpose of obtaining agreement to rectify such defects or completing the missing elements of the previously completed work order. In the case, where the operator declines to have such maintenance carried out, then the certifying staff will issue a CRS within the approved aircraft limitation. Certifying staff will enter such fact in the aircraft CRS before the issue of such certificate.

e).

Detailed procedure of invoking and revoking of MEL is explained in EPM Section-4, Chapter-6.

ANALYSIS OF DEFECTS AND RECTIFICATION – HUMAN FACTORS – MAITNENANCE PROGRAMME IMPLICATIONS

a).

All major defects and repetitive minor defects will be analyzed in a meeting conducted every three months, for its cause by a team comprising of chief engineer and Type rated Engineer or Manager – Technical Services and Quality Manager using Defect Evaluation Form

b).

Rectification action taken and preventive measures required to be followed will also be discussed while closing the defect analysis.

c).

Above meeting will be conducted on occurrence of major defect / minor repetitive defect / receipt of any investigation report from repair agencies & before releasing the aircraft to service. Result of such defect evaluation will be intimated thru Technical circulars as preventive measures to avoid similar defects arising on the same or other aircraft.

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d).

If a Human factor is found to be the reason for the defect, a suggestion to the Accountable Manager will be made to initiate conduct of additional training to the concerned person and also to persons discharging similar duties. If fatigue / over load of work are found to be the reason, suggestion will be made to streamline the work allotment.

e).

During defect analysis, if it is found that improvement to maintenance programme is required to be made by increasing the frequency of inspection schedule, then the Chief Engineer will initiate the amendment to the Aircraft Maintenance Program and submit to Regional Airworthiness Office for approval.

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RELEASE TO SERVICE PROCEDURE (Ref: CAR 145.A.50 & EPM Section-2 Chapter 7)

a).

This section outlines the policies, requirements and brief procedures regarding issue of certificate of release to service for aircraft under line / base maintenance and for components under shop maintenance.

b).

Detailed procedure for release of aircraft to service is provided in EPM Section-2, Chapter-7.

COMPANY POLICY

a).

On completion of any maintenance activity (except BFF / Transit / ALF inspection) including all types of defect rectification, a CRS will be issued by a certifying staff specifically authorized to issue CRS.

b).

Certificate of Release to Service will be issued i.a.w CAR 145.A.50, by the authorized certifying staff on behalf of the organization, after ensuring the following; 1.

Maintenance ordered as per due report / work order has been properly carried out by the support /certifying staff.

2.

Latest Maintenance data is available and is used for carrying out maintenance.

3.

There are no non-compliances which are known, that may hazard seriously the flight safety.

c).

New defect or previously released incomplete maintenance work identified during the base / line /component maintenance will be brought to the attention of the aircraft owner / operator for the specific purpose of obtaining agreement to rectify such defects or completing the missing elements of the previously completed work order. In the case, where aircraft operator declines to have such maintenance carried out, then the certifying staff will issue a certificate of release to service within the approved aircraft limitations. Certifying staff will enter such fact in the aircraft certificate of release to service before the issue of such certificate.

d).

Component certifying staff will issue a component CRS at the completion of any maintenance on a component in an approved shop, whilst off the aircraft. Issue of Authorized Release Certificate, CA Form No.1 for Component will constitute the release of the component to service. Components belonging to Deccan Aviation, will also be issued with Component Certificate of Release to Service (CA Form No.1) for internal release to service.

CRS ISSUE CONDITIONS & CRS STATEMENT

a).

It is a requirement to issue a CRS for scheduled maintenance, overhaul, repair, replacement, modification, mandatory inspection and defect rectification. The CRS must be issued by a duly authorized certifying staff when satisfied that all of the required maintenance of the aircraft or aircraft component has been properly carried out by the support staff of CAR-145 approved maintenance organization using: 1)

Up to date maintenance data / instructions including manuals, drawings, specifications, DGCA mandatory modifications, standard practices and company procedures.

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2)

Recommended tools and test equipment, which are within its current calibration date (if applicable).

3)

Proper working environment & approved manpower for the work carried out.

4)

Approved material with proper release certification issued from bonded stores.

b).

Issuing a CRS certifies (states) that the work specified except as otherwise stated, is carried out in accordance with CAR-145 and in respect to that work, the aircraft / aircraft component is considered ready for release to service.

c).

Detailed procedure for release to service is given in EPM Section-2, Chapter-7.

ISSUE OF CRS AFTER BASE MAINTENANCE

a).

Certifying staff will issue CRS for an aircraft after completion of all Maintenance activity at base / sub-base facility.

b).

When a multiple work is carried out under a single work package, one CRS will be issued by summarizing all the work carried out with cross reference to the serial number of the related work orders.

c).

Certifying staff, specifically authorized by the quality manager will only issue CRS for whole aircraft after completion of base maintenance inspections. However, the individual support / certifying staff will be solely responsible for the quality of work carried out and signed off by them in the inspection schedule / procedure sheets / off-job sheets.

d).

Maintenance certification in the logbook or history card by the support / certifying staff will refer to the revision status of the maintenance data (Maintenance Manual, Repair & Overhaul Manual) used for carrying out the activity.

ISSUE OF CRS AFTER LINE MAINTENANCE

a).

Certifying staff will issue CRS for an aircraft after completion of all line maintenance activity (except transit inspection & after last flight inspection) including all types of defect rectification.

b).

Certification in the tech. log column after carrying out BFF / Transit inspection will be considered equivalent to CRS certification. Hence no separate CRS will be issued after carrying out BFF inspection.

ISSUE OF CRS AFTER DEFECT RECTIFICATION

a).

A CRS will be issued after defect rectification by line / base maintenance certifying staff on ensuring the following; 1. 2. 3. 4.

Defect is recorded in detail in the tech. log. Work carried out as per work order generated by the certifying staff as per MOE 2.10.2 Trouble shooting and rectification carried out as per maintenance manual. Relevant rectification action recorded along side the defect record in the Tech. Logbook.

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ISSUE OF CRS WITH IN-COMPLETED WORK

a).

Aircraft will not be released to service with in-complete inspection / mandatory maintenance work. Hence NO CRS will be issued with un-completed (mandatory) work. Mandatory maintenance work here refers to various mandatory inspections, replacement of life expired SLL /TBO components, Airworthiness Directives, Alert Service Bulletins and Mandatory Modifications etc.

b).

If a new defect or previously in-complete maintenance work is identified during base / line maintenance, the same will be informed to the aircraft owner / operator by the base engineering manager or chief engineer to obtain concurrence for carrying out the defect or missing elements of previously completed maintenance work order.

c).

If operator agrees to carryout the work on his aircraft / component, the same will be carried out and CRS issued.

d).

If operator refuses to have such maintenance work accomplished in his aircraft / component, then the operator will provide DGCA approval to defer such work. On receipt of such approval to defer the work, the certifying staff will issue CRS within the approved aircraft limitations. Certifying staff will enter the approval (letter No.) of the authority to defer such work, in the aircraft certificate of release to service, before issue of such certificate.

ISSUE OF CRS AFTER SHOP MAINTENANCE

a).

CA Form-1 (Authorized Release Certificate) will be issued by the certifying staff after completion of any maintenance on the component whilst off the aircraft at a DGCA approved shop under CAR-145 process.

b).

A certificate (CA Form-1) will not be issued for any item when it is known that the item is unserviceable except in the case of an item undergoing a series of maintenance processes at several maintenance organizations approved under CAR-145 and the item needs a certificate for the previous maintenance process carried out, for the next maintenance organization approved under CAR-145 to accept the item for subsequent maintenance processes. Clear statement of limitation will be endorsed in block 13 (of CA Form-1), by the certifying staff.

c).

Maintenance certification by the support / certifying staff will refer to the revision status of the maintenance data (Maintenance Manual, Component Repair & Overhaul Manual) used for carrying out the activity

SIGN OFF AFTER MAINTENANCE TASK COMPLETION a).

Sign off is a statement / confirmation by the competent person performing or supervising the work, that the task or group of tasks have been correctly performed. A sign off relates to one step in the maintenance process and is therefore different to release to service of the aircraft.

b).

In order to prevent omissions while carrying out any maintenance activity, each item of inspection will be signed off by the support / certifying staff, in progressive manner, as soon as the inspection or work is completed.

c).

No support / certifying staff will follow the practice of accumulating the signing off work, till the end of the day / shift.

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d).

Work carried out by not authorised personnel (i.e. temporary staff, trainees) will be checked by support / certifying personnel before the same is signed off.

e).

Support / certifying staff signing the inspection item will do in such a way that the signature will not deface the stamp

f).

Support / certifying staff will record the inspection starting time & date and closing time & date in the appropriate columns provided in the inspection schedule.

CERTIFICATION - IDENTITY - QUALIFIED STAFF

a).

Quality Manager will issue company approval to qualified & competent support staff for carrying out and signing off the inspection items and defect rectification activities.

b).

Quality Manager will issue certification authorization to qualified & competent certifying staff who are then eligible to issue CRS.

c).

Support / Certifying will affix their signature and the stamp (approval /authorization number) given to them, without defacing each other.

d).

Identity of the individual support / certifying staff can be established from the company approval / authorization number allotted by quality manager.

e).

Quality Manager will maintain a list of all support / certifying staff (as per MOE 1.6) issued with company approval / authorization.

CROSS-REFERENCE TO WORK PACKAGE a).

All maintenance activity will be carried out by the support staff, after generating a work order as per MOE 2.10.2.

b).

On completion of the single / multiple maintenance activity, under single / multiple work orders, a single CRS will be issued by summarizing all the work carried out, with a unique cross reference (work order numbers) to the work pack containing full details of maintenance carried out. CRS will have cross reference to all the work order numbers related to it.

c).

Dimensional information will also be retained in the work order / package records.

RE-RELEASE OF COMPONENTS REMOVED SERVICEABLE FROM A/C a).

Any component removed from the aircraft as serviceable will be issued with a “Serviceable tag” by the support / certifying staff and deposited to the stores.

b).

Item will be stored in the bonded stores and the same will be re-released to maintenance with out a requirement of re-certification.

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2.16.12

MAINTENANCE PROCEDURES

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RELEASE OF AIRCRAFT AFTER FIMTENT OF COMPONENT WITH SUITABLE CRS (Ref: CAR 145.A.50.f)

a).

If an aircraft is grounded at a location other than the main line station or main maintenance base due to the non-availability of a component with the appropriate release certificate, it is permissible to temporarily fit a component without the appropriate release certificate for a maximum of 30 flight hours or until the aircraft first returns to the main line station or main maintenance base, whichever is the sooner, subject to the aircraft owner agreeing to it and the said component having a suitable release certificate but otherwise in compliance with all applicable maintenance requirements.

b).

Such components will be removed by the above prescribed time limit unless an appropriate release certificate has been obtained in the mean time under CAR 145.A.50 (Certification of Maintenance) and accepted into bonded stores under CAR 145.A.42 (Acceptance of components) & MOE 2.2 (Acceptance/Inspection of components & materials).

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.17

2.17.1

2.17.2

2.17.3

MAINTENANCE PROCEDURES

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RECORDS FOR THE CONTRACTED OPERATOR (CUSTOMER) (Ref: CAR 145.55 (c) and EPM Section-1, Chapter 20 and Section-3, Chapter-17)

a).

This section outlines the policies, requirements and brief procedures regarding record keeping, arrangements for processing and retention of operator’s maintenance records.

b).

Detailed procedure regarding various records to be maintained for the customer (operator) is provided in EPM Section-1, Chapter-20 and Section-3, Chapter-17.

COMPANY POLICY a.

Original Maintenance technical records pertaining to the customer’s aircraft will be updated, stored and retained till the time the aircraft is maintained by the company.

b.

On conclusion / termination of the contract, all records will be returned to the customer and scanned copy of the records will be retained for a period of two years from the date of conclusion / termination of the contract.

CONTRACTED OPERATOR’S RECORD KEEPING.

a).

As part of the maintenance contract terms and conditions, proper entries of all maintenance activities in appropriate aircraft documents will be carried out by support / certifying / Technical services personnel.

b).

Operator’s maintenance records will be controlled by Deccan Aviation as per MOE 2.14 (Technical Records Control).

c).

Detailed procedures for control of Technical records are provided in Section-1, Chapter-20 and Section-3, Chapter-17

ARRANGEMENTS FOR PROCESSING AND RETENTION OF OPERATOR'S MAINTENANCE RECORDS

a).

All records of maintenance work carried out by maintenance personnel on customer aircraft will be processed and retained in Technical Service Section by Tech. Officer (records & software) to provide maintenance personnel with information essential in adhering to the established maintenance programme.

b).

Original Records of operator’s (customer’s) aircraft will be maintained till the time the maintenance contract is in place and returned thereafter to the customer.

c).

Scanned copy of all detailed maintenance records and any associated maintenance data will be retained for a period of two years from the date of conclusion / termination of maintenance contract.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.18

2.18.1

MAINTENANCE PROCEDURES

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REPORTING OF OCCURENCES ( MAJOR DEFECTS, INCIDENTS & ACCIDENTS) (Ref: CAR 145.A.60, EPM Section-3, Chapter-1 & 2)

a).

This section outlines the policies, requirements and brief procedures regarding reporting of various occurrences on the aircraft / component such as Major Defects, Incidents, Accidents, Investigation and retention of data related to occurrences.

b).

Detailed procedure for internal and external reporting of occurrences are provided in EPM Section-3, Chapter 1 & 2, Section-2, Chapter-6

COMPANY POLICY

2.18.2

a.

Occurrences (Major defects, Incidents & Accidents) or any condition of the aircraft or component identified by the organization that has resulted or may result in an unsafe condition that hazards seriously the flight safety will be reported to Airworthiness / Air-safety offices at respective regional or sub-regional airworthiness office of Civil Aviation Department, state of registry (in case of foreign registered aircraft) and to the type certificate holder (organization responsible for the design of the aircraft or component).

b.

Internal occurrence reporting will be established in the organization to enable collection and evaluation of information for taking necessary preventive measures.

c.

Reports will be prepared in a form and manner to ensure that they contain all pertinent information about the condition of the occurrence and the evaluation results known to the organization.

d.

Copy of the occurrence report will be provided to the owner / operator (customer) of the aircraft, who has entered into the maintenance contract with Deccan Aviation, for maintenance of their aircraft / component.

REPORTABLE OCCURENCES & REPORTING OF OCCURENCES TO THE DGCA / OPERATOR / MANUFACTURER. (Ref: EPM Section-2, Chapter 6 & Section 3, Chapter 1 & Chapter 2)

a).

Occurrences that are reportable (internal & external) to various authorities are given below Occurrences

Minor Defects

Repeating Minor Defects

Reportable By

Report to

Period - Means

Defect Entry to be made in Tech. Logbook by operating crew or certifying staff. Certifying staff will transfer the defect entry to work order and then carryout rectification action and close the work order. Tech log defect entry will be closed with a brief rectification action and cross reference to the work order number.

Engineer in-charge / Base Engg. Manager

Chief Engineer Quality Manager Manufacturer

Immediately after repeating nature is confirmed, by mail or telephone

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

Major Defects or Damage requiring major repair, excluding incidents or accidents.

MAINTENANCE PROCEDURES

Maintenance & Operation Personnel Engineer in-charge / Base Engg. Manager Base Engg. Manager/ Chief Engineer Quality Manager

Incidents / Accidents

Maintenance & Operation Personnel Engineer in-charge / Base Engg. Manager Base Engg. Manager/ Chief Engineer Quality Manager

Engg. In-charge / Base engineering manager Chief Engineer Quality Manager Manufacturer RAWO – Bangalore & Local Airworthiness Office

Engg. In-charge / Base engineering manager Chief Engineer Quality Manager Manufacturer RAWO – Bangalore & Local Air-safety and Airworthiness Office

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Immediately by Telephone Immediately by Telephone Immediately by mail / fax Immediately by Telephone. In writing within 72hrs of occurrence

Immediately by Telephone Immediately by Telephone Immediately by mail / fax Immediately by Telephone. In writing within 72hrs of occurrence

b).

Defects are classified as Minor or Major depending on its effect on the safety of the aircraft or its occupants and include defects discovered as a result of the occurrence of any emergency or in the course of normal operation or maintenance.

c).

Minor / Major Defect noticed by the operating crew or maintenance personnel during operation or line maintenance of the aircraft will first be recorded by the person observing the defect in the tech. logbook. Such recorded defects will be transferred to the work order for rectification action. Certifying staff will enter the work order number in the tech. logbook for quick cross reference.

d).

Minor / Major Defect noticed by the non-certifying / support / certifying staff during base or shop maintenance of the aircraft will be recorded as observation in the additional work to be carried out columns in the inspection schedule. Defect recorded in the additional work to be carried out will then be transferred to the work order for rectification action. Support / certifying staff will enter the work order number in the inspection schedule (in additional work carried out column) for quick cross reference

e).

All minor / major defects recorded will be trouble-shooted / investigated for taking appropriate rectification action.

f).

Any minor defect repeating more than three times on the same aircraft or appearing on three different aircraft within the span of one month period will be called as Repetitive Defect and the same will be considered as Occurrence and reported by Regional / Base Engineering Manager / Engg.in-charge to Chief engineer & Quality Manager using occurrence reporting form (Form No. 004). Such repetitive defects will be intimated to the manufacturer for suggestions to avoid the same and investigation carried out to prevent further occurrence. Investigation result of repetitive minor defect will be intimated to all maintenance personnel thru Technical circulars.

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2.18.3.2

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g).

All defects classified as Major or damages requiring Major Repair or those which are serious in nature and attracting public attention will be intimated to Regional Airworthiness Office, Bangalore (and Local airworthiness office, in case of line station) immediately on telephone and followed by written information with in three days (72hrs) of the occurrence of the defect.

h).

All major defects will be reported to the concerned aircraft / engine / propeller or component manufacturer for obtaining any recommendation to avoid such defects in future.

i).

All major defects will also be reported to the owner / operator of the aircraft for taking consensus about the repair action to be under taken on the aircraft / component.

PERSONS RESPONSIBLE FOR REPORTING (Ref: EPM Section – 3, Chapter – 2)

a.

2.18.3.1

MAINTENANCE PROCEDURES

PAGE NO : 76

Reporting of occurrences is divided into Internal / External reporting and the same is explained below.

INTERNAL REPORTING

a).

All maintenance and operation personnel will report any defects encountered by making an entry in the Tech. Logbook.

b).

Regional / Base engineering manager / Engg. In-charge will inform the Chief engineer and the Quality manager telephonically, as the information is received by them.

c).

Base engineering manager / Engg. In-charge will collect information, fill up the occurrence reporting form (Form No. 004) for all major defects or damages requiring major repair, incidents, accidents, repetitive minor defects (as defined in MOE 2.18.2.d), incidents, accidents and send it to Chief Engineer and Quality Manager, at the earliest, but within 48hrs of the occurrence.

EXTERNAL REPORTING

a).

Any occurrence (major defects, damage requiring major repair, incident & accident) reportable to DGCA (airworthiness & air-safety directorate) will be reported telephonically within 24hrs of occurrence of the defect. Defect reporting form with all relevant details will be submitted within 3 days (72hrs) of occurrence of the defect.

b).

Quality manager will report all major defects, damages requiring major repair, incidents & accidents to Regional Airworthiness office, Bangalore / Local airworthiness office (in case of sub-base / line station) for aircraft owned and/or operated by Deccan Aviation.

c).

Major defects / damages requiring repair, incidents & accidents pertaining to aircraft maintained by Deccan Aviation, but owned by customer / operator, will be reported by the Operator. This requirement will be reflected in the terms and conditions of the maintenance contract.

d).

Quality Manager will report telephonically, within 24hrs, all damages requiring major repair, incidents & accidents to the Office of Air-Safety in the region, where the damages, incidents or accidents has occurred as soon as information is received and detailed report as per Defect reporting form (Form No. 025).

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e).

Chief engineer will report all major defects, damages requiring major repair, incidents & accidents to the manufacturer of the aircraft, requesting for suggestions /recommendations to be followed to avoid such occurrences in future.

f).

Chief engineer will also intimate the owner of the aircraft about all mandatory reportable occurrences to take consensus for carrying out repair / rectification action.

g).

All reports will be made on a defect report form. (Form No. 025). Defect reporting form (Form No. 025) will include the following pertinent information; 1. 2. 3. 4. 5. 6. 7. 8. 9.

2.18.4

MAINTENANCE PROCEDURES

PAGE NO : 77

Name and approval number of the organization. Aircraft serial number and registration number. Date and time of defect identified. Place/ station Nature of defect as observed / experienced. Phase of operation during when, the defect was observed. Details of affected components (Part number/ Serial number/ hours/ cycles/ hours and cycles after last overhaul/ bench check) Immediate rectification action initiated Any other information evaluated

INVESTIGATION PROCEDURE AND FOLLOW UP ACTION (EPM Section-1, Chapter-12) a).

All major defects will be recorded, reported and investigated to find out the reason for the occurrence of the defect and necessary rectification action required to be taken to prevent further occurrence of the defect.

b).

Investigation will be carried out by type rated certifying staff & base engineering manager / chief engineer in very detailed manner with specific emphasis on the reasons for occurrence of such defects and also will try to enumerate steps to prevent recurrence in future.

c).

Manufacturer’s advice will be by sought where necessary (if reason for the defect is not confirmed), before finalizing the investigation report.

d).

If investigation facilities are not available with Deccan Aviation, then the component/ equipment will then be sent to a manufacturer approved agency capable of carrying out the detailed investigation.

e).

All efforts will be taken to ensure that the investigation is completed within a period of two months from the date of occurrence of the defect.

f).

The investigation results then will be evaluated by a team comprising of Quality Manager / Chief Engineer / Type engineer (or pilot if the defect is operational related) and necessary actions will be undertaken to avoid re-occurrence.

g).

Copy of the investigation report and action taken report will be submitted to the Regional Airworthiness Office, Bangalore and local airworthiness office (if the defect occurred at other stations).

h).

Observations / Suggestions / Recommendations resulting from investigation will be circulated to all technical personnel in the form of technical circulars issued i.a.w Section-2, Chapter-4.

i).

Detailed company procedures for investigation of major defects are provided in EPM Section-1, Chapter-12.

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CONTENTS OF INVESTIGATION REPORT & RETENTION OF DATA

a).

The final investigation report will contain the following information in addition to the information provided as per MOE 2.18.2 1. 2. 3. 4. 5. 6. 7.

b).

2.18.6

MAINTENANCE PROCEDURES

PAGE NO : 78

Identification of parts / systems involved. Life of affected component since new and since last inspection n terms of flight hours / landings / cycles. Contributing factors. Root cause for the occurrence Recommendation of the investigation team. Any disciplinary action, taken by the organization, against any of the employees. Whether the organization considers the investigation “closed” or “open” and if “open” the time it would take to complete the investigation.

All data pertaining to the defects and its investigation will be retained till the time; the organization has scope of approval to maintain such models of aircraft / component.

INVESTIGATION OF INCIDENTS & ACCIDENTS

a).

Investigation of incident and accident are subjects which fall under the purview of DGCA. Hence all necessary information, documents, facility, equipments required for investigation of incident or accident will be provided as required by the inspector of accidents or inquiry officer.

b).

Chief engineer and Quality Manager will provide necessary information and direct the staff to cooperate with the Inspector of accidents or Inquiry officer.

c).

Accountable Manager will appoint an Internal investigation team consisting of the Quality Manager and suitable operation / maintenance personnel to carryout an internal investigation of incident / accidents, without affecting the enquiry ordered by the authority or without disturbing the evidences.

d).

Internal investigation will prepare an investigation report in the same format as explained above in MOE 2.18.5.

e).

Recommendations provided by the internal investigation team will be executed without waiting for the investigation report / recommendation from DGCA.

f).

Detailed company procedures for investigation of major defects, incidents & accidents are provided in EPM Section-1, Chapter-12.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.19

2.19.1

2.19.2

MAINTENANCE PROCEDURES

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RETURN OF DEFECTIVE AIRCRAFT COMPONENTS TO STORE a).

This section outlines the policies, requirements and brief procedures regarding return of defective aircraft components removed from aircraft to store.

b).

Detailed procedure for return of defective components to store is given in Logistics Procedure Manual chapter- 12.

COMPANY POLICY

a).

Components identified as defective will be identified & tagged properly by attaching appropriate tag and returned to stores for necessary action.

b).

Repairable components will be sent to approved repair centre (company approved contractor) for repair.

c).

Components beyond economic repair will be termed Unsalvageable and scrapped for disposal.

LABELLING AND IDENTIFICATION.

a).

A component or any item that is removed from an aircraft suspected as defective will be issued with a ‘Unserviceable Tag’ by the support staff, specifying a reason for the suspicion and the part will be drained, blanked and packed as necessary.

b).

If the item is removed on completion of its life, the same will be reflected by the support staff in the status tag (scrap (unsalvageable) tag) attached to the part.

c).

If the item removed is for the reason that it contains a non-repairable defect, then the same will be reflected by the support staff as Unsalvageable (scrap) and handed over to stores for disposal as per scrap disposal policy. Such items will be defaced to an extent that it cannot be returned to service by spurious parts dealers. (CAR 145.A.42.d refers).

d).

If the item is removed due to premature failure, then the support staff will specify in the unserviceable tag that the failure investigation report is required.

e).

Any component returned as defective to the store without unserviceable tag will not be accepted in the store.

f).

Unserviceable tag will have the following information about the component or aircraft from which it was removed; 1. 2. 3. 4. 5. 6. 7. 8. 9.

Part Number, Description, and Serial Number (as applicable). Aircraft / Engine – Registration, Serial No. etc. Airframe / Engine – TSN, LSN, CSN, CSO Component – TSN, LSN, CSN, CSO Reason for removal. If repairable, what action is required? If premature failure, state whether investigation report required? Action to be taken by logistics personnel – Instruction to obtain component data from Tech. Officer (Records). Signature of support / certifying staff & Date

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.19.3

2.19.4

MAINTENANCE PROCEDURES

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g).

If the support staff is not aware of the component details (Hrs /landings /cycles/RINS) etc, then instruction be given to logistics personnel to obtain the data from the Tech. Officer (Records).

h).

The item will then be handed over to Stores for dispatching to a repair agency for repair or overhaul.

i).

The store inspector will verify that the item is correctly inhibited prior to dispatch for repair or overhaul. If not, the same will be reported to the engg-in-charge / base engineering manager for necessary action.

HANDLING AND MOVEMENT OF COMPONENTS

a).

Support & Certifying staff removing the component from the aircraft will handle the components properly and carryout necessary work to avoid damage to the component or the surrounding environment; 1. Plug all connectors to avoid damage to electrical contact pins, 2. Drain all fluids from the components, unless the fluid is required to prevent damage to the component. 3. Blank all openings / unions with suitable size plugs to avoid dripping of any fluid. 4. Wrap necessary packing materials around the component and box it with required amount of cushions to prevent damage during transit.

b).

Bulky components will be hoisted / lifted on to the packing boxes / vehicles to avoid damage to the components and injury to the personnel.

c).

Whenever a component is removed from the aircraft, the support staff will ensure that proper packing is available to move / transport the component from one place to another. Support staff will ensure that the component is wrapped with appropriate packing material and placed inside appropriate transportation box. Support staff will adhere and ensure any instruction provided in the maintenance manual for handling and transportation.

d).

Whenever a Component is sent from one station to other station, the proper final packing will be done by the stores in-charge, ensuring that all related documentation is in the packing or sent separately by courier, as appropriate for the situation.

e).

Movement of the component by air/road/rail transport is coordinated by the Stores In charge inside the country and by the Logistics - Head for international routes.

f).

The stores in charge / Logistics-Head will be responsible for co-ordination of movement of the parts, till it is received by the consignee.

STORAGE OF DEFECTIVE COMPONENTS

a.

Defective component, which could be returned to service after servicing will be sent for repair / overhaul at the earliest opportunity. Any Defective Component which is beyond economical repair will be disposed off as per Company’s Scrap Disposal Policy.

b.

Any component removed as defective from an aircraft under base maintenance will immediately be tagged with “Unserviceable tag (Repairable) or scrap tag”, by the support staff. Item may be handed over to stores inspector / in-charge immediately or kept in appropriate area near the aircraft and handed over to stores inspector / in-charge at the time of completion of work on the aircraft.

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2.19.5

MAINTENANCE PROCEDURES

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c.

Any component removed as defective from a component under shop maintenance will immediately be tagged with “Unserviceable tag (repairable) or scrap tag”, by the support staff. Item may be handed over to stores inspector/ in-charge immediately or kept in appropriate area in the shop till the work in the component is completed and then handed over to stores inspector.

d.

Defective components will not be kept in stores for longer period of time, except under financial compulsions / nil requirements. All necessary steps will be taken to service and return the components to bonded stores.

e.

Any repairable components will be in the store premises, clearly separated from incoming / quarantine / bonded / dispatch stores and marked as “Repairable Parts Store” / “Repairable Store”.

COMPONENTS "ON HOLD"

a).

When a complex snag exists in the aircraft, support staff may fit & remove multiple line replacement units to rectify the snag in the aircraft.

b).

During such situations, support / certifying staff may keep certain equipments removed from aircraft “ON HOLD”, till they zero upon the faulty unit.

c).

Such equipments will be issued with an ON HOLD TAG (means “Suspected Defect – Component kept on hold till confirmation”) and retained in appropriate shelf in the hangar or returned to stores.

d).

Stores inspector / in-charge will retain such items in “Repairable parts store” unless it is confirmed that the unit is serviceable and status tag changed to “Serviceable”, by appropriately qualified support staff.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.20

2.20.1

2.20.2

2.20.3

MAINTENANCE PROCEDURES

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DESPATCH OF DEFECTIVE COMPONENTS TO OUTSIDE CONTRACTORS (Ref: MOE L2.5 & LPM Chapter -13) a).

This section outlines the policies, requirements and brief procedures regarding dispatch of defective components for repair / overhaul / test to company approved contractors.

b).

Detailed procedures for dispatch of defective components to outside contractors are given in Logistics Procedure Manual chapter- 13.

COMPANY POLICY a).

All unserviceable components will be sent to company approved contractors only for repair, overhaul, test, calibration etc.

b).

Components sent to contractors will be attached with proper information about the component and its status.

c).

Investigation report will be sought for all prematurely failed components.

DESPATCH OF COMPONENTS / TOOLS FOR REPAIR / OVERHAUL / CALIBRATION

a).

The Head-Logistics will dispatch the defective components for repair / overhaul / calibration to DGCA / FAA /EASA approved agencies (company approved Contractors) only.

b).

He will maintain a register / computer record of all components dispatched for repair/ overhaul/ calibration.

c).

Tools & Equipments requiring calibration will be sent by tools & equipment in-charge, to approved shops with unserviceable tag mentioning reason for dispatch.

d).

All items sent for repair/ overhaul / calibration will be accompanied by a repair (purchase) order. Repair (purchase) order requirements are elaborated in MOE 2.1.5 (System of placing orders).

CONTROL OF DISPATCH, LOCATION AND RETURN

a).

Support / Certifying staff removing ESDS items from the aircraft will ensure that the items are packed in original ESDS packing and returned to the stores. They will also ensure that the components are drained off any fluid, electrical connectors are properly covered and units are preserved before returning the unit to stores

b).

Stores in-charge / station engineer in-charge is responsible for verifying preservation, proper blanking of components, packing of components in suitable boxes to ensure that no damage will occur in transit.

c).

The Logistics Control of Dispatch of Defective Components (Deccan owned or loaned components) to company approved Contractors will be under the supervision of Head-Logistics.

d).

The Head-Logistics will identify the one of the company approved facility to which the Defective Component can be sent for repair/overhaul and provide the necessary current approval documents of the organization to the Quality Manager.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

e).

f).

g).

2.20.4

2.20.5

MAINTENANCE PROCEDURES

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Before the Defective Component is sent for Repair / Overhaul the Quality Manager will apply to Regional Airworthiness Office, Bangalore for issuance of NO-OBJECTION Certificate (NOC) for the Component, in case the component is sent to a company approved facility outside the country for repair/overhaul. Head-Logistics will monitor for the compliance of the work as per the repair (purchase) order and organize for return of components from the approved facility. Components sent for repair / overhaul will be accepted into Bonded stores after repair / overhaul, only after Stores Inspector is satisfied about the Release to Service authorization, which accompanies the component.

IDENTIFICATION OF REQUIRED WORK a).

Support / certifying staff removing an item, due to various reasons such as premature failure, suspected faulty, requiring test / calibration, due for inspection / overhaul will specify in the unserviceable tag, the required work to be carried out on the component.

b).

Components such as engine module require combination of work such as overhaul / replacement of wheels / mid life inspection or complete overhaul to be carried out along with the repair work, to avoid another visit of the same component to the external facility. In such case, stores in-charge / head-logistics will consult with the Chief engineer and take appropriate action to cover such additional scope of work in the repair (purchase) order.

c).

When a component is received in to the stores, the stores inspector will ensure that the work carried out in the component is in line with the purchase (or repair) order. On ensuring the same, the item will be accepted into the bonded store. In case, if the work carried out is not line with the purchase (or repair) order, the same will be intimated to Logistics-Head, who will take up the matter with the supplier and provide further instructions to stores personnel for disposal.

RETURN OF “UNSERVICEABLE” LOAN PARTS a).

Any component which has been taken on loan by Deccan Aviation for installation on its fleet of aircraft will be covered by a rental / loan agreement with the supplier.

b).

During the period of operation if the Component becomes unserviceable the same will be returned to the supplier with a request to forward the investigation report to Deccan Aviation.

c).

On receipt of the investigation report, it will be analyzed by the Chief Engineer for providing any technical / operational instructions to the respective staff.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.21

2.21.1

2.21.2

MAINTENANCE PROCEDURES

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CONTROL OF COMPUTER MAINTENANCE RECORD SYSTEMS (Ref: EPM Section-3, Chapter – 19)

a).

This section outlines the policies, requirements and brief procedures regarding use and control of computer based maintenance record systems.

b).

Detailed procedures for control of computerized maintenance record system is given in Engineering Procedure Manual Section-3, Chapter-19.

COMPANY POLICY a).

Web based Computer Software system (FLYPAL) will be used to monitor maintenance records of various aircraft, maintained by Deccan Aviation.

b).

Procedures will be established that authentic information is only fed into the system for routine monitoring.

c).

Access to maintenance record information software will be restricted to authorized personnel only.

d).

Editing rights will be provided to one person only to control misuse of information, by varying the data. Records of such editing will be maintained.

e).

All information will be maintained in hard copies such as logbooks, history cards, work order etc as alternate source of information.

INFORMATION FEED TO THE SOFTWARE SYSTEM a).

Technical Officer (software) will feed various monitoring requirements into the FLYPAL, based on the following information; 1. Aircraft Maintenance Programme. 2. Service Life Limit and Time Between Overhaul of various parts / assemblies. 3. Periodic Inspections – airframe / engine / propeller / Avionics equipments. 4. Out of Phase Inspections – airframe / engine / propeller. 5. Lubrication service inspections. 6. Corrosion control inspections. 7. Continuous airworthiness inspections provided by Optional equipment manufacturer. 8. Directives (Airworthiness Directives, Service Bulletins / Letters, Mandatory Modifications). 9. CAR Requirements.

b).

If any revision is issued to technical publications, in which the above data is revised / modified, then the Manager – Technical services evaluating the incoming publications will send Inter office communication (IOC) to the Technical Officer (software) to edit the master list of FLYPAL.

c).

Technical Officer (software) will modify the Master list of various monitoring requirements to meet the revised / amended technical publication requirement and keep a documentary evidence for every single feed / editing of information to the FLYPAL maintenance record system.

d).

Technical Officer (software) will function as an Administrator for the software and will control the log in ID and password allotment to individual certifying staff, who is attached with the aircraft or responsible for specific aircraft.

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INFORMATION RETRIEVAL

a).

Information retrieval from the software can be done from any location by using the specific URL, log in ID and password.

b).

Allotment of log in ID and password will be controlled by Technical Officer (software) and will allot only the accessing rights for a specific aircraft or fleet of aircraft.

c).

Information such as Inspection / Replacement due report, Parts / Assemblies status report, Directives status report can be retrieved from the software by logging in with the given ID and password.

d).

Maintenance Due Information can be extracted from the software for the following variable monitoring units;

1. 2. 3. 4. 5. e).

Calendar periods. Flying Hours Landings Cycles RINS

Reports can be drawn for the following data; 1. 2. 3. 4.

2.21.4

MAINTENANCE PROCEDURES

PAGE NO : 85

Flight Log Report. Maintenance Due Report C of A report Directives status report.

BACK-UP SYSTEMS AND SECOND SITE STORAGE

a).

Conventional flight log and maintenance recording system will be continued so that regulatory requirements are met and back up information is available in the form of hard copy records.

b).

Hard copy records includes the following minimum; 1. 2. 3. 4.

Tech Log Book ( for daily flight log information) Airframe / Engine / Propeller logbook. Work orders / Inspection schedule / Procedure sheet / off-job sheet History cards, Tags, CRS, Authorized Release certificate etc

c).

Back up data from FLYPAL database will be taken once in 15 days and stored at a different building other than the location, where the server containing original data is located. Disc will be kept in a fire proof safe case, which is controlled by the office administrator.

d).

Back up data will be taken in a portable hard disc, in which the scanned copies of the technical records (i.a.w MOE 2.14.4.4) of all aircraft are maintained.

e).

Necessary procedures are reflected in EPM Section-3, Chapter-19 and will be followed to avoid loss of information due to piracy, flood, fire and theft.

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SECURITY AND SAFEGUARDS TO UNAUTHORISED ACCESS

a).

Only authorized persons will have access to the FLYPAL software maintenance records.

b).

Log in to FLYPAL will only be, by means of an ID & password which will be kept as confidential to the individual to whom it is allotted.

c).

The individual technical officers who are handling a specific work in the Technical Records / Quality Department will have a password to data pertaining to their scope of work.

d).

Certifying staff / Base Engg. Manager will be allotted and ID & password for access to FLYPAL system for the aircraft being maintained at their location.

e).

Access to edit FLYPAL data, once entered, will remain with the Technical Officer (software) only. Any person, who has made a mistake during data entry, will have to send a specific request by mail to correct a wrong entry. Such a request will be kept as a proof of change request by the Technical Officer.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.22

2.22.1

2.22.2

MAINTENANCE PROCEDURES

PAGE NO : 87 REV NO

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DATE

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CONTROL OF MAN-HOUR PLANNING VERSUS SCHEDULED MAINTENANCE WORK (Ref: EPM Section -1, Chapter -11)

a).

This section outlines the policies, requirements and brief procedures regarding man-hour planning to carryout scheduled maintenance work.

b).

Detailed procedures are given in Engineering Procedure Manual Section-1, Chapter-11.

COMPANY POLICY. 1.

Scheduled maintenance activities will be planned in advance so that all requirements in terms of facility, manpower, tools, equipments, literature are made available before starting the work.

2.

Un-scheduled maintenance activity, which arises due to damage / defect / incident will also be planned, after the scope of maintenance is known, so that the work is carried out with the necessary / acceptable facility, and required tools, equipments, literature and manpower.

COMPANY PLANNING Vs SCHEDULED MAINTENANCE WORK

a).

The actual man-hours required for scheduled maintenance tasks will be calculated for carrying out the work as per the inspection schedule and taking into account all other man-hours required to gain access, position work stands, remove & install sub-assemblies, de-fuel, purge fuel tanks, troubleshoot, or correct discrepancies found while performing the task.

b).

Man-hours required for scheduled maintenance will be listed aircraft wise in the Engineering Procedure Manual, Section-1, Chapter-11

c).

Technical Officer (Planning) will have a system to control maintenance planning versus scheduled maintenance work, based on following factors; 1. 2. 3.

Estimated man-hours, if provided by the manufacturer or based on organization’s experience. DGCA approved facility for Base maintenance inspections. Tools, Equipments, Spares & Consumables requirements as listed in the respective inspection schedule.

d).

All information will then used by Technical Officer-Planning to estimate the work-load, type of skills necessary to perform the work and aircraft ground time for accomplishing the task. Similar procedure will be followed by Technical Officer-Planning for Out of Phase inspection also.

e).

Technical Officer (Planning) will then intimate the customer or operator about the impending maintenance activity to be performed on the aircraft and the number of days it may take to complete the work.

f).

The Planning advisory / remainder will be issued by Technical officer (Planning), containing the following information: 1.

Scheduled maintenance work for the 100hrs / 30days issued on the first of the month – aircraft wise.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.

g).

2.22.3

2.22.4

REV NO

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DATE

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Scheduled maintenance work for the half yearly period, issued on 1st January / 1st July of the year. – aircraft wise

The planning advisory / remainder will be sent by Technical Officer (Planning) to the following personnel’s: Certifying staff in-charge of the aircraft. 1. 2. Base Engineering Manager / Base Engineering in-charge. 3. Chief Engineer 4. Nodal Officer or Operator’s representative. 5. Logistics Personnel

COMPLEXITY OF WORK a).

Major inspection / repair / overhaul, will be planned in advance, considering the complexity of work.

b).

Chief engineer may allot two qualified Engineers for critical tasks. This will reduce mistakes / oversight from happening due to the complex nature of the work.

ORGANISATION OF SHIFTS a).

2.22.5

MAINTENANCE PROCEDURES

PAGE NO : 88

When a work is required to be carried out more than 8 hours in a day due to requirement of high production output, chief Engineer may decide to increase the work force and organize the work to be performed in shifts as per MOE 2.26

ACCOUNTS OF HUMAN PERFORMANCE LIMITATION

a).

Limitations on human performance, in the context of maintenance related tasks will be taken into consideration while planning maintenance work.

b).

Detailed procedures of control of man hour planning versus scheduled maintenance activities are provided in EPM Section-1, Chapter-11.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.23

2.23.1

2.23.2

2.23.3

MAINTENANCE PROCEDURES

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CONTROL OF CRITICAL TASKS (Ref: EPM Section -4, Chapter -9)

a).

This section outlines the policies, requirements and brief procedures regarding control of critical tasks.

b).

Detailed procedures for control of critical tasks are given in Engineering Procedure Manual Section4, Chapter-9.

COMPANY POLICY a).

Line / Base / Shop Maintenance procedures which are critical in nature, that could endanger the safety of the aircraft if not carried out properly, will be identified to minimise the risk of errors occurring / repeating in the aircraft / component.

b).

Maintenance work carried out in aircraft / engine control system will be inspected by another qualified person, to avoid maintenance error

CRITICAL TASKS PROCEDURES AND CONTROL a).

Critical tasks in line / base / shop maintenance will be identified by Chief engineer and Quality Manager. Procedures will be established by Chief engineer & Quality Manager to control the critical task and the same will be detailed in Engineering procedure manual section-4, chapter-9.

b).

In order to minimize the risk of multiple errors, wherever there is a task involving critical systems such as flight control rigging, installation and rigging of engine controls, the same will be subjected to duplicate inspection by another approved person.

c).

EPM Section-4, Chapter-9 provides the established procedure to be followed to ensure that more than one person is involved in carrying out any maintenance task involving large element of disassembly/ reassembly of several aircraft components during a particular maintenance check. This is to minimize the rare possibility of an error being repeated and aircraft components reassembled wrongly thereby compromising on safety.

d).

Ultimately, when only one person is available to carryout these tasks then, the work card/ work sheet will include an additional stage for re-inspection of the work after completion.

e).

Some examples of such items are removal / installation of engine / gearbox, removal / installation of various control systems. Such detailing of maintenance personnel for carrying out critical tasks will be carried by the Base Engineering Manager / Chief Engineer.

DUPLICATE INSPECTION PROCEDURES

a).

After carrying out any work on an airframe / engine / propeller controls, the aircraft will be released to service only after carrying out a duplicate inspection.

b).

A duplicate inspection is defined as an inspection, which is first made and certified by one support / certifying staff and subsequently made and certified by a second approved person / support or certifying staff before the aircraft is released to service. The second part of the inspection must follow immediately after the first part. The date and time will also be documented.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

c).

REV NO

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DATE

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Duplicate inspection of all control system will be carried out: 1. 2.

2.23.4

MAINTENANCE PROCEDURES

PAGE NO : 90

Before the first flight after replacement, repair adjustment or modification of the control system. If after the second check the control systems are disturbed in any way and any time.

d).

Control inspection (first and second) after base maintenance inspection will be carried out by support / certifying staff only.

e).

When the aircraft is under line operation at any station( away from base / sub-base / usual night halt station), then the duplicate (second) inspection will be carried out by support / certifying staff or by a pilot whose CPL / CHPL is endorsed for the type of aircraft.

CRITICAL TASK LIST

a).

Following is the list of critical tasks on: 1. 2. 3. 4. 5. 6. 7.

b).

Removal and installation of primary & secondary flight control surfaces. Rigging of Flight, Engine & Propeller Controls Installation of engine, rotors, propeller etc Overhaul of engine, propellers, transmissions, gearboxes etc Repairs in primary structures. Simultaneous (both RH & LH) maintenance of brake system, thrust reverser, air data system. Simultaneous (both RH & LH) engine, gearbox or hydraulic oil change / replenishment and closing of oil tank cap.

Detailed company procedures for control of critical task are provided in EPM Section-4, Chapter-9.

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2.24

MAINTENANCE PROCEDURES

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SPECIFIC MAINTENANCE PROCEDURES /GROUND HANDLING

a). This section outlines the policies, requirements and brief procedures regarding various maintenance procedures to be followed during base / line maintenance. b). Detailed procedures for carrying out ground handling and various specific maintenance procedures are given in Engineering Procedure Manual Section-4.

2.24.1

2.24.2

2.24.3

2.24.4

COMPANY POLICY a).

Maintenance manual of the aircraft, engine, propeller, component will be referred to, while carrying out specific maintenance procedures.

b).

Standard procedures and practices specified in Engineering Procedure Manual will be followed while carrying out ground handling & general maintenance activities.

ENGINE RUN (Ref: EPM Section-4, Chapter-10).

a).

Ground running of aircraft engines is considered as a special maintenance task. Hence it will only be carried out by suitably trained and authorized person strictly in accordance with POH / AFM / AMM / EMM.

b).

Rules and regulations of airport where such maintenance and engine running is carried out will be followed and ATC clearance on landline or on RT will be obtained.

c).

Support / Certifying staff or company approval holder, entrusted with the task of engine ground run will be responsible for safe conduct of engine ground run operation.

d).

The detail procedure to be followed for engine ground running is given in EPM Section-4, Chapter 10.

AIRCRAFT PRESSURE RUN (EPM Section-4, Chapter-10)

a).

During the course of maintenance, it may be necessary to carryout aircraft pressure run on the ground.

b).

The aircraft POH / maintenance manual / task cards for this specific type will always be followed. Only authorized personnel / type rated pilot will carry out the aircraft pressure run.

c).

Detailed company procedures for authorization of personnel and necessary precautions to be followed are provided in EPM Section-4, Chapter-10.

AIRCRAFT TOWING (EPM Section-4, Chapter-1)

a).

Whenever an aircraft is required to be towed by means of a tow tractor, certain procedures will be adhered to, in order to ensure a safe and efficient operation.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.24.5

2.24.6

2.24.7

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b).

Towing of aircraft is defined as an aircraft moved by a tow tractor with an authorized person for application of brakes on board. A minimum of 3 persons including tractor driver will be required to carryout towing operations.

c).

Company authorization holder for towing, who is entrusted with the towing operation will be responsible for safe conduct of entire towing operation.

d).

Detailed company procedures for issue of authorization for towing operation including experience required for towing, necessary precautions to be taken are provided in EPM, Section4, Chapter-1.

AIRCRAFT TAXIING (EPM Section-4, Chapter-1)

a).

Aircraft will normally be towed for positioning at another location for maintenance or parking for departure. However, certain circumstances may rise when aircraft has to be taxied.

b).

Taxiing may be carried out by the type rated pilot or company authorized taxi permit holder.

c).

The taxi permit holder who is entrusted with the taxiing operation will be responsible for safe operation.

d).

Detailed company procedures for issue of taxi operation and necessary precautions to be followed while taxiing are provided in EPM Section-4, Chapter-1.

AIRCRAFT JACKING (EPM Section-4, Chapter-12)

a).

During the course of maintenance, it may be necessary to raise complete aircraft clear off the ground using jacks.

b).

Main and nose landing gear legs may be raised individually to enable replacement of wheels/ brake units by using bottle jacks. However, when both the tires on same axle are deflated, main jacks may be used at appropriate wing jacking points.

c).

For replacement of skids, Helicopter will be lifted equally on all jacking points.

d).

All maintenance personnel will be made conversant with aircraft jacking procedure during initial / refresher training.

e).

It is the responsibility of Support / Certifying staff to ensure that correct jacking procedure given in the maintenance manual is followed.

f).

Detailed general company procedures to be followed are provided in EPM Section-4, Chapter12.

DESALINATION / PERFORMANCE RECOVERY WASH ( EPM Section-4, Chapter-25)

a).

Turbine engines are susceptible for accumulation of contaminations or deposits (dirt / salt) when operated in dusty, salty, polluted, volcanic environments. Such accumulation will drastically reduce the performance in short period of time. Hence engine manufacturer’s recommend to carryout compressor / turbine wash on periodic basis to avoid deterioration of engine performance.

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b).

2.24.8

2.24.9

2.24.10

2.24.11

Chief engineer will formulate the detailed procedures to be followed for de-salination / performance recovery wash as per the engine manufacturer’s recommendations and the same will be provided in EPM Section-4, Chapter-25. AIRCRAFT MARSHALLING PROCEDURE (EPM Section-4, Chapter-2)

a).

Standard Marshalling procedure will be followed for engine start clearance, dispatch and for receiving the aircraft.

b).

Marshalling procedure and precautions will be included in organization’s training programme for engineers and technicians.

c).

Marshalling training programme will include admission of first aid and fire drill, which may be required in the event of an emergency.

d).

Detailed procedures for approving Marshaller’s, their training programme/records, explanation of various Marshalling signals are provided in EPM Section-4, Chapter-2.

HANDLING AND CONTROL OF WASTE MATERIALS

a).

Organization has a Company policy for disposal of Waste and Scrap Materials. The Waste Materials will be subdivided into different group’s viz. aircraft scraps, consumable wastes, cotton waste etc.

b).

The working area and hangar area will have sufficient bins and trays for maintenance personnel to dispose the various types of waste in the right bins.

c).

All waste materials collected will be stored in such a way to prevent environmental pollution and disposed off to the agency that is approved for waste material processing.

SCRAPPING OF PARTS

a).

Whenever any component/ equipment or a part is beyond economical repair the same will be declared as a “SCRAP”.

b).

The Support / Certifying staff will issue a “SCRAP TAG” along with the item and deface the part in such a way that it cannot be put to use and also make a cross / scribe with a permanent red marker or scriber on the part at a place which is easily visible.

c).

The scrapped part will then be returned to the Store for storing in Scrap store till the same is disposed in accordance with Scrap Disposal Policy.

WORKING AWAY FROM APPROVED BASE / SUB-BASE STATIONS

a).

Scheduled Maintenance including routine / periodic inspections or unscheduled maintenance work may have to be done on the aircraft away from base / sub-base due to various reasons explained below; 1. Company requirement to operate an aircraft for longer duration. 2. Unexpected requirement to operate an aircraft for longer period than planned. 3. Aircraft grounded for longer period where in scheduled inspections has fallen due.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

b).

MAINTENANCE PROCEDURES

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Following procedure is permitted to be followed before undertaking maintenance work away from base / sub-base station for carrying out scheduled or unscheduled maintenance; 1.

Scope of work permitted to be carried out at location away from base / sub-base station, based on the verification of facilities by support staff, after carrying out a self verifying audit check list and attaching the same with the work order; i). ii).

iii).

2.

Scope of work permitted to be carried out at location away from base / sub-base station, based on the physical audit carried out by the Quality Manager and approval issued by the Quality Manager on the strength of the audit findings; i).

3.

Unscheduled maintenance such as replacement of engine, engine module, rotor blades, tail boom, skid assemblies, gearboxes etc, Unscheduled maintenance such as replacement of landing gear assemblies, shock absorber / landing gear oleo, wheel / brake assembly, primary or secondary control surface. All out of phase inspections

Any scheduled / routine / periodic maintenance inspection up to and including 100hrs or 150hrs or Annual inspection.

Scope of work to be carried out at location away from base / sub-base station, based on the approval issued by the Regional Airworthiness Office, Bangalore; i).

Any scheduled / routine / periodic maintenance inspection up to and including 300hrs inspection and above

c).

Whenever any such scheduled or unscheduled maintenance / inspection is required to be carried out away from the approved base / sub-base stations, the Technical officer-Planning will ensure that all tools, literature, spares required for carrying out intended maintenance jobs at outstation is made available prior to the inspection, so that the Support / Certifying staff can undertake the inspection.

d).

The Support / Certifying staff will ensure the presence of all tools, equipments, consumables, spares and the ground facilities required for carrying out the work. He will then intimate the Chief Engineer and the Quality Manager of the same.

e).

The Quality Manager will carry out an audit of the facilities and issue approval or approach the office of the Regional Airworthiness Office, Bangalore for issue of approval as detailed in subpara b.2 & b.3 above.

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MAINTENANCE OF PERSONAL LOGBOOK

a).

All maintenance personnel are required to possess and update the personal logbook on daily basis describing the work carried out by them with reference to the aircraft / engine / component serial nos.

b).

Such logbooks will be considered as quality experience gained by the individual while carrying out / associating himself with other certifying authorization holder. All maintenance personnel’s personal logbook entries should co-relate to the respective inspection schedule / work orders.

c).

Detailed company procedures for maintaining a personal logbook and its consideration as experience gained for company authorization examination are provided in EPM, Section-2, and Chapter-5.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.25

2.25.1

2.25.1.1

2.25.2

MAINTENANCE PROCEDURES

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PROCEDURES TO DETECT AND RECTIFY MAINTENANCE ERRORS (Ref: EPM – Section 3, Chapter – 29) a).

This section outlines the policies, requirements and brief procedures to detect, document, investigate and rectify maintenance errors.

b).

Detailed procedures for detection and rectification of maintenance errors are given in Engineering Procedure Manual Section-3, Chapter-29.

COMPANY POLICY a).

All employees will be encouraged to participate in the reporting of maintenance errors and to suggest solutions to avoid the same.

b).

Human factors are the biggest single cause of maintenance errors and the organization will adopt a policy to openly investigate maintenance errors.

c).

Continuous monitoring by the management personnel to detect and rectify maintenance error will be practiced.

d).

Any defect / incident / accident will be internally investigated to find out the root cause for the occurrence and action taken to correct the fault in the procedures and practices.

e).

Repetitive failures will be closely monitored and root cause analyzed to avoid serious hazard to flight safety.

f).

Failures reported by other operators / accident investigation reports and suggestion put up in the websites of various airworthiness authorities will be reviewed to find out and eliminate such errors.

AIMS AND OBJECTIVES OF ERROR MANAGEMENT SYSTEM a).

The aim of the maintenance error management policy is to identify the factors contributing to incidents and to make the system resistant to similar errors.

b).

The procedure of detection and rectification of maintenance errors as given here under will be followed. This process will consist of: 1.

Observe

2.

Report

3.

Investigation

4.

Decision and compliance

5.

Feedback

PROCESS OF IDENTIFYING MAINTENANCE ERROR AND RECORDING a).

The maintenance errors will be identified by 1. 2. 3. 4.

reported defects abnormal observations made during maintenance / operation spot checks audit

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.25.2.1

2.25.4

: 01

DATE

: Aug 2008

All employees will be encouraged to report observed errors, for their own safety, so that necessary corrective action could be taken to avoid repeat of error, which may endanger the safety of the aircraft and its occupants, maintenance personnel, ground handling personnel etc.

CODE OF PRACTICE: a).

2.25.3

REV NO

ENCOURAGEMENT OF REPORTING

a).

2.25.2.2

MAINTENANCE PROCEDURES

PAGE NO : 97

Every individual will be encouraged to follow right ethical work practice while carrying out their allotted maintenance duties.

DESCRIPTION OF PROCESS THAT REPORTS MAINTENANCE ERRORS a).

Whenever a maintenance error is noticed by any employee of the organization, he will intimate the same to the Base Engineering Manager or Engineer-in-charge, in writing as per procedures given in Quality Deficiency & Hazard System Procedure, using QDHRS Form No. 009.

b).

A suggestion box will be kept in the hangar and those who wish to remain anonymous while reporting maintenance errors will drop their observations and suggestions in the suggestion drop box.

c).

Management personnel in base / sub-base station such as Chief engineer / Base Engineering Manager will continuously monitor maintenance activities and document any errors noticed during such monitoring using QDHRS form No. 009.

d).

If no error is noticed / reported, Base engineering manager will send a nil report by mail to Quality Manager

DESCRIPTION OF PROCESS THAT RECORDS MAINTENANCE ERRORS.

a).

Base Engineering Manager / Chief Engineer / any maintenance personnel will forward the filled up QDHRS form to the Quality Manager.

b).

QDHRS form will have the following minimum information to enable accurate reporting of maintenance errors; 1. 2. 3. 4. 5. 6. 7. 8.

Detail of error noticed Place, Date of observation Error observed on aircraft / maintenance procedures. Suggestion for correction, if any Investigation finding by the team. Recommendation for prevention Corrective action taken Dissemination of information

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

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2.25.6

REV NO

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c).

Quality Manager will allot a serial number for each received form, so that list of maintenance errors reported can be recorded for evaluation purpose.

d).

The same will also be used while incorporating training to engineers / Technicians to as to avoid similar errors in future.

DESCRIPTION OF PROCESS THAT INVESTIGATES MAINTENANCE ERRORS.

a).

QDHRS Forms received highlighting maintenance error, deficiency in quality of work will be analyzed for the root cause by a team consisting of Quality Manager and Chief engineer as given below WHAT / WHEN / WHERE / HOW / WHY

b).

Team will suggest maintenance practices need to be followed to avoid re-occurrence of such errors.

c).

Recommendations will be recorded in the same form and steps will be initiated by Chief Engineer in the form of circulars to disseminate information to all maintenance personnel, thus preventing similar errors in future.

d).

Any corrective action to undo the deficiency / damage caused by the specific error reported will be initiated by the Chief engineer. Chief engineer will advise the Base engineering manager, who will then issue a work order (if it is aircraft based) or initiate a issue / revision in procedure provided in relative procedure manual (if it is process based)

e).

Once in three months, reported errors of serious implications (which have caused / might have caused serious flight safety hazard) will be reviewed by the chief engineer and quality manager to implement a change / issue of engineering procedures.

f).

Suggestions will be made in the form of Technical circular and circulated to all through Technical Officer (Library).

ANYALISIS OF MAINTENANCE ERROR.

a).

2.25.7

MAINTENANCE PROCEDURES

PAGE NO : 98

All maintenance error will be analyzed to find out the reason for occurrence and the procedures to follow, to avoid re-occurrence of the same.

MANAGEMENT ACTIONS IN RESPONSE TO OCCURRENCE FINDINGS a).

If the maintenance error is investigated and found to be due to negligence, the same will be reported to the Accountable manager for further action.

b).

Accountable manager may decide on the action to be taken (in consultation with the HR Department) based on the following: c). Service tenure of the individual d). Individual nature and his commitment towards work. e). Is error due to willful negligence or by mistake?

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.25.8

2.25.9

MAINTENANCE PROCEDURES

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f).

If it is found that error is due to lack of training, then action would be taken to improve the training standards.

g).

If the error is found to be due to willful negligence, suitable counseling / penal action will be initiated, based on the type of negligence and effect of the same on the organization / personnel.

FEEDBACK TO STAFF a).

When a maintenance error is noticed, investigated and found to be due to willful negligence or due to lack of knowledge / training the concerned individual will be called and a cordial discussion be carried out to highlight the error and the (possible) result of such error on safety of Passengers / staff / aircraft.

b).

Idea of this feedback to the staff is to make the individual understand his mistake and correct accordingly.

SHARING INFORMATION FROM INVESTIGATION a).

All observation / suggestions from the investigation team will be shared with all other employees who are doing similar work, so as to avoid reoccurrence of the same.

b).

Detailed company procedure for maintenance error management is provided in EPM Section-1, Chapter-21.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.26

2.26.1

2.26.3

REV NO

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SHIFT/ TASK HANDOVER PROCEDURES (Ref: CAR 145.A.47.c, EPM Section-1, Chapter-21)

a).

This section outlines the policies, requirements and brief procedures related to shift or task handing over or taking over procedures, when group / team of people are involved in a specific maintenance activity.

b).

Detailed procedures of shift or task hand over / take over procedures are given in Engineering Procedure Manual Section-1, Chapter-21.

COMPANY POLICY

a).

2.26.2

MAINTENANCE PROCEDURES

PAGE NO : 100

Hand over / take over of the maintenance activity when a maintenance task is required to be handed over to another person to continue with the same will be done through a register (log) detailing the work completed, in pending and in progress.

OBJECTIVES OF SHIFT TAKEOVER a).

Objective of shift handover / Take over procedure is to smoothly handover / take over the routine production work which will continue from one shift to another.

b).

Shift / Task handover process is required when the production output requirement is more than the ability of one team to produce within a specified period of time.

TRAINING OF PERSONNEL IN SHIFT / TASK HANDOVER PROCESS

All maintenance staff employed in shift / task, hand / take over system of functioning will be trained by the shop engineer-in-charge / Base engineering manager in the Handover / Take over of:

a).

1. Work being carried out. 2. Special instructions to be followed. 3. Proper accounting of tools / spares etc.

2.26.4

RECORDING OF SHIFT / TASK HANDOVER

a).

Shop in-charge / Support or Certifying staff’s are responsible for all hand over / take over, of shift / task will documentation in a register, day & shift wise. Recording will include but not limited to the following. 1. 2. 3. 4.

b).

Names and number of people Tools and equipment details Scope and level of work done and pending. Level of utilization of critical equipments ad any restrictions on further utilization.

Person handing over / taking over will append their signature in the register against the information exchanged between the two persons indicating that the required information for smooth functioning is exchanged without any doubts.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

c).

2.26.5

MAINTENANCE PROCEDURES

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Apart from the documented exchange of information, verbal exchange of information will also be done between the person handing over and taking over to avoid any communication gap.

DESCRIPTION OF SHIFT HANDOVER PROCESS a).

Shift / task handover process will be done during the overlap time, which means the working hours of handing over / taking over shift personnel will be so planned that they overlap for a period of minimum of 30 minutes.

b).

During this overlap period the shift or task, handover / takeover process will happen.

c).

Shift / task, hand over / take over will contain smooth transfer of data / information flow from one shift to another which will contain the following information, recorded in a register.

1.

FACILITY STATUS i. ii iii

2.

WORK STATUS i. ii. iii. iv.

3.

iii.

Any issues which is outstanding and may have detrimental effect on the productivity of work / safety. The outstanding issues will be handed over in proper detail, by making a clear cut noting in a register.

OTHER ISSUES i.

d).

Number of Employees who are carrying out the work Number / station of employees required for smooth transition / completion of running work / task Overlapping of employees at each work station for smooth hand / take over of the work.

OUTSTANDING ISSUE i.

5.

Scope of work under progress Level of completion Expected level of completion / target for the next shift. Status of reporting regarding the work continuing / completed to appropriate people.

MANPOWER STATUS i. ii.

4.

Status of facility in terms of its equipment usage. Any restrictions on further usage of such critical equipments in terms of time / energy level etc. Any faults / breakdown / issue in facility such as power (Electric / Hydraulic / Pneumatic) etc.

Any other issues not pertaining to the work but related to the general administration in nature.

Detailed company procedures for shift management are provided in EPM Section-1, Chapter-21.

********************

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.27

2.27.1

2.27.3

: 01

DATE

: Aug 2008

a).

This section outlines the policies, requirements and brief procedures related to the procedures for notification of maintenance data inaccuracies and ambiguities to the type certificate holder.

b).

Detailed procedures for notification of maintenance inaccuracies and ambiguities to the type certificate holder is given in Engineering Procedure Manual Section-1, Chapter-18.

COMPANY POLICY Any inaccurate, incomplete or ambiguous procedure, practice, information or maintenance instruction contained in the maintenance data (technical publications) used by maintenance personnel is recorded and notified to the author of the maintenance data. (CAR 145.A.45c refers)

DEFINITIONS OF MAINTENANCE DATA AMBIGUITIES. a).

Incomplete, inaccurate or ambiguous information in the maintenance data, provided by the manufacturer/given in the manuals is known as maintenance data ambiguities.

b).

Whenever maintenance personnel come across such ambiguities, they will record and report such details on a maintenance data inaccuracy/ ambiguity form (Form No. 027) or using Feedback form, provided in the maintenance publications. to Manager – Tech services

c).

Manager – Tech services / Chief Engineer will in turn forward the same to the manufacturer and obtain the clarification, which will then be circulated to maintenance personnel, in the form of Technical circulars.

RESPONSIBLE PERSON FOR CO-ORDINATION OF REPORTING AND REMIDIAL ACTIONS. a).

2.27.4

REV NO

PROCEDURES FOR THE NOTIFICATION OF MAINTENANCE DATA INACCURACIES AND AMBIGUITIES TO THE TYPE CERTIFICATE HOLDER (CAR 145.A.45.c, & EPM Section-1, Chapter-18)

a).

2.27.2

MAINTENANCE PROCEDURES

PAGE NO : 102

Manager – Tech services will notify the details of the maintenance data inaccuracy to the manufacturer and seek clarification on the subject.

METHOD OF INTERNAL REPORTING OF MAITNENANCE DATA AMBIGUITIES. a).

A file will be maintained by the Manager – Tech. Services about the maintenance data ambiguities received from various maintenance personnel.

b).

Any personnel observing such maintenance data ambiguities in Manuals / Bulletins will send an email / fax using the feedback form provided in the respective publications, explaining the issue with reference to the subject / manual being referred.

c).

All such issues will be recorded in the file with a specific serial number for continuous monitoring.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.27.5

2.27.6

MAINTENANCE PROCEDURES

PAGE NO : 103 REV NO

: 01

DATE

: Aug 2008

MEHTOD OF EXTERNAL REPORTING OF MAITNENANCE DATA AMBIGUITIES TO THE AUTHORS OF THAT DATA.

a).

Whenever the Manager – Tech. Services receives an issue of Maintenance data ambiguity, the same will be discussed with either the Quality Manager (Quality related issues) or with the Chief Engineer / Senior / type rated engineer (Maintenance related issues).

b).

If found reasonable the same will be taken up by the Manager – Tech Services / Chief Engineer with the relevant manufacturer / TC holder for resolving the issue.

FEEDBACK TO STAFF AND IMPLEMENTATION OF TC HOLDER/ MANUFACTURER CORRECTIONS

a).

On receipt of clarification from the TC Holder / Manufacturer, the same will be circulated to respective maintenance / operation / quality staff, in the form of Technical circular, by the Manager –Tech. Services.

b).

Detailed procedures to be followed for collecting, reporting, finding a solution and communicating to relevant personnel’s for maintenance data inaccuracy or ambiguity is provided in EPM Section-1, Chapter-18.

********************

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

2.28

2.28.1

2.28.2

2.28.3

MAINTENANCE PROCEDURES

PAGE NO : 104 REV NO

: 01

DATE

: Aug 2008

PRODUCTION PLANNING PROCEDURE (Ref: CAR 145.A.47, EPM Section-1, Chapter-11 & -21) a).

This section outlines the policies, requirements and brief procedures related to the production planning procedures to be followed by the organization.

b).

Detailed procedures to be carried out for production planning are given in Engineering Procedure Manual Section-1, Chapter-11 & 21.

COMPANY POLICY a).

A system appropriate to the amount and complexity of work, to plan the availability of all necessary personnel, tools, equipment, material, maintenance data (Technical publications) and facilities in order to ensure the safe completion of the maintenance work will be created.

b).

Human performance limitations will be taken into account, while planning of the tasks and organizing of shifts.

c).

A system of handing over the continuation or completion of maintenance tasks during shift or personnel change over, so that relevant information will be adequately communicated between outgoing and incoming personnel.

ESTABLISHMENT OF A CLEAR WORK ORDER a).

Organization will enter into a written maintenance agreement with the owner of aircraft for carrying out maintenance on aircraft, owned by them.

b).

Maintenance contract will have the following minimum elements clearly defined with details of responsibility between the maintenance organization and the owner (operator); 1. Provision of Maintenance Data (Technical publication) and its subscription service. 2. Provision of facility, hangar, tools, equipment, consumables, spares. 3. Provision of manpower, inspection and certification limitations. 4. Updation of Technical records.

c).

No maintenance activity will be carried out on any aircraft without a written contract.

d).

One-off maintenance activity on any aircraft will be carried out only after written purchase order / commercial work order from the customer. Such commercial work order will be transferred to Technical work order by the certifying staff and work undertaken on the aircraft / component

e).

All work on aircraft will be carried out only after a work order is raised by the concerned certifying staff as per procedures given in MOE 2.10, based on due list generated from the FLYPAL software.

PROCEDURES FOR ESTABLISHING ALL NECESSARY RESOURCES ARE AVAILABLE BEFORE COMMENCEMENT OF WORK a).

Tech officer (Planning) / Regional or Base Engineering Manager or Engg. In-charge will coordinate with the various departments for ensuring the availability of manpower / tools / equipments / spares and also for positioning of the same at the right locations before commencement of work.

b).

They will refer the schedule / manuals / EPM Section-1, Chapter-11 to ascertain the requirement of number of support / certifying staff and Technician, spares/ tools / consumables

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-2

MAINTENANCE PROCEDURES

PAGE NO : 105 REV NO

: 01

DATE

: Aug 2008

required for completion of the task and organize for the same, in consultation with the concerned certifying staff / chief engineer. 2.28.4

2.28.5

2.28.6

PROCEDURES FOR ORGANISING MAINTENANCE PERSONNEL AND PROVIDING ALL NECESSARY SUPPORT DURING MAITNENANCE a).

Tech Officer (planning) / Regional or Base engineering manager or in-charge will ensure that all necessary planning in terms of manpower, tools, equipments, spares, and approval are carried out as well in time before commencement of scheduled inspections / replacement etc.

b).

They will also remain in touch with the maintenance team, while the work is being carried out to provide necessary assistance in terms of coordination for additional manpower / tools / equipment requirements which may arise.

c).

Above procedure will apply for unscheduled maintenance activity such as defects / repairs to be carried out as a result of defect / incident / accident etc.

CONSIDERATION OF HUMAN PERFORMANCE LIMITATION a).

While planning the manpower requirement for scheduled / unscheduled maintenance activities, the technical officer (planning) will keep in mind the limitations of human performance for carrying out their allotted duties.

b).

48 Man hours / week will be the expected output from maintenance personnel. All maintenance planning will be carried out @ 48 man hours / week and accordingly required man power will be allotted for each work.

c).

If maintenance work is required to be carried out during extended working hours, due consideration to human performance limitation will be given and no critical task will be carried out during extended working hours.

d).

In case, if critical task is required to be performed, during extended working hours, two support staff will be allotted for the specific task, so that work carried out can be double checked immediately by another qualified support staff.

e).

If a maintenance person is required to be involved for more than 8 hrs a day, the following limitations will apply; 1. Maintenance personnel will be allowed to work an additional time period of 2hrs per day only. 2. Such additional time period of two hours will be restricted to three consecutive days only. 3. If a maintenance person is allotted work for 10hrs a day for three days, then the person will be rested on the fourth day.

f).

During shift working, extended working will not be practiced. Time taken for closure of work, documentation will be part of the shift hours and will not be carried out by extending the shift working hours.

PLANNING OF CRITICAL TASK a).

When a critical maintenance activity is required to be performed, Regional Engineering Manager / Chief Engineer will enquire to find the previous experience of the maintenance personnel. Maintenance personnel who have similar / appropriate experience will only be deputed to perform critical task.

*******************

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.1.0

L2.1.1

L2.1.2

PAGE NO : 1 REV NO

: 01

DATE

: Aug 2008

LINE MAINTENANCE CONTROL OF AIRCRAFT COMPONENTS, TOOLS, EQUIPMENT, Etc. a).

This section outlines the policies, requirements and brief procedures related to line maintenance control of aircraft components, tools & equipments.

b).

Detailed procedures for line control of aircraft components, tools, equipments are given in Engineering Procedure Manual Section-4, Chapter-5

c).

Stores in-charge at sub-base or engineer in-charge at line station will be carrying out the procedures given below for control of aircraft components, tools, equipments etc.

d).

Word “station engineer in-charge” in this part will mean Regional / Base engineering manager at main / sub-base, engineer manager or in-charge at sub-base / line station for the purpose of highlighting the procedural responsibility.

COMPANY POLICY a).

Aircraft components, tools, equipments, literatures issued to line maintenance facility will be controlled at issue and at receipt locations for quality & quantity.

b).

Usage of components, tools & equipments will also be monitored to increase the level of traceability of usage and accountability.

COMPONENT / MATERIAL ACCEPTANCE - (REQUIRED DOCUMENTATION, CONDITION, "QUARANTINE" PROCEDURE) a).

All components/ materials will be supplied to line stations on need basis, based on the store requisition from the line station.

b).

Station engineering in charge / stores in-charge is responsible for the acceptance of the spares and materials dispatched from base station.

c).

The following actions will be carried out by the station in-charge (Engg / Stores) before accepting the items at line stations.

1. 2. 3. 4. 5. 6. 7.

Verification the accompanying document i.e. Release Documents or its equivalent. Inspection the item for proper packing and for any transit damage. Inspection the item visually for evidence of defect, deterioration, contamination, corrosion. Ensuring that serviceable tag/Parts Acceptance Tag is correctly filled in and attached. Verification of shelf life. Verification of the item by its part no. for its suitability as per requirement. Verification that the maintenance required at interim period is carried out.

d).

Station in charge (Engg /Stores) will maintain a separate register where receipt and dispatch of items will be recorded.

e).

Documentation, acceptance and quarantine procedures of components/ materials received into line station stores will be carried out as per Logistics Procedure Manual.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

f).

L2.1.3

L2.1.4

PAGE NO : 2 REV NO

: 01

DATE

: Aug 2008

Movement of spares, tools & equipments received at the line station will be monitored by station in-charge (engineer / stores).

COMPONENTS REMOVED SERVICEABLE FROM AIRCRAFT a).

When a serviceable component is removed from aircraft to rectify defect in another aircraft (cannibalizing), support / certifying staff who removes the item will issue a Serviceable Tag, and the certifying staff who is installing it in the other aircraft will issue a CRS post installation.

b).

Item taken on loan from other organization’s bonded store / aircraft on loan basis, will also be entered in the stock register

c).

Support / certifying staff will enter all details such as aircraft from which it is removed / installed, part no., serial no., hours/ cycles, and forward to technical officer - Records under work order raised by the individual. Technical Officer (Records) will update the history card, based on the history card.

d).

When it has been established by certifying staff that the replaced component did not correct the problem and it has been determined that the trouble was not caused by the changed component then the corresponding item removed from the aircraft will be returned to store as serviceable after cleaning, tagging and protecting it by support /certifying staff. Support / certifying staff will also issue a Serviceable Tag for the Component.

PROCEDURES FOR MAINTAINING SATISFACTORY STORAGE CONDITIONS a).

Station In-charge (Engineering) will ensure the following procedures when a component is removed from the aircraft and till the time it is handed over to the stores; 1. 2. 3. 4. 5. 6.

Parts removed from the aircraft is properly drained / blanked. Tagged to identify the status as per MOE 2.3.4 & LPM Chapter-4. Protected properly to avoid external damage / corrosion etc Handled properly without causing damage to the part i.a.w 2.3.2. Handed over to stores in-charge in the original packing (using packing material came with the new component/ parts). Reduce the time period between the time it was removed from the aircraft and handed over to stores for avoiding any damage due to uncontrolled storage in hangar.

b).

Stores in-charge will ensure the following for storing of components / parts in proper condition; 1. Documentation of all parts received for receipt, condition, serviceability status (for status tags) including acknowledgement of the same to the dispatcher. 2. Inspection for received parts and acceptance into stores i.a.w MOE 2.2.3 & LPM chapter-3 3. Storage, tagging & release of parts / components to maintenance i.a.w MOE 2.3 and LPM chapter-4, 5, 6, 7 & 8.

c).

Stores in charge will ensure that all components received on loan / removed from the aircraft is taken into stores after acceptance inspection and then issued to maintenance.

d).

Stores in-charge will maintain record of parts / components movement, between bases / line station / supplier / contractors. Records will contain the following information;

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

1. 2. 3. 4. 5. 6.

L2.1.5

L2.1.6

L2.1.7

PAGE NO : 3 REV NO

: 01

DATE

: Aug 2008

Date on which the item is received / dispatched. Details of parts (Part No., Sl.No., Description, Qty etc) Location where the item is dispatched. Mode of dispatch and dispatch details Intimation of dispatch information to the consignee. Condition of the parts when received.

SYSTEM FOR CONTROL OF SHELF LIFE AND MODIFICATION STANDARD a).

Station in-charge (engg / stores) will maintain a shelf life register for those parts having life and needs to be monitored in line station.

b).

Register will have a quarter (such as 1Q 2009, 2Q 2009 …..) listed on top of each page. Any item falling due within that quarter will be entered in the register with other information such as part no. description, batch no. RNN number, quantity available etc.

c).

On completion of the quarter, all the items listed in that page, will be identified and scrapped due life expiry. Scrapped items will either be disposed off as per company scrap disposal policy or sent to Bangalore for disposal.

d).

First In – First out system will be followed while issuing shelf life parts to use on aircraft for maintenance.

e).

Station in-charge (engg / stores) will follow the procedure given in MOE 2.3.5 for control of modification standard of parts kept in line station stores.

TAGGING / LABELLING SYSTEM (SERVICEABLE, UNSERVICEABLE, ROBBERY, SCRAP ETC) a).

Support staff removing the part from the aircraft is responsible for tagging and labelling of all components removed from aircraft and returned to stores.

b).

Support staffs will handover the items removed from the aircraft to the stores at the earliest opportunity so that damage to parts due to uncontrolled storage in the hangar will be avoided.

c).

Station stores in-charge will ensure tagging and labelling of all components dispatched to base station. He will also maintain record of all details of components dispatched to base station. Procedure as given in MOE 2.3.4 will be followed.

ISSUE OF COMPONENTS TO THE MAINTENANCE PROCESS a).

Issue of components to maintenance process will be carried out by station in-charge (engg /stores) of line station.

b).

The support staff will fill all details about the component installed / removed in the work order and forward to Tech. Officer (Records) at Bangalore, along with the respective FLYPAL due report.

DECCAN AVIATION LIMITED

PAGE NO : 4

MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES c).

L2.1.8

L2.1.9

L2.1.10

: 01

DATE

: Aug 2008

Stock register and bin card updation will be the store in charge’s (engg / stores) responsibility. Procedure given in MOE 2.3.7 will be followed.

FREE-ISSUE DISPENSING SEGREGATION) a).

REV NO

OF

STANDARD

PARTS

(CONTROL,

IDENTIFICATION,

Procedure of free issue dispensing of Standard parts to the maintenance personnel will not be followed in line / base station.

TOOLS AND TEST EQUIPMENT, SERVICING AND CALIBRATION PROGRAMME / EQUIPMENT REGISTER a).

Servicing and calibration programme of tools and test equipment held at line station will be monitored by the station in-charge (engg / stores) of line station.

b).

He will also be sending a monthly updation list to the Bangalore Base tools & equipment in charge for records. Procedure given in MOE 2.5 will be followed

IDENTIFICATION OF SERVICING / CALIBRATION DUE DATES a).

Station in charge (engg /stores) will maintain a record for identifying calibration / servicing due date of tools and equipment held at line stations.

b).

He will ensure procedure given in MOE 2.5.4 is strictly followed.

********************

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.2

L2.2.1

L2.2.2

L2.2.3

PAGE NO : 5 REV NO

: 01

DATE

: Aug 2008

LINE MAINTENANCE PROCEDURES INCLUDING SERVICING / FUELLING Etc.

a).

This section outlines the policies, requirements and brief procedures related to line maintenance procedure related to aircraft servicing, fuelling, etc.

b).

Detailed procedures for servicing, fuelling are given in Engineering Procedure Manual Section-4, Chapter-11.

COMPANY POLICY a).

Fluid (oil, fuel etc) or Gas (Nitrogen, Oxygen etc) servicing of the aircraft in line station will be carried out as per procedures given in the respective aircraft maintenance manual.

b).

If procedures are not provided in the maintenance manual, then established standard procedures will be followed.

c).

Necessary steps will be taken to ensure that the surrounding environment is not polluted while servicing the aircraft.

MAINTENANCE DOCUMENTATION - (CONTROL AND AMENDMENT) a).

All maintenance documents such as tech. log book, work orders, schedules, and task cards will be completed and certified by certifying person and forwarded to Technical Officer (Records) at Bangalore.

b).

Engineering In-charge will make sure that all inspection schedules and task cards available at line station are as per latest revision. Any superseded documents will be destroyed.

c).

Engineering in-charge will follow the Maintenance documentation procedure given in MOE 2.13.

d).

Control of maintenance records kept at line stations will be done by engineering in-charge of the station.

AIRWORTHINESS DATA - (CONTROL AND AMENDMENT) a).

All airworthiness data such as Airworthiness Directives, Mandatory modifications, Alert service bulletins, Flight manual supplements will be sent by Technical officer (library) from Bangalore base.

b).

Station engineering in-charge will ensure that revisions received are incorporated and records of date of receipt, person received, date and person incorporated will be maintained. All the superseded documents will be destroyed.

c).

Station engineering in-charge receiving the airworthiness data will liaise with the support staff incharge of the aircraft and ensure that the work as per airworthiness data is carried out after raising a work order.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.2.4

REV NO

: 01

DATE

: Aug 2008

FUEL SUPPLY - QUALITY & QUANTITY MONITORING. (Ref: EPM, Section – 4, Chapter 11 & Chapter 17) a).

Fuel for aircraft is available only thru DGCA approved fuel vendors located at most of the airports, namely Airport Fuelling Station (AFS).

b).

Deccan will uplift fuel in barrels or in its approved (by Controller of Explosives) fuel bowser for supply of the same to the aircraft maintained / operated, at various locations away from the airport. At airport, where fuel vendor is available, fuel will be directly uplifted into the aircraft from the vendors fuelling vehicle.

c).

Aircraft operating crew or the approved maintenance staff handling the aircraft will ensure proper type /grade of fuel is uplifted into the aircraft by positively ensuring that the grade specified for the aircraft (in the flight manual and near the fuel cap) matches with that grade mentioned in the fuelling vehicle.

d).

Operating / Maintenance crew will also verbally check with the employee of the fuel delivery vehicle about the type / grade of the fuel to double check the type / grade of fuel before upliftment.

e).

Quality of fuel supplied by approved vendors at airport will be checked by the operating / maintenance personnel by general inspection of fuel for sediments and for presence of water using approved water detecting capsule.

f).

The quality of fuel (for Water contamination, sedimentation, clarity) held under storage with the organization will be checked every day / prior to each uplift by the foreman (or senior most technician) and the same will be recorded in a Fuel Quantity / Quality Register.

g).

Fuel Quantity / Quality Register will contain the following minimum details 1. 2. 3. 4.

h).

L2.2.4.1

PAGE NO : 6

Date of checking. Quantity of fuel remaining at station. Signature to confirm against a statement that the fuel quantity and quality is verified and found satisfactory. Remarks if any.

If the stored fuel is not used for more than six months the same will be returned to the fuel vendor for detailed quality checks. On recertification of the quality of the fuel by the fuel vendor the same will be kept in the fuel store / bowser. If fuel quantity held is insufficient or economical for testing, then the remaining fuel will be degraded and disposed off without polluting the environment.

BULK STORAGE a).

Deccan Aviation as an operator & maintenance agency will store fuel in bowser or barrels, at certain line stations to meet the operational requirements but the stock held by Deccan Aviation will not exceed the bulk storage quantity allowed as per CAR & Indian Petroleum Act / Petroleum Rule 1937 in effect, at any given time.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES L2.2.4.2

REV NO

: 01

DATE

: Aug 2008

AIRCRAFT REFUELLING

a).

Aircraft refueling will be carried by the following means: 1. 2. 3.

b).

L2.2.4.2.1

PAGE NO : 7

Thru approved fuel vendors available at various airport. Using approved Bowser owned by Deccan Aviation Using fuel procured from fuel vendor & stocked in barrels by Deccan Aviation.

Operating crew will oversee and maintenance personnel will carryout aircraft fuelling and will follow all precautions and procedures enumerated in Engineering Procedure Manual Section-4, Chapter 11 & 17 to ensure that proper quality and quantity of fuel is uplifted into the aircraft.

FUELLING FROM FUEL VENDOR AT AIRPORT a).

Aircraft operating crew or the approved maintenance staff handling the aircraft will ensure proper type /grade of fuel is uplifted into the aircraft by positively ensuring that the grade specified for the aircraft (in the flight manual and near the fuel cap) matches with the grade mentioned in the fuelling vehicle.

b).

Aircraft operating crew will ensure the correct grade / type of fuel uplifted by clearly reading out the grade / type of fuel mentioned in the fuel uplift voucher issued by the fuel vendor.

c).

Aircraft operating crew or the approved maintenance staff will also verbally check with the employee of the fuel delivery vehicle about the type / grade of the fuel to double check the type / grade of fuel before upliftment.

d).

Quality of fuel supplied by approved vendors at airport will be checked by the Aircraft operating crew or the approved maintenance staff by general inspection of fuel for sediments and for presence of water using approved water detecting capsule, prior to uplifting the fuel into the aircraft.

e).

Aircraft operating crew or the approved maintenance staff will monitor the refueling operations carried out by the fuel vendor. Aircraft operating crew or the approved maintenance staff will ensure that all general precautions and compliance with procedures of refueling operations such as those which are given below are strictly adhered to; 1. 2. 3. 4.

Fuel bowser is bonded to the aircraft and to the ground Fuel sample is checked free of water and other contaminants (by sampling), Fuel load is uplifted according to the flight requirement Fuel caps / panels are securely replaced on completion of fueling operation.

f). An entry will be made in the aircraft technical log for the fuel quantity uplifted and the total amount on board the aircraft by the Aircraft operating crew or the approved maintenance staff. g). The accomplishment of all ground refueling operations and their associated procedures will be subject to quality audit surveillance. h). A copy / detail of fuel vouchers for each fuel uplift supplied by fuelling company will be kept at respective stations for a period of three months.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES L2.2.4.2.2

REV NO

: 01

DATE

: Aug 2008

FUELLING FROM COMPANY OWNED APPROVED BOWSER a).

Aircraft operating crew or the approved maintenance staff handling the aircraft will ensure proper type /grade of fuel is uplifted into the aircraft by positively ensuring that the grade specified for the aircraft (in the flight manual and near the fuel cap) matches with that grade mentioned in the fuelling vehicle.

b).

Aircraft operating crew will ensure the correct grade / type of fuel uplifted by clearly reading out the grade / type of fuel mentioned in the fuel uplift voucher issued by the fuel delivery personnel.

c).

Aircraft operating crew or the approved maintenance staff will also verbally check with the fuel delivery personnel for dispensing fuel from the fuel delivery vehicle about the type / grade of the fuel to double check the type / grade of fuel before upliftment.

d).

Quality of fuel supplied by company owned approved (By Controller of Explosives) bowser will be checked by the Aircraft operating crew or the approved maintenance staff by general inspection of fuel for sediments and for presence of water using approved water detecting capsule.

e).

Aircraft operating crew or the approved maintenance staff will monitor the refueling operations carried out by the company owned, approved fuel bowser operator. Aircraft operating crew or the approved maintenance staff will ensure that all general precautions and compliance with procedures of refueling operations such as those which are given below are strictly adhered to; 1. 2. 3. 4.

L2.2.4.2.3

PAGE NO : 8

Fuel bowser is bonded to the aircraft and to the ground Fuel sample is checked free of water and other contaminants (by sampling), Fuel load is uplifted according to the flight requirement Fuel caps / panels are securely replaced on completion of fueling operation.

f).

An entry will be made in the aircraft technical log for the fuel quantity uplifted and the total amount on board the aircraft by the Aircraft operating crew or the approved maintenance staff.

g).

The accomplishment of all ground refueling operations and their associated procedures will be subject to quality audit surveillance.

h).

A copy / detail of fuel vouchers for every fuel uplift supplied by company owned & approved fuel bowser will be kept at respective stations for a period of three months.

BARREL REFUELLING a).

Deccan Aviation will undertake barrel refueling at locations, which are not serviced by the approved fuel vendors.

b).

Base engineering manager / engineering in charge of the station will control the quantity and quality of fuel uplifted in barrel from fuel vendors, procedures followed for transportation, storage and issue of fuel from such barrels to aircraft.

c).

Fully epi-coated barrels will only be used for uplifting, storage and issue of fuel to the aircraft.

d).

Detailed procedures for upliftment, transportation, storage and delivery of fuel from barrel are mentioned in the EPM, Section-4, and Chapter-30.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.2.4.2.4

PAGE NO : 9 REV NO

: 01

DATE

: Aug 2008

HOT REFUELLING (REFUELLING WITH PASSENGERS ON BOARD OR ROTOR TURNING) a).

Hot refueling in helicopter will be undertaken with passengers embarking, on board, disembarking or when the rotor is turning after setting forth the conditions and procedures under which such fuelling may be carried out.

b).

All precautions laid down in rule 25A of the Aircraft Rules, 1937 regarding fuelling of aircraft will be adhered to while refueling.

c).

Additional precautions will be followed when refueling with fuels other than aviation kerosene or when refueling results in a mixture of aviation kerosene with other aviation turbine fuels, or when an open line is used.

d).

Hot refueling means the refueling of a helicopter with its engine I engines I rotors running.

e).

Helicopter Operations at few locations such as Katra, Amarnath require Hot Refueling for the following reason; 1) Adverse weather conditions allowing few hours of operational time. 2) Requirement to carry higher number of passengers 3) To balance the Engine Hour and Cycle utilization ratio.

f).

Only turbine engine helicopters using fuels that have a flash point equal to or greater than JET A or JET A-I fuels will be fueled while an engine is operating.

g).

Helicopter being refueled while an engine is operating will have all sources of ignition of potential fuel spills located above the fuel inlet port(s) and above the vents or tank openings. Sources of ignition include, but are not limited to, engines, exhausts, and combustion-type cabin heater exhausts.

h).

An appropriately qualified helicopter pilot will be at the aircraft controls during the entire hot refueling process.

i).

Passengers will be off-loaded to a safe location prior to hot refueling operations. Passengers will not be loaded or off-loaded during hot refueling.

j).

Only designated personnel, properly trained in hot refueling operations, will operate the equipment.

k).

Regional engineering manager / Chief engineer will make available the written procedures for safe handling of the fuel and equipment at the fuelling location.

l).

All door, windows, and access points allowing entry to the interior of the helicopter that are adjacent to, or in the immediate vicinity of, the fuel inlet ports will be closed and will remain closed during hot refueling operations.

m).

Before refueling the helicopter, the helicopter will be bonded to the fuel source to equalize static electricity between the fuel source and the aircraft.

n).

One refueling coordinator will be in place with direct eye-contact with the pilot, the person operating the dispensing hose or nozzle and the person operating the equipment.

o).

Refueling equipment will be operated on receipt of clearance signal from the Pilot and the Person holding the dispensing hose or nozzle. Similarly the operation of the equipment will be stopped if

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any of the people involved in hot refueling gives an emergency signal. Refueling coordinator will ensure immediate stoppage of the operation of the equipment. p).

“NO SMOKING” signs will be displayed in the cabin(s), tarmac and fuel storage area. No smoking rule will be enforced.

q).

One day training will be conducted by the Engineer-In-Charge to all persons involved in Hot Refueling, to familiarize the procedures to be followed during hot refueling or any emergency that may occur in relation to the refueling and the same will be documented.

r).

Hot refueling equipment may be in the following form as required; 1) Barrel and Hand operated pump. 2) Barrel and Electrically operated pump. 3) Barrel and Fuel operated pump.

L2.2.5

s).

Suitable and properly maintained fire fighting equipment will be positioned for use, in case an emergency occurs during the refueling.

t).

Fuel in the barrel intended for hot refueling is required to be tested for presence of water before commencement of Hot refueling by the Engineer / Pilot (on Ground) , who is present at the location.

u).

The quantity of fuel to be loaded must be decided before hot refueling is commenced.

v).

Before the helicopter’s fuel filler cap is removed, the refueling equipment and the helicopter must be earthed and connected so as to ensure they are of the same electrical potential.

w).

While hot refueling is taking place, radio transmissions from the helicopter will be restricted to the greatest extent practicable.

x).

While hot refueling is taking place, an HF transmitter or radar equipment on the helicopter must not be operated.

y).

Detailed procedure for hot refueling is provided in EPM Section-4, Chapter-11.

GROUND DEICING a).

L2.2.6

Policies and procedures will be elaborated before undertaking operating at such environments.

MAINTENANCE CARRIED OUT IN THE OPEN SPACE - (LIMITATIONS) a).

Base stations of Deccan Aviation for maintenance of an aircraft are established with the minimum scope of maintenance (i.e.) at least up to 100FH / 150FH inspections and OOP inspections.

b).

If due any situation, hangar facilities are not available, the line maintenance activities at base / line stations will be carried out in the open space subjected to weather condition.

c).

All the limitations for carrying out maintenance in the open space as given in AMM / EMM will be strictly followed by the support staff.

d).

All maintenance activities will be suspended during adverse weather conditions.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.2.7

L2.2.8

: 01

DATE

: Aug 2008

When a prolonged maintenance is anticipated, the support staff will obtain weather report and take appropriate action to cover the aircraft system / components to prevent them from getting contaminated.

f).

Similarly, prolonged maintenance will not be undertaken during adverse weather condition (dusty, rainy or heavy wind).

MAINTENANCE OF GROUND SUPPORT EQUIPMENT a).

Ground support equipment held at all stations will be inspected and serviced as per the periodicity assigned (Ref: Annexure 10.1, LPM Chapter-10) in the respective equipment history card by the person designated by the Base Engineering Manager / Engineer in-charge.

b).

Station Base engineering manager / engineering in charge will monitor maintenance of ground support equipment and take appropriate action for keeping all ground equipment in serviceable conditions.

c).

Master list of ground support equipment with assigned periodicities for maintenance / servicing will be maintained at each base / line station by the station stores in-charge / engineering in charge.

d).

In case any maintenance action is required on the ground equipments the same will be undertaken in coordination with the tools & equipment in charge (for spares requirement) and Technical OfficerPlanning will be intimated about unavailability of the said equipment for the stipulated time.

MAINTENANCE OF SUB-CONTRACTED GROUND HANDLING AND SERVICING Ground handling and servicing of aircraft at all locations will be handled by the organization. The policies will be elaborated, when ground handling and servicing is subcontracted.

CARE AND MAINTENANCE OF ULD AND CARGO LOADING SYSTEMS/RETENTION EQUIPMENT a).

L2.2.10

REV NO

e).

a).

L2.2.9

PAGE NO : 11

Presently no ULD or cargo loading systems are being used. The policies will be defined, when such systems are put to use in the organization.

TARMAC & APRON SAFETY a).

Standard tarmac and apron safety procedures will be followed by all maintenance staff, while attending an aircraft at all line / base stations.

b).

Company approved standard tarmac and apron procedures to be followed by the maintenance personnel are provided in EPM, Section-4, Chapter -26.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.3

L2.3.1

L2.3.2

L2.3.2.1

: 01

DATE

: Aug 2008

a).

This section outlines the policies, requirements and brief procedures regarding rectification of defects arising during line maintenance activities at base or during line maintenance at regularly operating / occasionally operating line stations.

b).

Detailed procedure for line maintenance control of defects including repetitive defects are provided in EPM Section-4, Chapter-14.

COMPANY POLICY a).

All defects noticed during line maintenance by operation or maintenance personnel and action taken by support / certifying staff as per maintenance data for rectification of the same will be recorded in appropriate document.

b).

No defect rectification will be carried out by any support / certifying staff based on verbal communication of defects.

REPORTABLE DEFECTS a.

Any defects observed by all operational & maintenance personnel during any phase of control of or execution of work or association with the personnel involved in operation, maintenance or ground handling are classified as reportable defects.

b.

A system or part suspected to be malfunctioning, but unable to concretely prove that any malfunction existing is also classified as Reportable Defect and can be reported as a suspicion.

PILOT REPORTED DEFECTS All defects reported by pilots will be entered by them in the appropriate column in the Tech Log Book. Thereafter the defect will be analysed and rectified by support / certifying staff as per policy given MOE Para 2.15

MAINTENANCE PERSONNEL OBSERVED DEFECTS a).

L2.3.3

REV NO

LINE MAINTENANCE CONTROL OF DEFECTS AND REPETITIVE DEFECTS (Ref: EPM Section – 4 -, Chapter 14)

a).

L2.3.2.2

PAGE NO : 12

All defects observed by maintenance personnel will be entered by them in the appropriate column in the Tech Log Book. Thereafter the defect will be analysed and rectified by the support staff as per policy given MOE Para 2.15

DEFERRED DEFECT CLASSIFICATION SYSTEM a.

Deferring of defects is permitted by invoking the operator’s MEL, approved by DGCA. Deferring of defects allows continuation of flight with inoperative equipment, which doesn’t render the aircraft un-airworthy for the particular flight.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

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b.

Deferring of defects is permissible only in occasionally operating line stations only. MEL will not be invoked in stations from which operation is intended for more than 15days At base stations, defects noticed during an hour before take off can be deferred under the provisions of MEL

c.

Deferrable Defects are classified under four categories, based on the time limit allowed for rectification action and the classifications are specified against each deferrable item in the MEL. 1

Category - A

:

2

Category - B

:

3

Category - C

:

4

Category - D

:

Items in this category will be repaired with in the time interval specified in the remarks column of the MEL Items in this category will be repaired with in three (3) consecutive calendar days, excluding the day the malfunction was recorded in the tech. logbook. Items in this category will be repaired with in ten (10) consecutive calendar days, excluding the day the malfunction was recorded in the tech. logbook. Items in this category will be repaired with in one hundred and twenty (120) consecutive calendar days, excluding the day the malfunction was recorded in the tech. logbook.

RULES FOR DEFERRING a).

MEL can be invoked from occasionally operating line stations by operating or maintenance personnel.

b).

Pilot having at least a CPL / CHPL on the type of aircraft, can invoke MEL and defer items that has effect on operating procedures only at stations, where support / certifying staff has not been positioned.

c).

MEL can be invoked from the base station, if the defect is found within one hour prior to departure.

d).

Certifying staff including Daily Inspection approval holder can invoke MEL and defer items requiring Maintenance (M) & Operational (P) procedures to be followed.

e).

They cannot invoke items requiring maintenance procedures to be completed for deferring.

CONFORMITY WITH MEL PROVISIONS a).

Operational (O) and Maintenance (M) provisions are provided in the MMEL issued by the airworthiness authority of the country of origin.

b).

Such provisions are required to be converted in to step by step procedure by the operator in consultation with the maintenance agency and approval of MEL obtained from the office of DGCA.

c).

Certifying person releasing the aircraft will ensure that the necessary maintenance procedures are completed and certified in the tech. logbook.

d).

Certifying person will also ensure that necessary placarding as given in the maintenance procedure is completed and pilot advised of about the operational procedure to be complied due invoking of MEL.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

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CERTIFICATION OF DEFECT RECTIFICATION – TRANSFER OF DEFECTS TO WORK ORDER a).

Any defects (Minor / Major) will be reported by making an entry in the tech. logbook, by the operating crew or by the maintenance personnel, who is aware of the defective condition of the aircraft.

b).

No defect rectification will be initiated by support staff, without first making a defect entry in the tech. logbook.

c).

Every defect entered in the tech. logbook will be transferred to a work order (un-scheduled maintenance) and rectification action taken will be recorded in the work order.

d).

Certifying staff will transfer the defect reported to the work required column in the tech. logbook and enter the rectification action taken with publication references in the action taken column of the work order. Certifying staff will also attach any procedure sheets used for defect rectification to the work order.

e).

Certifying staff will make an entry in the tech. logbook about the brief detail of the rectification action taken and refer the work order number for more details.

f).

If the brief rectification action cannot be contained in the columns of the tech. logbook, then the certifying staff will state the following in the tech. logbook for any defect rectification. “Defect rectified. Refer work order no. DAX-2008-01-30-121 for details. Aircraft released for flight.”

L2.3.5

L2.3.6

AWARENESS OF DEFFERRED DEFECTS CARRIED BY THE AIRCRAFT a).

Deferred defects if still not rectified and being carried forward within the time period, will be reflected in the tech logbook, under the table namely MEL release.

b).

If there is no deferred defect being carried forward, then Nil entry will be made by the certifying person in the tech. logbook to ascertain that the aircraft doesn’t carry any deferred defects.

MONITORING OF REPITITIVE DEFECTS a.

Any minor defect repeating more than three times on the same aircraft or appearing on three different aircraft within the span of one month period will be called as Repetitive Defect and the same will be considered as repetitive defects (also as an Occurrence) and reported by Base Engineering Manager / Engg.in-charge to Tech. Officer (Directives & Occurrences), Manager – Tech. services, Chief engineer & Quality Manager using occurrence reporting form (Form No. 004).

b.

Such repetitive defects will be intimated to the manufacturer by Manager – Tech. services for suggestions to avoid the same and investigation carried out as per MOE 2.18.3 to prevent further occurrence.

c.

Investigation result of repetitive minor defect will be intimated to all maintenance personnel thru Technical circulars for avoiding future.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES d.

L2.3.7

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Detailed procedure for line maintenance control of defects including repetitive defects are provided in EPM Section-4, Chapter-14.

COMMUNICATION WITH BASE a).

Engineering in-charge at regularly / occasionally operating line station will send a weekly report of operational and maintenance information to the Base Engineering Manager and Tech. Officer (software) at Bangalore.

b).

Engineering in-charge at regularly / occasionally operating line station will send details of defects noticed and rectification action taken including occurrence report, in case of any occurrences as per MOE 2.18. Defect information with rectification action will form part of the weekly report information. Occurrence information (incident /accident) will be sent as and when it occurs.

c).

For line operation being carried out at base stations, the certifying staff of the respective aircraft will provide the information on daily basis to the Tech. Officer (Base station). Tech. Officer (Base station) will send the weekly report (and /or update the FLYPAL) to the Tech. Officer (software) at Bangalore.

d).

The station engineering in charge (Base /line) will remain in communication with the base (Chief Engineer / Manager-Technical services / Quality Manager) for all engineering and operational matters by e-mail and telecommunication.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.4

L2.4.1

L2.4.2

L2.4.3

L2.4.4

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DATE

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LINE PROCEDURE FOR COMPLETION OF THE TECHNICAL LOG (Ref: EPM Section – 4, Chapter – 3)

a).

This section outlines the policies, requirements and brief procedures to be followed for data / information entry in the technical logbook and its control including retention.

b).

Detailed procedure explaining the responsibilities of various personnel for completing the technical log is provided in EPM Section-4, Chapter-3

COMPANY POLICY a.

System for logging sector wise operational and maintenance information will be followed and the details recorded in the Tech. Logbook.

b.

The technical log book layout will meet the intent of the CAR Series-X, Part-VI requirement in terms of information to be recorded before, during and after flight.

EXPLANATION OF TECHNICAL LOG SYSTEM.

a).

Technical log system allows recording of sector wise maintenance and operational information such as fuel / oil upliftment, daily inspection certification, weight and balance, pilots acceptance, crew details, flight information, flight parameters, defect & rectification details, MEL invoking & Deferred defect details etc.

b).

Detailed explanation of each of the column of the technical log book is provide in EPM section4, Chapter-3

COMPLETION OF FLIGHT SECTOR RECORD

a).

Flight crew will be responsible for completion of each and every flight sector record information.

b).

If any defect is observed during a flight sector, the same will be entered by the flight crew immediately after completion of the flight.

c).

If no defect is observed, the flight crew is required to enter NIL defect and sign.

d).

Any defect observed by the Maintenance personnel will be entered as soon as the defect is noticed and the aircraft will be released after carrying out necessary defect rectification.

DISTRIBUTION OF COPIES

a).

The white sheet (Original – First sheet) remain in the technical log and will form a part of the permanent record of the aircraft.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

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REV NO

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b).

The green sheet (Copy – second sheet) will be removed after the last flight and sent to technical Officer - Records.

c).

The pink sheet (copy – third sheet) will be removed before the first flight of the day and retained on ground from where the aircraft had taken off for the day. This sheet will be retained by the certifying person who released the aircraft for the flight, till the last landing of the day / till the removal of the pink sheet and then filed in a folder, as this sheet is the proof of pilot acceptance of the aircraft.

d).

If the aircraft was released by the approved pilot for the day, then the pink sheet (copy –third sheet) will be removed and provided to any of the responsible maintenance personnel on the ground and then collected from him at the end of the day.

CERTIFICATION / SIGN OFF a).

L2.4.5.1

PAGE NO : 17

This sub-section outlines the policies, requirements and brief procedures to be followed by the organization for control of line maintenance personnel qualification and approval limitations.

BEFORE FIRST FLIGHT / TRANSIT INSPECTION / AFTER LAST FLIGHT INSPECTION a).

After satisfactory completion of the Before First Flight / Transit Inspection, approved person will sign off in the appropriate columns of the tech log book, which will be considered as aircraft release to Service for the sector, provided no defect is reported by the operating crew.

b).

General description of servicing and inspection to be carried out during BFF / transit / after last flight inspection is provided in EPM Section-4, Chapter-4.

TYPICAL TASK PERMITTED AFTER TASK TRAINING (FOR TASK TRAINED MECHANICS) a).

Task trained and authorized persons will be allowed to perform simple defect rectifications at line stations and issue CRS i.a.w CAR 145.A.50 with respect to the work carried out on the aircraft.

b).

Any defect rectification work performed by the task trained person will be carried out after recording the defect (work required to be carried out) on the work order. Work carried out will also be recorded in the work order. Work order cross reference will be mentioned in the Tech. logbook with a brief reference to the work carried out.

c).

Sample list of simple defect rectification are provided below; 1.

Routine lubrication and replenishment of all system fluids and gases.

2.

Replacement of wheel assemblies, brake units, emergency equipments, ovens, boilers, beverage makers, internal & external lights, filaments, flash tubes, windscreen wiper blades, pax / cabin crew seats, seat belts, harnesses, toilet system components including gate valves, static wicks, batteries, in-flight entertainment system components excluding passenger addressing system.

DECCAN AVIATION LIMITED

PAGE NO : 18

MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.4.5.3

L2.4.5.4

DATE

: Aug 2008

3.

Closing of cowling and re-fitment of quick access inspection panels

4.

De-activation of duplicate controls and system components permitted by MEL.

a).

Minor scheduled line maintenance means any minor scheduled inspection / check up to and including a weekly check specified in the maintenance programme of the aircraft. If weekly check is not provided in the manufacturers maintenance programme, check considered equivalent and approved by the Regional airworthiness office, Bangalore will be identified as Minor scheduled line maintenance activity.

b).

Sample list of simple defect rectification is provided in MOE L2.4.5.2.c

LINE MAINTENANCE RECTIFICATION

ABOVE

MINOR

SCHEDULED

INSPECTION

WITH

DEFECT

Inspection above weekly or equivalent inspection, but below scheduled base maintenance inspection as listed in table in MOE 1.9.e is called Line maintenance inspection above minor scheduled inspection.

DUPLICATE INSPECTION

a).

Aircraft / engine / Propeller control system if disturbed, is required to be inspected and certified by one certifying staff / approved person and subsequently another inspection is required to made and certified by a second approved person before the aircraft is released for service. Second part of the inspection must be carried out as near as possible and should follow immediately after the first inspection. Second part of the inspection is called as Duplicate inspection.

b).

Duplicate inspection of all control system will be carried out; 1. 2.

c).

L2.4.6

: 01

MINOR SCHEDULED LINE MAINTENANCE AND SIMPLE DEFECT RECTIFICATION

a).

L2.4.5.5

REV NO

Before the first flight after overhaul, replacement, repair, adjustment or modification of the control system. If after the second check, the control system is disturbed in any way and any time.

Pilot having CPL / CHPL on the type aircraft and have successfully completed internal task training on duplicate inspection of controls on specific aircraft type will be provided with an approval to carryout duplicate inspection at outstations (line stations) only.

MAINTENANCE CONTROL SYSTEMS a.

This sub-section of MOE (L2.4.6) provides the policies and procedure to be followed for control of scheduled / out of phase inspections and special inspections in line maintenance.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.4.6.1

L2.4.6.2

PAGE NO : 19 REV NO

: 01

DATE

: Aug 2008

b.

Scheduled (Routine or Periodic) inspections are those inspections, which are provided in ATA Chapter-5 or equivalent in aircraft / engine / propeller maintenance manual and required to be carried out repetitively (or periodically). These inspections apply to the whole of the airframe / engine / propeller.

c.

Lubrication servicing / inspection are those servicing inspection, which are provided in ATA chapter -12 or equivalent and are required to be carried out repetitively (or periodically) or when a condition is noted such as low oil / gas level or aircraft flown through rain or parked in rain etc

d.

Corrosion protection and corrosion prevention (CPCP) inspection are those inspection provided in aircraft maintenance manual or corrosion prevention manual provided by the aircraft / engine manufacturer and is required to be carried out repetitively (or periodically) or when a condition is noted such as extensive corrosion or when parked / operated in mild / moderate / severe corrosive environment.

e.

Out of phase inspection are those inspections applicable for a component / system or for few components / system and required to be carried out repetitively (or periodically). Repeating periodicity may be equal to or different from the scheduled inspection periodicity. Out of phase inspections are described so, because they need not be clubbed with the scheduled (some time referred as phase) inspection and carried out at intervals, they fall due.

f.

Special inspections are required to be carried out as a continuous or follow up action, following a specified maintenance activity. For example : Engine ground run / operational check of fuel system after replacement of a fuel system component, Torque check of a dynamic component such as TGB, MGB, Mast installation after specified flying hours since installation etc.

g.

Specialized inspections are those inspections which are required to be carried out and certified by specially qualified persons with Certificate of competency issued by DGCA. Details of such inspections are FPI, MPI, Eddy current, Ultrasonic, Radiography, Borescope, Coin tap test etc.

SCHEDULED, LUBRICATION, CORROSION & OUT OF PHASE INSPECTIONS

a).

All inspection occurring on repetitive basis such as scheduled inspection / lubrication servicing inspection / corrosion prevention inspection / out of phase inspections will be monitored under the computerized FLYPAL system and a due report will be provided to the support staff to carryout the work.

b).

Support staff / certifying staff will raise a work order based on the due report, carryout the same and certify the inspection. Certifying staff will scrutinize the work carried out and issue CRS i.a.w CAR. 145. A.50 procedures.

SPECIAL INSPECTIONS

a).

Special inspection defined above in MOE L2.4.6.f are monitored based on the entry in the Tech. logbook in next maintenance due column.

b).

Support staff who is carrying out the initial maintenance activity (like TGB / MGB installation) will raise a work order for installation and also raise another work order for the follow up maintenance activity, such as torque check after 10hrs of component operation.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.4.7

REV NO

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DATE

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c).

He will record the follow up maintenance activity due hours in terms of airframe hours in the tech. log book at a specific location namely “Maintenance Inspection Next Due at ……….Hrs and …………. (Date).

d).

He will also leave the pending work order in the pouch provided in the tech. logbook.

e).

If same / another certifying person is required to maintain and certify the aircraft, the certifying staff will access the information from the Maintenance inspection next due column in the tech. log book and use the work order left in the tech log book pouch to carryout the work.

f).

On completion of the work and certification in the tech logbook, work order and working copy logbook, the work order will be sent to the Tech. Officer (records) for entry in the original logbook and retention.

RETENTION OF TECH LOGBOOK.

a).

L2.4.8

PAGE NO : 20

All tech log books will be retained up to two years from the date of de-registration of the aircraft / permanent withdrawal from service whichever is earlier.

MAINTENANCE STATEMENT

a).

Whenever a certifying staff or approved Person signs a Tech Log Column for inspection after completing Before first flight, or a certifying person issues a CRS certificate for scheduled line / base inspection or defect rectification, the signature will be taken as Certificate of Release to Service i.e. “Certifying that work specified except otherwise as stated was carried out in accordance with CAR and in respect of that work the aircraft is considered ready for release to service”.

b).

CRS is not required to be issued after transit inspection.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L.2.5

L2.5.1

L2.5.2

REV NO

: 01

DATE

: Aug 2008

LINE PROCEDURE FOR POOLED PARTS AND LOAN PARTS (Ref: LPM Chapter -13)

a).

This section outlines the policies, requirements and brief procedures to be followed by the organization for control of pooled and loan parts.

b).

Detailed procedure for control of parts loaned from other organization / personnel are provided in Logistics Procedure Manual Chapter-13.

COMPANY POLICY a).

Presently, organization has no arrangements for pooling of parts with another operator. Policies for pooling will be provided when such agreements are in place.

b).

Part taken on loan from other operator may be fitted on the aircraft after ensuring that the part meets the airworthiness standards.

VERIFICATION OF APPROVED SOURCES OF LOAN PARTS a).

L2.5.3

PAGE NO : 21

Head-Logistics will resort to loaning of parts as procurement procedure, during the following occasions; 1.

If parts are not available for procurement, but available on loan basis.

2.

If the defective part is required to be sent for repair / overhaul and to avoid grounding of aircraft till the time the part sent for repair / overhaul is returned back.

b).

Loaning of parts will be initiated from the company approved suppliers / contractors only. If the parts are not available with the company approved supplier / contractor, then loaning from other agencies will be initiated.

c).

In such case, the other agencies approval details will sought and supplier / contractor evaluation procedure as per MOE 2.1 will be followed by Head-logistics.

d).

Parts will be loaned, only after company approval is granted to the supplier / contractor by the Quality Manager.

VERIFICATION OF HISTORY OF PARTS - MODIFICATION STANDARD AND AD COMPLIANCE a.

History of parts being considered to be taken on loan will be obtained from the company approved supplier / contractor and forwarded to the Base Engineering Manager / Chief Engineer for acceptance.

b.

History of parts obtained by Head-logistics for evaluation by base engineering manager / chief engineer is given below; 1.

Copy of history card providing the date of initial installation and service life thereafter.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES 2. 3.

L2.5.4

L2.5.5

REV NO

: 01

DATE

: Aug 2008

Repair / Overhaul carried out during the life of the component. History of any incident to the part or to the aircraft on which the part was fitted, such as High temp, Hard landing, Sudden stoppage, Wind damage (damage due to thunderstorm, twister etc) / accident. Life completed in terms of flying hours, calendar period, cycles, landings, RINS etc Details of sub-assemblies / life limited parts fitted on the major assembly /component. Status of Modification standard including DGCA modifications and AD’s issued by the airworthiness authority of the country of origin.

4. 5. 6.

c.

PAGE NO : 22

On obtaining the acceptance from the Base engineering manager / chief engineer, Head-logistics will initiate a loan contract document and process the loan procurement (or import) procedure for the part.

COMPLIANCE WITH LOAN AND CONTRACT REQUIREMENTS – TRACKING & CONTROL a).

On obtaining the acceptance of the history of part to be loaned from base engineering manager / chief engineer, Head-logistics will enter into a loan contract clearly specifying the terms and conditions of the loan.

b).

After signing of the loan document, Head-logistics will initiate loan procurement (or import) procedure.

c).

Head logistics will intimate the supplier to send a copy of the service record, commercial invoice, packing slip and a declaration that the part is intended to be used on aircraft for quick processing of customs and import formalities.

d).

Head logistics will advise the supplier to send the original service record by post /courier to avoid loss of original documents by postal / custom staff handling, which may render the part to be quarantined on receipt, defeating the purpose of loan.

e).

Head logistics will track the part when it is in transit to reduce the freight movement time between the supplier facility and the organization destination facility.

PROCESSING OF REMOVED LOAN PARTS FOR RETURN TO SOURCE – SERVICE RECORD a).

When the necessity of loan ceases, advisory to remove the part will be provided by the Chief engineer / Base engineering manager to support staff.

b).

Support staff removing the part from the aircraft will carryout the following procedure given below; 1. 2. 3. 4. 5. 6.

c).

Raise a work order as per instruction received by mail / phone / fax from chief engineer / base engineering manager. Remove the part from the aircraft as per approved maintenance data / instructions. Drain the fluid as necessary and blank all openings with appropriate blanking. Cover all openings with appropriate materials. Provide a status tag for the loan part (serviceable, unserviceable, repairable etc) Fill up the work order with all relevant details and Complete the work order and forward to Tech. Officer (Records)

Tech. Officer (Records) will calculate the life completed by the part, between its installation / removal by the organization and update the original service record of the part / module.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES

L2.5.6

REV NO

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d).

Tech. Officer (Records) will retain hard copy of the updated service record of the part / module and hand over the original to Stores inspector for dispatch the supplier /contractor who provided the loan part.

e).

Stores inspector will always send a copy of the report with the part and send the original by post / courier to avoid loss of original service record by customs / postal officials during export / dispatch of the part.

ROBBERY SYSTEM – CONTROL PROCEDURES & AUTHORITY a).

b).

c).

L2.5.7

PAGE NO : 23

During base / line / shop maintenance, situation may arise to remove a part from one of the serviceable aircraft / component and fit in other aircraft or component due following reasons; 1.

Operational reasons such as to avoid grounding of an aircraft or to retrieve an aircraft which had a defect / damage etc.

2.

Maintenance reasons such as to confirm / troubleshoot the snag on another aircraft / component.

Support staff requiring to rob a part from an aircraft / component in base / line / shop / stores facility will raise a parts robbing permission form (Form No…..) and submit the same to the base engineering manager / chief engineer for permission. On receipt of permission to rob the part, support staff will raise a work order (on the printed booklet allotted for the aircraft from which the part is being removed) mentioning the removal of part from the aircraft / component and for fitment on the unserviceable aircraft.

d).

Part robbed from the aircraft will be handed over to the stores inspector with the serviceable tag and then re-possessed from the stores after issue to the aircraft on which it is required to be installed

e).

In case of part being removed from the component undergoing repair / overhaul, the robbery detail will be entered in the relevant shop work order to inspect and certify the airworthiness of the part and then hand it over to the stores inspector with the serviceable status tag, for forwarding to the aircraft / component requiring the robbed part.

f).

A warning tag will be put on the aircraft / component, closer to the location of the part / system and on the cockpit of the aircraft, from which the part is removed to indicate to the other operation / maintenance personnel about the part removed from the aircraft.

g).

If a part is being robbed from one serviceable aircraft and intended to be fitted on the other serviceable aircraft during line operation of the aircraft or the serviceable part is being removed from an unserviceable aircraft, for trouble shooting purpose, the support / certifying staff will raise relevant work order for both the aircraft and swap the part for confirming the snag as part of snag rectification process. In such case, the part need not be routed thru the bonded stores.

UPDATION OF AIRCRAFT LOGBOOK & COMPUTER SYSTEM

a).

Any parts removed / installed by the support staff will be first entered in the work order created by them for the purpose. Support staff will enter the details in the working copy of the logbook, available at the sub-base / line station.

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b).

Tech. officer (sub-base) or Engineer in-charge (line station) will send weekly report to Tech. Officer (records) with operational and maintenance activities carried out on the aircraft to enable to update the FLYPAL.

c).

Completed work order is handed over to Tech. officer (sub-base) and the same is forwarded to Tech. Officer (records) at Bangalore. Tech. Officer (records) will update the FLYPAL computer system about the removal / installation of the components.

d).

Detailed procedure of logbook and computer system updation of work carried out at sub-base / line station is explained in MOE 2.10.2

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART – L2 ADDITIONAL LINE MAINTENANCE PROCEDURES L2.6

L2.6.1

L2.6.2

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LINE PROCEDURE FOR RETURN OF DEFECTIVE PARTS REMOVED FROM AIRCRAFT (Ref; LPM Chapter-12 & EPM Section – 4, Chapter- 5)) a).

This section outlines the policies, requirements and brief procedures regarding return of defective aircraft components removed from aircraft during line operation and return to stores.

b).

Detailed procedures to be followed by line maintenance personnel for return of defective parts removed from aircraft are given in EPM Section-4, Chapter-5 & Logistics Procedure Manual chapter- 12.

COMPANY POLICY d).

Components identified as defective will be tagged properly by attaching appropriate tag, drained & blanked, well protected to avoid handling damage and returned to stores for necessary action.

e).

Repairable components will be sent to approved repair centre (company approved contractor) for repair.

f).

Components beyond economic repair will be termed Unsalvageable and scrapped for disposal.

PROCESSING ADVICE OF REMOVAL AND DISPATCH TO TECHNICAL SERVICES SECTION INCLUDING SERVICE RECORD UPDATION. a.

Defective parts will be removed from the aircraft by a support / certifying staff after raising a work order. Procedure sheets will be followed, if the parts removal procedure is a complex one such as engine removal etc.

b.

On removal of the part, support / certifying staff will attach a status tag duly filled with all relevant information and return the part to stores in-charge of the base station or stores inspector at Bangalore.

c.

Support / Certifying staff removing the part / Technical officer (of base station, where line operation is carried out) will send the work order related to the part removal to the Tech. Officer (Records).

d.

Tech. officer (Records) will update the original history card / service record of the part.

DISPATCH OF PARTS FOR RECTIFICATION

a).

Defective parts removed from aircraft at line / base station (where line operation is carried out) are normally returned to stores at main base by station engineering / stores in-charge for dispatching to repair stations for repair / overhaul.

b).

Support / certifying staff will attach Unserviceable Tags with the component and all columns completed with full details of the defect including symptoms entered. Using of work “Unserviceable” is not acceptable and the support / certifying staff has to declare the detailed defect / malfunction noticed. It is important to state the full reason for removal in order to assist the component repair shop in identifying the defect and having to do away with unnecessary & expensive testing.

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c).

All ESDS items being sent back for repair will be packed in ESDS packing only by the support / certifying staff using the packing of the new part or with the packing material obtained from stores, to avoid damage due to static discharge.

d).

Occasionally, the parts removed will be sent to approved contractor’s facility directly from line / base station to avoid unnecessary movement of parts from one station to other.

e).

All components removed as unserviceable / defective from the aircraft, engine or equipment will be sent to the stores / company approved contractors facility along with duly filled in unserviceable tag and using parts return voucher (Form no. 011).

f).

Logistics -Head at Bangalore will co-ordinate with Technical Officer (records) to obtain the updated service record / history card of the part for dispatch to the approved contractor’s facility.

g).

Logistics -Head at Bangalore will send the items / co-ordinate the dispatch along with necessary original documents by post / courier to repair stations for repair / overhaul.

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L.2.7

L2.7.1

L2.7.2

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LINE PROCEDURE FOR CONTROL OF CRITICAL TASKS (MOE 2.23, EPM Section-4, Chapter-8&9, Section-1, Chapter-17) a).

This section provides brief policies and procedure to be followed for control of critical tasks and maintenance away from base / sub-base station.

b).

Detailed procedures are provided in EPM Seciton-4, Chapter 8 & 9, Section-1, Chapter-17.

COMPANY POLICY

c).

Line Maintenance procedures which are critical in nature, that could endanger the safety of the aircraft if not carried out properly, will be identified to minimise the risk of errors occurring / repeating in the aircraft / component.

d).

Maintenance work carried out in aircraft / engine control system will be inspected by another qualified person, to avoid maintenance error.

e).

Occasional requirement to carryout scheduled maintenance activity at line stations will be permitted by the Quality Manager after satisfactory audit of the available facility in terms of tools, equipments, manpower, literature, facility etc

CONTROL OF CRITICAL TASK AT LINE FACILITY

a).

Certifying staff attached with the aircraft will follow the procedure given below for effective control of critical task; 1.

Dual control installation / Removal - Certifying staff will complete the dual control installation / removal and then advise another approved support staff / the pilot attached with the aircraft to carryout the duplicate inspection. Both the inspection including installation / removal will be documented in a work order.

2.

In case of scheduled activity falling under critical task ( as listed in MOE 2.23.4), the Tech. officer (planning) will advise the Base engineering manager / chief engineer of a requirement to position another person for carrying out the duplicate inspection / inspection on the parallel system (on twin engine aircraft as per EPM section-4, chapter8 &9).

3.

In case of unscheduled activity, certifying staff attached with the aircraft / base engineering manager planning the quantum of work to be carried out will initiate the requirement for another person to carryout the work falling under critical task.

4.

In case of minor activity like replacing engine / gearbox oil, replenishing oil and replacing oil cap on both the engines, the certifying staff carrying out the work, will request the pilot of the aircraft to carryout the inspection of such minor task, but critical in nature. Such inspection by the pilot will also be documented in the work order.

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CONTROL OF MAINTENANCE AWAY FROM BASE / SUB-BASE

a).

Occasions may arise when a scheduled or unscheduled maintenance is required to be carried out at a location away from the established main base / sub-base station due to various reasons such as aircraft grounded at out station due defect, parts not available to service the aircraft on time, operational requirement etc.

b).

When a situation arises that a scheduled (periodic / routine) inspection is required to be carried out or an unscheduled major work is required to be carried out at stations away from approved main base / sub-base then such tasks are considered as Critical task under line maintenance and the procedure given below is required to be followed as listed;

Scheduled maintenance activities up to 100hrs/150hrs or Annual inspection Scheduled maintenance activities including 200hrs and above except out of phase inspections Unscheduled maintenance activities like out of phase inspection, engine or engine module change, gearbox change, landing gear change etc

c).

:

Work will be carried out on one time basis after a physical audit carried out by the Quality Manager and approval granted by the Quality Manager based on the audit findings.

:

Work will be carried out after obtaining approval from the Regional airworthiness office, Bangalore.

:

Work will be carried out based on the based on the verification of facilities by support staff, after carrying out a self verifying audit using a check list and attaching the same with the work order.

Detailed policies and procedures for control of critical tasks during the line maintenance of aircraft are mentioned in MOE 2.23, EPM Section-4, Chapter -8 & 9.

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3.1

3.1.1

3.1.2

QUALITY AUDIT OF ORGANISATION PROCEDURES (Ref: CAR 145.65.c & EPM Section-3, Chapter-3, 4 & 5)

a.

This section outlines the policies and procedures adapted by the organization for establishing an Independent Quality Management Group and the systems established to carryout audit, highlight non-conformances and ensure corrective action.

b.

Detailed procedures for carrying out quality audit of organization procedures are provided in EPM Section-3, Chapter 3, 4 & 5.

COMPANY AUDIT POLICY

a).

Independent Quality audit will be conducted by the Quality Manager / Auditor at regular intervals to assess compliance status of the organization with respect to the regulatory requirements which are listed below; 1. Functioning of the organization as per CAR 145 requirements. 2. Policies declared in MOE are being adhered or not? 3. Procedures established in procedure manuals are being followed or not? 4. Product of the organization is meeting the specification requirement or not?

b).

Audit will be conducted by trained auditors, using customized check list for all processes and products covering the entire organization activities and products at all locations under the organization’s scope of approval at an interval not exceeding 12 months

c).

Audit will be conducted to cover all the activities of the organization and any deviation observed will be recorded as Non-conformances. Non-conformances will be addressed to the responsible person and his immediate senior for corrective action.

d).

Regular review meeting will be conducted to check progress on rectification action for nonconformances

e).

Organization (Quality Department) will monitor and ensure thru the quality audit and feedback system, the compliance with required aircraft / component standards and adequacy of procedures to ensure that such procedures invoke good maintenance practices and airworthy aircraft / aircraft components.

f).

Audit findings will be reviewed by the Accountable Manager at an interval not exceeding six months.

QUALITY MANAGEMENT SYSTEM & GROUP a).

3.1.2.1

This sub-section will define the setting up of Quality Management Group and the functions of the Quality Management System.

INDEPEDENCE a.

The INDEPENDENCE of the audit will be established by always ensuring that audits are carried out by personnel not responsible for the FUNCTION (Maintenance of aircraft / component), PROCEDURE (Maintenance /Logistics / Training) or PRODUCTS (Airworthy aircraft / component) being audited.

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b.

3.1.2.2

3.1.2.3

The independent audit is an objective process of routine sample checks of all aspects of the CAR145 approved maintenance organisation and its ability to carry out all maintenance to the required standards and includes product inspections, as this is the end result of the maintenance process.

ACCESS TO ACCOUNTABLE MANAGER a).

Quality Manager will provide an annual audit plan in the form of a schedule to the Accountable Manager and the same will be part of EPM Section-3, Chapter-3.

b).

All level-1 non-compliance which may affect the airworthiness of aircraft / component will be brought to the notice of the Accountable Manager, with suggestions for corrections.

c).

Half yearly review feedback about the various audit results, non-conformances raised, corrective action taken will be provided to the Accountable Manager.

d).

Quality Manager will have direct access to the Accountable Manager to discuss about serious nonconformances and the required corrective action to be taken to rectify the same.

COMPOSITION AND FUNCTIONS OF QUALITY MANAGEMENT GROUP a).

Quality Management Group will consist of Quality Manager and a team of trained Quality auditors, who will not be engaged in any production related activities.

b).

The main function of the team is to conduct independent audits, as programmed by quality manager, raise & report findings and follow up to check the findings are rectified satisfactorily.

c).

Quality Management activity provides information on the ability of the organization to deliver a safe product and the effectiveness of systems in meeting regulatory authority and company’s requirements.

d).

Quality Management system will also ensure that non-conformances observed are corrected, resulting in improving the ability of the organization in delivering a safe product and remaining in compliance with the requirements.

e).

Audit plan will cover all processes and product sampling at all locations where maintenance and related activities are being carried out.

f).

Quality manager will publish a yearly schedule and distribute the same to Regional Airworthiness Office (Bangalore), Chief Engineer, Manager- technical services and all line stations. This plan encompasses aircraft, base facilities, line facilities, logistics, training and the associated procedures.

g).

Quality manager will control and monitor implementation of the audit plan, which will allow for reaction to unforeseen circumstances and arrange scheduled audits at the most appropriate time.

h).

Audit plan will documented as appendices of the EPM Section-3, Chapter-3 and will be updated by quality manager based on the varying scope of approvals / locations during the period of the year.

i).

Independence of audit will be maintained by always ensuring that audits are carried out by dedicated audit personnel not responsible for the function, procedure and products being checked.

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Requirements for issue of Approval / Authorization

j).

3.1.3

For a medium size organization (employing less than 500 persons in the AMO), competent personnel from one section / department not responsible for the production function, procedure or product to audit another section / department, and overall planning and implementation will be controlled by the Quality Manager.

ANNUAL REVIEW OF MAINTENANCE PROCEDURES

a). The quality manager will implement an audit plan, which during a twelve-month period will address the whole maintenance system and management activity and all of the aspects of CAR-145, that have a bearing on the ability of the organization in delivering a safe product the meeting the company requirements. b). The quality audit programme will also address, through individual audits, the aspects of the individual aircraft maintenance, which are covered by the DGCA’s approval. Organization’s quality audit programme consist of;

1.

Base station (Facility & Procedures) audit

2.

Line stations (Facility & Procedures) audit.

3.

Aircraft / Component (Product) audit

c). Half yearly review report of audit findings and corrective action carried out will be sent by Quality Manager to Accountable Manager. d). The annual review report of audit findings for the year and corrective actions carried out will be sent by Quality Manager to the Regional Airworthiness Office, Bangalore at the end of the year.

3.1.4

AUDIT PROGRAMME

a). Audit programme consists of compiled customized check lists for various functional areas of the organization to ensure compliance with manufacturers and regulatory authorities requirements. b). Internal audit by the quality audit team is a continuous process to ensure that the firm is in compliance with all the requirements and deficiencies noted, if any, during internal audit, are corrected properly. c). Internal audit always ensures there are no possible deviation from defined standards and provides recommendation to the Chief Engineer & Accountable Manager for Quality improvement. d). Quality Manager with internal auditors will compile a checklist to ensure coverage of the maintenance and related activities. Such checklists will be reviewed yearly to incorporate any changes or additional audit requirement.

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e). The audit program will include at least the following areas; a.

Base station audit

Technical Services – Base station

1 2 3 4 5 6 7

Maintenance Base station

–

Logistics & Stores – Base station

b.

Line station audit

Sub base / Line station Audit – Maintenance, Tech. Services, Logistics & Stores

c.

Technical literature - Receipt - Control and Amendment. Maintenance program – Preparation – Control - Amendment Inspection Schedules and procedure sheets - Preparation – Approval - Amendment Generation of Due report - Scrutiny of work order / work packages – Record keeping Original Log books – Entries, Upkeep Modification/ Airworthiness Directives Data – Receipt – Action-Data keeping Records retention Hangar facilities. Ground servicing equipment Aircraft maintenance and certification. CRS procedures. Defect recording, analysis, investigation and statistics. Engine trend monitoring. Training of Personnel Records of certifying persons. Supplier / Contractor evaluation and control Inspection & Acceptance of components & materials Tagging, Storage & Release of components & materials Procurement & acceptance of tools and equipments Calibration of tools and equipments Issue of tools and equipments to maintenance & control

1 2 3 4 5 6 7 8

Line maintenance control of spares. Maintenance documentation procedure. Oil, fuel uplift records. Line station defect control. Technical log completion. Returning of defective components. Ground support equipment servicing. Servicing/ calibration of tools and equipment.

1 2 3 4 5 6 7

Shop approval and Capability. Designated areas for various activities. Pneumatic / Electrical power / Water availability Shop tables / Fire extinguishers / Special tools & equipments. Environmental conditions. Publication control – subscription, receipt, amendment, processing, dissemination. Inspection / Overhaul / Repair schedules – Preparation, scrutiny, approval, amendment w.r.t publication revisions. work order – Issue / Preparation, scrutiny for completion, CRS issues Completed schedules – scrutiny & retention. Support / certifying staff – Approval / Authorization, validity, specimen signature. Availability of tools, spares & consumables.

Shop Audit

Shop Audit – Maintenance, Tech. Services,

8

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Requirements for issue of Approval / Authorization

d.

Product Audit (Aircraft)

Product audit aircraft

e.

Aircraft interior / exterior - condition placards etc. Corrosion on structure and other areas. Documents to be carried on board. Trend monitoring & Power assurance of engine.

Product Audit (component)

Product audit component

3.1.4.1

1 2 3 4

1 2

Component receipt documentation & incoming inspection. Dismantling, Cleaning, Inspection, Processes, Assembly, Packing & Dispatch.

ADEQUATE AND SATISFACTORY FACILITIES a.

Audit check lists, which forms the part of the procedure manual will cover the aspects of verifying adequate and satisfactory facilities while conducting audit of base, line and shop station facilities.

b.

Adequate and satisfactory facilities will include the following : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Facility for parking the aircraft in the hangar during base maintenance. Facility for keeping the components removed from the aircraft during base maintenance. Facility for keeping and accessing the hard copy / electronic maintenance data, while carrying out the work during base maintenance. Facility for printing the electronic version of maintenance data to hard copy for ease of reference. Facility for Tech. services personnel for carrying out the work, in terms of office space for personnel, records etc. Facility for storage of serviceable, unserviceable, quarantine, scrap parts, tools, equipments and consumables required for base maintenance. Facility in terms of pneumatic, electric power, water etc. Facility capable of protecting the aircraft / personnel from adverse weather conditions such as hailstorm, snow, heavy wind etc. Facility to attend and service the aircraft like fuelling, lubrication servicing, gas charging etc at line maintenance locations. Facility at shop locations in the form of work benches for inspection, maintenance, packing, tools & equipments, power requirements, cleaning baths, testing facilities, ovens etc as required for meeting the scope of work granted for the shop.

c.

Quality auditors carrying out the audit will verify whether the facilities are adequate and are being maintained satisfactorily to carryout the maintenance functions within the scope of approval grated without compromising the quality of work being carried out.

d.

Any non-standard facilities or non-conformances in maintaining the quality of facility will be recorded as non-compliance and followed up for suitable corrective action, with in the agreed time period.

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3.1.4.2

COMPLIANCE WITH APPROVED PROCEDURES a).

The audit program will include, verification of compliance with the procedures approved in respective procedure manuals, which are listed below station wise; 1.

Base Station i. ii. iii. iv. v.

2.

Line Station i. ii.

3.

Maintenance Procedures Stores Procedures.

Shop Location i.

3.1.4.3

Maintenance Procedures. Tech. Services Procedures Logistics Procedures Internal Training Procedures & personnel Approval procedures. Quality Assurance (Audit process & auditors)

Maintenance Procedures

DATES AND TIME SCALES (Ref: EPM Section – 3, Chapter – 3)

a). An internal audit plan will be drawn up, as given here under, ensuring that all sections of the Approved Maintenance Organization responsible for aircraft maintenance functions are audited at least once in every 12 months. b). The quality manager will maintain master folder of audit check lists with index for reference and use of personnel. c). This plan will be made during the month of December for the succeeding year. Programme will be provided to Accountable Manager and chief engineer, Regional engineering manger and Head-Logistics. d). Typical audit plan is provided as annexure in EPM Section-3, Chapter-3. e). Audit schedule for the year is given below in a calendar wise / location wise table.

STATION\MONTHS DELHI JAMMU KATRA MUMBAI SURAT RAIGARH KOLKATA BHUBANESHWAR VIZAG HYDERABAD

JAN √ √ √

FEB

MAR

√ √ √

APR

MAY

JUN

JUL √ √ √

AUG

SEP

√ √ √ √ √ √ √

√ √ √ √

OCT

NOV

DEC

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√

TORNAGALLU BANGALORE WHEEL & BRAKE SHOP BATTERY SHOP CHENNAI KOPPAL

3.1.4.4

√ √ √

√ √

√ √ √

√ √ √

AUDIT OF SUPPLIERS & CONTRACTORS (Ref: EPM Section – 3, Chapter – 12)

a).

Organization procures parts and materials from company approved supplier and outsources maintenance activities beyond the scope granted by DGCA to company approved contractors.

b).

Company approvals for suppliers / contractors are provided based on the approval issued by airworthiness authority of the country (where it is located), with whom the Govt. of India (Ministry of Civil Aviation) has bi-lateral agreements.

c).

Such organization may be approved under EASA Part-145 or FAA Repair station approval procedures or Transport Canada approval procedure or by any other process / category of approval in effect, in such countries.

d).

Physical audit of such facilities and the periodicities will be carried out based on the following criteria, which will be decided by the Quality Manager & Accountable Manager on case to case basis. 1. 2.

Geographical location of the organization (i.e. Distance from Bangalore). Volume of material being purchased / maintenance work being outsourced.

e).

All suppliers and contractor evaluation will be carried out as per procedure given in MOE 2.1

f).

Detailed procedures for evaluation and control of contractors are provided in LPM Chapter -14

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3.2

3.2.1

3.2.2

QUALITY AUDIT OF AIRCRAFT / COMPONENT a).

This section outlines the policies and procedures adapted by the organization for carrying out a product audit on aircraft at base / line stations and component audit at shop facilities.

b).

Detailed procedure for audit of aircraft / component is provided in EPM Section-3, Chapter-4.

SYSTEM DESCRIPTION AND INITIATION OF CORRECTIVE ACTION

a).

Audit will be carried out to verify the condition of the facility, procedures and practices in place for carrying out maintenance, product sampling (aircraft / component), which is the result of the procedures followed by maintenance personnel.

b).

Auditing will be based on the checklists, which are used to find out the anomalies in the facilities, procedures, products and non-conformances recorded.

c).

Non-conformances recorded will be referred to the relevant clause of MOE, EPM or regulatory requirement.

d).

Reference to the evidences related to the non-conformances will be mentioned in the nonconformances and copy retained in file for future reference.

e).

Signature of the auditee will be obtained in the non-conformances.

f).

List of non-conformances will be communicated to section in-charge (immediate senior in line) and Regional engineering manager,

g).

Corrective measures will be suggested to correct the discrepancies and followed up for ensuring compliance.

AUDIT PROGRAMME – AUDITING STANDARDS

a).

3.2.2.1

Auditing standards will be based on company requirement provided in MOE, Procedures given in various procedure manuals and based on self experience to correct the discrepancies observed. Audit points will be complied in the form of checklists and the same will be used.

PRODUCT SAMPLES (AIRCRAFT AND / OR EQUIPMENT) a).

Auditing of aircraft / component will include verification of the airworthiness status of aircraft by following checklists and using experience to observe the discrepancies which may affect the airworthiness of the aircraft / component.

b).

Status of completion of schedules, work order, procedure sheets and off-job sheets including the transfer of defects to work order / on the columns provided for recording the additional work carried out in the inspection schedule, will be verified.

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Requirements for issue of Approval / Authorization

c).

Compliance to the following requirements will be verified; 1. 2. 3. 4. 5. 6. 7.

d).

3.2.2.2

3.2.3

a).

Regular Audit will be conducted on aircraft / equipment once every twelve months, as per published audit plan.

b).

Variation to audit plan will be maintained to maximum of plus or minus one week and could be due to reasons beyond control of the organization such as weather, civil unrest etc.

c).

Spot check audit will be carried out without any prior intimation to the personnel at the location.

AUDITING METHODS (Ref: EPM Section – 3, Chapter – 3)

Sampling and Trail method of auditing process will be followed, while preparing the audit check list for various maintenance and related activities.

SAMPLING a).

3.2.3.2

Record of audit and spot checks made with respect to each aircraft will be maintained by the Quality Auditors and a photo copy of the report will also be retained at the respective station by the Base engineering manager / engineering in-charge.

DATES AND TIME SCALES

a).

3.2.3.1

Compliance with manufacturers’ and the organization’s standard specifications and procedures; Condition of corrosion prevention and control treatments and other protective processes; Procedures followed to ensure that entire aircraft is checked on completion of any work or maintenance, for loose tools, loose articles, general cleanliness and housekeeping. Recording of observations. Correct certification of maintenance documents, log books and recording of all maintenance work. Adherence to the procedures. Condition of aircraft / equipment.

Sampling is an audit method in which one of the activity / end product is randomly selected and audited to know whether the organization follows the set systems and procedures to produce a quality end product. Auditing by sampling method will be followed while auditing various systems and functions of the organisation

“TRAIL” AUDITS a).

Trail Audit is a procedure by which the audit is conducted on a process starting from its Initialization to completion. For example; Audit subject: Use of Latest publication for maintenance activities.

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Trail Auditing will be carried out about the process used by the organization for ordering publication, keeping a track of its subscription status, system in place to ensure receipt of publication, documenting the receipt, dispatch of publication to various bases, review of publication, action taken to execute the requirement of the publication on the aircraft / component and so on. b).

Audit by Trail method will also be used while conducting audit of the AMO’s system and procedures.

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3.3

3.3.1

3.3.2

QUALITY AUDIT – FINDINGS –REPORTING - REMEDIAL ACTION PROCEDURE (Ref: CAR 145.65.c.2 & EPM Section – 3, Chapter – 6) a).

This section outlines the policies and procedures adapted by the organization for obtaining report from the auditee about the corrective action taken and evaluation of the same, whether it meets the requirement.

b).

Detailed procedures of quality audit findings, reporting of non-compliance, remedial action procedure are provided in EPM Section-3, Chapter-6

COMPANY POLICY

a).

Quality audit will be carried out by auditors using customized check lists as per audit plan and record non-conformance.

b).

Non-conformances recorded will be classified as per the severity of the non-compliance and its effect on flight safety.

c).

Non-conformances will be raised, with mutually agreed date (by auditor and auditee) for corrective / preventive action.

d).

On completion of audit, audit report along with all non-conformances will be sent to the auditee and the concerned department head.

e).

Action (corrective & preventive) taken report received from the auditee will be reviewed based on evidence or by another review audit to verify the adequacy of the action completed.

f).

Feedback about the action taken will be communicated to the auditee and the concerned department head.

g).

Half yearly review report will be provided to the accountable manager about the station wise details of findings and action taken and the pending non compliances.

AUDIT PROCESS & RECORDING OF FINDINGS a).

Audit is carried out using customized checklists prepared in accordance with the MOE, Procedural manual requirements and manufacturer’s specification / recommendations for maintenance.

b).

Customized check lists consists of audit inspection items in the form of questionnaire to find out whether the concerned personnel are following the policies and procedures given in MOE, Procedure manuals, Airworthiness data, Maintenance data, Maintenance instructions etc.

c).

Findings (Non conformances) observed by the auditors are classified into two levels as given below; 1.

Level 1 Finding is any significant non-compliance with CAR-145 requirements which lowers the safety standard and hazards seriously the flight safety.

2.

Level 2 finding is any non-compliance with the CAR-145 requirements which could lower the safety standard and possibly hazard the flight safety.

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d).

Audit observations are recorded in the customized check lists in the following manner ; 1. 2. 3. 4. 5.

e).

Any un-acceptable deviation from the procedures / non-compliance of the requirement will be recorded as Findings / Non-conformances in the audit check list.

f).

For every Non-conformance findings marked in audit check list a non-conformance report (NCR form no. 051) will be raised and the NCR number will be reflected in the completed audit check list.

g).

Non conformance Report (Form No. 051) will have the following information; 1. 2. 3. 4. 5. 6. 7. 8. 9.

3.3.3

√ - Satisfactory A – Acceptable X No – Non-Conformance No. N/A – Not Applicable NP – Not Performed

Non conformance report Number Location and Audit subject (Procedure / Product) Details of Non conformances found and its classification (Level I or II) Violation / Non-compliance details w.r.t MOE / Procedure Manual / Aircraft specification / Deviation from standard practices etc. Root cause information provided by the auditee Mutually agreed time frame for corrective / preventive action, with sign & date, by auditor and auditee. Space for auditee to record the corrective / preventive action with sign & date. Review comments by auditor & Quality Manager. Closing date by Quality Manager.

h).

Non-conformance will be rated by the auditor as Level-1 or Level-2 finding based on its effect on the flight safety, whether seriously hazards or possibly may hazard the flight safety.

i).

Level -I NCR is required to be actioned upon immediately and without any allowable timeframe.

j).

Product related to the Level-1 finding will be instructed to be kept in abeyance and not released to service, till the time the Non-conformance is properly actioned upon (corrective and preventive action).

k).

Level – II NCR raised will be discussed with the auditee and the time frame required to complete the action (corrective / preventive) will be mutually decided and documented in the NCR form.

l).

Audit report and One copy of the NCR (Level –I or II) will be handed over to the auditee for recording the corrective action and to return to the auditor.

QUALITY AUDIT REPORT AND FEEDBACK SYSTEM a).

Audit report is generated by the auditor after completion of the audit for the purpose of reporting to the auditee and his department head about the level of compliance to the CAR-145 requirement and the manufacturer’s specifications (aircraft maintenance programme & standard procedures).

b).

Audit report will consists of the following minimum information;

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c).

1. 2. 3. 4.

Audit report Number Location and Audit subject (Procedure / Product) List of findings and the attached NCR form related to the findings. Signature of the Quality auditor.

5. 6. 7. 8. 9.

Non conformances found and its classification Mutually agreed time frame for corrective / preventive action, with sign & date. Space for auditee to record the corrective / preventive action Review comments by auditor & Quality Manager. Closing date by Quality Manager.

Quality audit report (form No. 053.)with a details of observations will be sent to the following personnel for non-conformances in the areas, which are under their direct control and accountability;

Responsible Persons Base engineering manager Regional engineering manager Line station engineer incharge Shop in-charge Manager-Tech. services Head - Logistics Stores Inspector - Bangalore Tools & Equipments Incharge Bangalore Chief engineer

d).

All Base maintenance and associated line maintenance activity including Technical library, stores, tools & equipments including GSD, hangar, tarmac, base / line staff information control etc

Regional Engineering Manager Chief Engineer Chief Engineer

All line maintenance and related activity including literatures, tools and equipments, tarmac, fuelling and servicing etc All shop maintenance and related activity. All Technical Services activity at Bangalore.

Chief Engineer Head - Logistics

All logistics functions. All functions related to stores at Bangalore and at other stations and movement of goods between bases All functions related to control of tools and equipments at Bangalore and at all stations.

Head - Logistics

Accountable Manager

Area of responsibility

All activities listed above

Responsible persons listed above will carryout the following actions to close the non-compliance within the agreed timeframe within which it can be addressed; 1. 2. 3. 4.

e).

Immediate superiors Regional engineering manager Chief Engineer

Correct the discrepancy immediately to avoid further damage or reduction in level of safety / quality. Analyse the non-compliance and establish the root cause for the non-compliance. Initiate preventive actions for to stop repeat of such non-compliance. Prepare and submit a report to Quality Manager and Chief engineer and immediate superior giving above details against each observation.

Quality manager will monitor the response and compliance action by verifying the preventive & corrective actions carried out, raise a quality audit feedback report (Form No. 054) and forward it to the concerned responsible person & immediate superior, chief engineer.

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3.3.4

3.3.5

f).

Quality audit feedback will be provided by quality manager location wise and department wise. Feedback report will have two sections. First section will list station wise pending NCRs. Second section will provide the observation / findings (Non-conformances) and against each Nonconformances, and acceptable corrective and preventive action taken will be listed.

g).

If Quality Manager is not satisfied with the action taken, he will communicate the same to the auditee and his department head, under copy to the Chief engineer asking for review of action taken.

h).

In such case, review of action taken and justification will be provided by the Chief engineer and then the NCR will be considered closed.

i).

If satisfied about the action taken, Quality Manager may ask the auditor to close the specific audit. Else quality manager will require the auditor to carryout a review audit to confirm the adequacy of the corrective & preventive action taken.

j).

On completion of the review of action taken report / subsequent review audit, Quality Manager will provide a feedback report to the auditee / chief engineer about the closure of the NCR.

k).

The principal function of the quality audit feedback system is to ensure that all findings (Nonconformances) resulting from the independent quality audits conducted by the Quality auditors are properly actioned upon or corrected in a timely manner and to keep accountable manager informed of any safety issues and the extent of compliance with CAR-145.

l).

Quality Manager will carryout review every six months and prepare a review report for submission to the Accountable Manager

ACCOUNTABLE MANAGER / SENIOR MANAGEMENT REVIEW MEETING

a).

The Accountable manager will hold half-yearly review meetings with Chief Engineer and Quality Manager to check progress of corrective actions and to review the overall performance of the organization.

b).

Half yearly review report of audit findings and corrective action carried out will be submitted by Quality Manager to Accountable Manager, during the review meeting.

c).

Root cause analysis report, in general covering all areas of discrepancy will be prepared by the quality manager and submitted to the Accountable Manager and Chief engineer during the review meeting

d).

Discussions will be held to improve the areas of functions, which have higher and repeated nonconformances to avoid reduction in quality and safety rating of the organization.

CORRECTIVE ACTION AND TIMESCALE

a).

The Quality Audit non-conformance Report (Form No. 051) will be a composite form in two sections. i.e. Non compliance section and Action taken section.

b).

Non compliance section highlights the discrepancies observed by the auditor to the attention of the person responsible for the particular facility, procedure or standard.

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3.3.5.1

3.3.5.2

c).

Action taken section will provide the details of corrective action taken, root cause analysis for the non-compliance and preventive action taken to avoid recurrence.

d).

All non-conformities observed during audit will be recorded in the form with the details as listed in 3.3.2.g

e).

The form will allow one copy to be retained by the auditor until the corrective & preventive action is satisfactorily completed.

f).

Auditee will fill up the second section of the NCR form with applicable / relevant evidences, giving proof of corrective action, and sent to auditor for closing the NCR.

g).

Level -I NCR is required to be actioned upon immediately and without any allowable timeframe.

h).

Product related to the Level-1 finding will be instructed to be kept in abeyance and not released to service, till the time the Non-conformance is properly actioned upon (corrective and preventive action).

i).

Level – II NCR raised will be discussed with the auditee and the time frame required to complete the action (corrective / preventive) will be mutually decided and documented in the NCR form. In any case more than 2 -3 weeks will not be provided for closing of Level II NCR.

REMEDIAL ACTION

a).

When corrective action is performed the same will be recorded in the applicable columns of Nonconformance form, and returned to the Quality Auditor.

b).

Auditor will prepare a consolidated audit report (Form No. 053) listing all audit findings and related compliance action received from the auditee.

c).

After the compliance action is accepted by the Quality Manager, non-conformity report will be closed by the Quality auditor and intimation sent to the responsible person and his department head about the acceptance to the action taken.

DISCIPLINARY ACTION

a).

3.3.5.3

Whenever it is found that the discrepancy reported is due to willful negligence or casual attitude of any individual or a group of persons, then disciplinary action will be initiated by the Accountable Manager.

MANAGEMENT RESPONSIBILITIES FOR CORRECTIVE ACTION AND FOLLOW-UP

a).

It is the responsibility of the Chief engineer to ensure thru Base Engineering Manager’s, that nonconformity reports are satisfactorily resolved within a reasonable time frame.

b).

It is the responsibility of the quality manager or auditor to ensure that the action taken is adequate and likely to ensure future satisfactory performance and prevent recurrence.

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3.3.6

QUALITY AUDIT AND FEEDBACK RECORDS

a).

Quality audit and feedback records will be maintained by the quality auditor at Bangalore.

b).

Hard copy of the quality audit report, NCR forms and Feedback report will be maintained for a period of two years at Bangalore and at sub-base / line stations by the quality auditor / Tech. Officer / Engg. In-charge respectively.

c).

Quality audit and feedback records will be scanned and scanned copy will be maintained for a period of 5 years.

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3.4

3.4.1

3.4.2

APPROVED / AUTHORISED STAFF - QUALIFICATIONS AND TRAINING PROCEDURES (CAR 145.A.30.h, CAR 145.A.35 & EPM Section-3, Chapter 8, 9, 10 & 23)

a).

This section outlines the policies and procedures followed by the organization to ensure the support /certifying staff meets the qualification and competency standards set by the organization. This section also provides the training requirements to be met by the support / certifying staff.

b).

Support staffs are those who are licensed as per DGCA requirement / issued with approval by Quality Manager working in the base maintenance environment and do not hold necessary certification privileges to release the aircraft to service.

c).

Certifying staffs are those issued with a certification authorization by the quality manager permitting them to sign Certificate of Release to Service on behalf of the organization, within the limitations stated in such authorization.

d).

Task Trained and authorized Persons means a person who has received the appropriate task training within the trade category of experience and having granted an approval for performing limited tasks as part of minor scheduled line maintenance or simple defect rectification contained in AMC 145.A..30.g.2.

e).

Detailed procedures for control of qualifications, training requirements, competence assessment & issue of inspection approval / certification authorization to support / certifying staff is provided in EPM Section-3, Chapter-8, 9, 10 & 23.

COMPANY POLICY

a).

Qualified personnel will be recruited by the organization after carrying out internal competency assessment as per established procedure.

b).

All personnel employed in maintenance and related activities will be provided with induction, & continuation training.

c).

Qualified and competence assessed personnel will be provided with approval to carryout and certify maintenance activities / certification authorization to sign Certificate of Release to service.

INSPECTION APPROVAL AND CERTIFICATION AUTHORIZATION

a).

The following types of approvals / authorization will be issued by quality manager; 1.

Inspection Approval to carryout and certify maintenance on aircraft/ engine / propeller/ systems/ components. (Base / Component maintenance)

2.

Certification Authorization to carry out & certify maintenance on aircraft / engine / propeller / systems / components and also to sign certificate of release to service on behalf of the organization.

3.

Task Trained Personnel Authorization: Task Trained and Authorized persons will be authorized to carryout limited line maintenance tasks on aircraft / component and issue aircraft CRS with respect to the work, the aircraft is released to service.

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4.

Details of various types of approvals issued by the organization are indicated as annexure no.1 to this chapter

b).

Quality manager will control the system and procedures that are followed for issuing authorizations / approvals.

c).

The certifying staff hold authorizations which allow them to issue ‘Certificates of Release to Service’ after inspection, replacement, modification and defect rectification as defined in MOE 2.16 and in associated procedures within the provisions of DGCA requirements and limited to the company’s approved scope of work.

d).

Inspection approvals / Certification authorization will be issued in a style that makes its scope clear to the certifying staff and any authorized person (DGCA officials) who may require to examine the authorization. (CAR 145.A.35.h refers).

e).

Inspection approval will have the following minimum information; 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

f).

Name of the certifying staff. Company Approval Number. Date of initial issue Approval validity Holder’s signature & stamp Quality Manager’s signature & stamp AME Licence Number Date of initial issue Licence validity Basic licenses & Aircraft Type ratings & category Inspection approvals granted. Approval limitations Other privileges – Engine ground run / aircraft taxiing / duplicate authorizations.

Certifying authorization will have the following additional information; 1. 2.

Authorization Limitations. Certification authorization granted

g).

Task Trained Personnel authorization will be issued in the same format as the inspection approval / certification authorization, but will have Not Applicable entry on relevant columns related to Basic / AME licence details.

h).

Quality Manager will issue inspection approval / certifying authorization to support /certifying staff, on behalf of the organization and may nominate Quality Auditor’s to actually conduct examination and issue or revoke the inspection approval or certification authorization to support / certifying staff. (CAR 145.A.35.i refers).

i).

Detailed procedures for issue of inspection approval / certifying authorization is provided in EPM Seciton-3, Chapter-8

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3.4.3

GENERAL REQUIREMENTS FOR ISSUE / RENEWAL OF APPROVAL - AUTHORIZATION

a).

3.4.3.1

Minimum age for support / certifying staff is 21 years. (CAR 145.A.35.m refers)

ii.

Completed refresher training within preceding 24 months, (for renewal Only) (CAR 145.A.35.d refers)

iii.

Involved in maintenance at least six months in the preceding 24 months. (CAR 145.A.35.c refers)

iv.

Every maintenance personnel are expected to maintain a personal logbook, which will give the details of the individuals work experience, task performed under the supervision of authorized personnel. Such logbooks will only be considered as an experience for issue / extension of approval / authorization. Procedure for maintenance of personal logbook is explained in EPM Section-2, Chapter-5.

v.

Approval /Authorization will be issued to personnel meeting the minimum qualification requirements and passed the oral cum practical examination (competency assessment) conducted for the purpose by a board constituted by the Quality Manager. The board will consist of quality manager or auditor, Chief Engineer and / or senior type rating holder having appropriate endorsement and approval.

Requirement for issue of inspection approval to support staff in terms of qualification, minimum experience, training and competence requirement are provided in Annexure-1 of this Section (Part3).

REQUIREMENT FOR ISSUE OF CERTIFYING AUTHORIZATION TO ISSUE CRS.

a).

3.4.3.3

i.

REQUIREMENT FOR ISSUE OF APPROVAL – QUALIFICATION, EXPERIENCE, TRAINING & COMPETENCE.

a).

3.4.3.2

General Requirements for grant or renewal of inspection approval / certification authorization are given as under;

Requirement for issue of certification authorization to certifying staff in terms of experience to carryout such maintenance work, training and competence requirement are provided in Annexure1of this Section (Part-3).

TASK TRAINED AND AUTHORIZED PERSONS – REQUIREMENTS FOR ISSUE OF TASK BASED AUTHORIZATION AND LIST OF TYPICAL TASK PERMISSIBLE TO BE CARRIED OUT BY TASK TRAINED AND AUTHORIZED PERSONS a).

Requirements for issue of certification authorization for task trained person and authorized persons in terms of qualification, minimum experience to carryout such maintenance work, internal on-job training and competence requirement are provided in Annexure -1 of this section. (Part-3)

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b).

3.4.3.4

List of typical task permissible to be carried out by task trained & authorized persons are given below; 1.

Routine lubrication and replenishment of all system fluids and gases.

2.

Replacement of wheel assemblies, brake units, emergency equipments, ovens, boilers, beverage makers, internal & external lights, filaments, flash tubes, windscreen wiper blades, pax / cabin crew seats, seat belts, harnesses, toilet system components including gate valves, static wicks, batteries, in-flight entertainment system components excluding passenger addressing system.

3.

Closing of cowling and re-fitment of quick access inspection panels

4.

Installation / Removal and De-activation of duplicate controls (limited to installation / removal of dual control stick or pedals with its attachment rod and hardware without disturbing the primary control and its hardware) and /or system components permitted by MEL.

5.

Detailed procedure for on-job training and issue of authorization for task trained persons are provided in Section-3, Chapter -22.

EXAMINATION, TEST AND ASSESMENT PROCEDURES a).

Candidate fulfilling requirements in terms of qualification, experience, training and competence will apply using application for grant of approval / authorization (Form No. 005) with relevant enclosures and submit the same to the Chief engineer thru, Regional engineering manager.

b).

Regional engineering manager / Chief engineer will carryout initial assessment and recommend the application to the Quality Manager for conduct of competence assessment examination for issue of inspection approval / certification authorization.

c).

Quality Manager / auditor will constitute a board consisting of Quality Manager /auditor, Regional engineering manager / chief engineer and type rated AME / approval holder and conduct an oral cum practical examination to assess the competency of the personnel to carryout the work.

d).

Test will include oral cum practical examination to analyze the theoretical knowledge level, practical exposure on subject task expected to be performed and related precautionary / safety measures to be taken before undertaking the work.

e).

Questions asked by the exam board members and answers provided by the candidate in the oral cum practical examination will be documented and will form a part of the application form.

f).

At the end of the exam, candidate’s signature will be obtained against the answers provided by him for the questions put by the exam board members.

g).

If the candidate displays 70% knowledge during a oral cum practical examination, the candidate will be declared passed, and recommended for issue of approval / authorization.

h).

Quality Manager will issue approval / authorization (Form No. 058) to the candidates declared successfully passed by the examination board. Copy of the approval / authorization will be provided to the individual.

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i).

Approval / Authorization will have table containing the inspection approval / certification authorization privileges granted to the support / certifying staff.

j).

Approval / Authorization issued will be valid for a maximum period of one year, but restricted till the end of the issuing year, during initial issue. Later on, approval / authorization will be renewed for a period of one year.

k).

Support / certifying staff wish to renew their approval / authorization will submit a application for approval / authorization renewal duly countersigned by the Regional engineering manager.

l).

Requirement for renewal of approval / authorization is given below; 1. 2. 3. 4.

3.4.4

Duly filled application should be submitted to the Quality Manager. Medical certificate signed by atleast a MBBS should be attached. Proof of recent experience of 3 months in last 12 months should be shown. If approval/ authorization were not used during last 12 months, then the support / certifying staff should appear for competency exam before exercising the privileges.

CONTINUATION TRAINING- PROGRAMME & PROCEDURES

a).

Training manager will establish continuation training programme for support and certifying staff which will cover the requirements given in Airworthiness Advisory circular No. 8 of 2000.

b).

All support / certifying staff will attend continuation (refresher) training once in 24 months on the type of aircraft, on which they hold type rating / company approval or authorization.

c).

Support / Certifying staff requiring continuation training will contact training manager by mail and send a request for training on specific model of aircraft / component, at least 3 months before the expiry of the previous refresher training

d).

Training Manager will organize for conduct of the training at the training facility at Jakkur or organize for training to be provided at site.

e).

If training is to be provided at site due large number of staff at one place, training manager will propose with to the Quality Manager detailing the facilities organized at site for conduct of training and obtain approval from the Quality Manager.

f).

The continuation training procedure is given in Para 5.9 of Training Manual

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3.5

3.5.1

CERTIFYING STAFF RECORDS (Ref: EPM Section-3, Chapter-28) a).

This section outlines the policies and procedures followed by the organization to maintain support / certifying personnel’s records, so that the same can be retrieved when required.

b).

Detailed procedure for control of support / certifying staff records are provided in EPM Section-3, Chapter-28.

COMPANY POLICY a).

3.5.2

LIST OF SUPPORT / CERTIFYING PERSONNEL a).

3.5.3

Records pertaining to support / certifying staff will be maintained / retained in the organisation as per established procedures.

List of support /certifying staff is provided in MOE 1.6 and the same will be updated by the Quality Manager once in six months.

MINIMUM INFORMATION OF CERTFYING STAFF a).

The following minimum information will be kept on record of quality cell in respect of each certifying person. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

3.5.4

CONTROL OF CERTIFYING STAFF RECORDS a).

3.5.5

Name. Date of Birth. DGCA License No., Rating and Validity Basic Training. Type Training. Refresher Training. Experience. Qualification relevant to the approval. Scope of authorization Date of first issue of authorization. Validity of authorization. Identification number of authorization. Medical Record.

Persons authorized to have access to the system will be maintained at a minimum to ensure that records cannot be altered in an unauthorized manner or that such confidential records become accessible to unauthorized persons.

ACCESS TO STAFF RECORDS- AUTHORISED PERSONS, DGCA PERSONNEL, AUTHORISED MANAGERS a).

The certifying person will be given reasonable access on request to his own records.

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3.5.6

3.5.7

b).

Quality Manager will provide support / certifying staff with a copy of their inspection approvals / certification authorization in either a hard copy or soft copy format (CAR 145.A.35.k refers)

c).

DGCA personnel (Authorized persons), Quality Manager and Chief Engineer will have complete access to all records.

RETENTION OF RECORDS a).

Support / Certifying staff records will be retained for at least two years after the certifying person has ceased to be employed with the organisation or on the withdrawal of the authorization whichever is earlier.

b).

In addition, the certifying personnel will be furnished, on request, with a copy of their record on leaving the organization, after obtaining necessary clearances and completing standard company administration exit / severance formalities.

FORMAT OF INSPECTION APPROVAL / AUTHORIZATION DOCUMENT

a).

Inspection approval / Certification authorization including task trained person’s authorization is issued in the same format.

b).

The format of Authorization is provided as Form No. 058 in forms manual.

c).

Contents of the inspection approval / certification authorization is provided in MOE 3.4.2 (e. f & g)

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3.6

3.6.1

3.6.2

3.6.3

QUALITY AUDIT PERSONNEL (ASSURANCE PERSONNEL) (Ref: EPM Section-3, Chapter-30) a).

This section outlines the policies and procedures to be followed for employment of quality audit personnel (otherwise mentioned as Quality Assurance personnel) including their qualification requirement.

b).

Detailed procedure for competency assessment of quality audit (assurance) personnel are provided in EPM Section-3, Chapter-30.

COMPANY POLICY a.

Suitably qualified and experienced personnel will be recruited to function as Quality auditors.

b.

Quality audit personnel will remain independent of production functions.

c.

Quality audit personnel will be provided with continuation training and specialization training on audit techniques.

APPROVED / NOMINATED PERSONNEL a).

Person with appropriate knowledge and experience given in MOE 1.3.3.2 will be proposed as Quality manager to Regional Airworthiness Office, Bangalore for approval.

b).

Quality Auditors will be appointed by Quality Manager in consultation with Manager – Human Resource Department after competency assessment.

ALLOCATED MAN-HOURS(IF NO FULL TIME) a).

3.6.4

All quality Audit personnel will be working on full time basis.

INDEPENDENCE OF QUALITY AUDIT PERSONNEL

a).

Auditors will not have any day-to-day involvement in the area of maintenance activity that is to be audited.

b).

They will have freedom of access to all work areas, offices, files, records and personnel and will be reporting directly to the Quality Manager

c).

Auditors will be able to carry out their audits independently of routine management and in accordance with the company quality audit programme, report and record on the appropriate documentation, all findings and discrepancies to enable them to be dealt with under the closed loop process.

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3.6.5

EXPERIENCE, TRAINING AND COMPETENCE OF QUALITY AUDIT PERSONNEL a).

The personnel required to carry out the auditing tasks, will meet the following criteria ; 1. 2. 3.

10 years of aircraft maintenance experience, excluding ab-initio training. 2 years in quality audit /control department. Must have attended training on quality auditing techniques.

b).

Product audit personnel should have a company training on the aircraft / engine / propeller / system / component maintenance or type rated on the aircraft / engine.

c).

All quality audit staff involved in the audit process will receive appropriate audit training, including introduction to quality audit systems, audit techniques and the appropriate methods of reporting and recording.

d).

Refresher training will be provided every 24 months

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3.7

SUPPORT / CERTIFYING STAFF INCLUDING TASK TRAINED PERSONS (Ref: EPM Section -3, Chapter-8, 9 & 10)

MOE 3.4 details the certifying staff requirements.

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TASK TRAINED AND AUTHORIZED PERSONS (Ref: EPM Section-3, Chapter 10)

MOE 3.4 details the task trained and authorized staff’s requirements.

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3.9

3.9.1

AIRCRAFT OR COMPONENT MAINTENANCE TASK EXEMPTION PROCESS CONTROL (Ref: EPM Section-3, Chapter-26)

a).

Any deviation from an aircraft maintenance programme or specified maintenance task as given in maintenance manuals or other appropriate maintenance documents, in either the content of the task or the period / frequency at which it is scheduled to be accomplished, constitutes a "Maintenance Task Exemption".

b).

This section provides in brief the policy regarding the aircraft or component maintenance task exemption process control adapted by the organization.

c).

Detailed procedure for control of aircraft or component maintenance task exemption (variation) process is provided in EPM Section-3, chapter-26.

COMPANY POLICY a).

3.9.2

Deccan Aviation will not deviate from the requirements of the approved maintenance programme, except as a "Variation", or from the requirements of maintenance, overhaul or component maintenance manual or other approved specification.

VARIATION (MAINTENANCE LATITUDE) TO AIRCRAFT MAINTENANCE PROGRAMME

a).

Application will be made initially by the certifying staff / base engineering manager who requires “Variation” from the maintenance programme due to unavoidable reason, to the chief engineer.

b).

Chief Engineer will analyze the requirement and if found valid, will forward the request to the quality manager.

c).

Quality Manager will determine if the justification for the request is adequate after seeking the support of the manufacturer where it is essential.

d).

If the variation is already permitted by the manufacturer in the maintenance manual, Quality Manager may forward the application to Regional airworthiness Office, Bangalore for approval.

e).

Detailed procedures to be followed for variation in aircraft maintenance programme is explained in EPM Section-3, Chapter-26

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3.10

CONCESSION CONTROL FOR DEVIATION FROM ORGANISATION’S PROCEDURES (Ref: EPM Section -3, Chapter -15)

a).

Concession is defined as permission by Quality Manager to deviate from the company policies and procedures described in the MOE and associated procedure manuals

b).

This section outlines in brief the policies and procedures for control of deviation from organization’s established procedure on one time basis.

c).

Detailed procedure for control of deviation from organization’s procedures are provided in EPM Section-3, Chapter-15.

COMPANY POLICY

3.10.1 a).

3.10.2

Concession as defined above will be granted only in case of an emergency and unavoidable situation, permitting deviation from established policies and procedures in MOE, after ensuring that the deviation will not cause any kind of hazard to flight safety.

SYSTEM FOR APPROVAL AND CONTROL OF CONCESSION a).

All concession requests for deviation from organisation procedure will be raised by Regional engineering manager / Chief Engineer with justification and submitted to Quality Manager.

b).

Quality Manager will scrutinize the request and if found appropriate and justified, will grant one time approval to deviate from the organization procedure.

c).

All concessions used in the aircraft / aircraft component / process / procedures will be recorded in the appropriate work order and logbooks, by the respective certifying staff, who is releasing the aircraft / component under concession.

CONCESSION CRITERIA

3.10.3 a).

No procedures related to maintenance (materials, tools etc) and certification staff requirements, provided by TC holder / regulatory authority , respectively will not be entertained

b).

Concessions are deviations from the organization’s approved practices and procedures, as defined in this exposition, which needs approval by the Quality Manager.

c).

Concession will be requested when organization is unable to follow the standard procedure and has an option to follow an alternate procedure, which will not endanger the airworthiness / safety of the aircraft and its occupants.

d).

Concession request will not be entertained by the Quality Manager more than one time. If the procedures are such that , it is impractical to follow, concerned person may apply to the Quality Manager using policy / procedure revision request form for revision consideration. (Form No.006).

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REQUEST PROCEDURE, RESPONSE AND APPROVAL

3.10.4

3.10.5

a).

Where it is found that a policy or procedure described in the MOE cannot be adhered to on one time basis, the person involved may propose to deviate from that procedure.

b).

Requests will normally originate from the Regional engineering manager / Chief Engineer and submitted to the quality manager who will examine the request and determine whether it is appropriate or not.

c).

If found appropriate and justified, the quality manager will grant concession and intimate the originator and Regional engineering manager / chief engineer.

d).

Concessions are normally one-off events that have no recurrent effect. In cases where a time limit or other restriction is placed on a concession by the Quality Manager, it will be monitored by the Regional Engineering Manager to ensure that the granted limits are not exceeded.

e).

Quality Manager will keep an index and details of various concessions issued, with justifications for audit by DGCA.

EVALUATION OF CONCESSION REQUEST

a).

The proposed deviation must meet the following conditions: 1.

The proposed alternative procedure will guarantee an equivalent level of safety and quality.

2.

While evaluating the request made by the Base engineering manager / Chief Engineer for the Concession, the Quality Manager will also verify the reasons as to why the laid down procedures and maintenance instructions cannot be adhered to, and also the justification for asking for a concession.

3.

The substantiation of the request must prove that the proposal to deviate is justified. When evaluating a request for concession and before granting the same, the quality manager will take into account the effect on the airworthiness of the aircraft or aircraft component and the applicable regulations / requirements, and the organization’s scope and the terms of the approval.

4.

The quality manager cannot vary the organisation’s scope of work or permit any action, which would jeopardize the approval held by the company. The quality manager may, however, able to vary a company procedure defined in the associated procedure manuals, provided that the policies and the intent of this MOE are not jeopardized.

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3.11

QUALIFICATION PROCEDURE FOR SPECIALISED ACTIVITIES SUCH AS NDT / NDI, Etc. (Ref: EPM Section -3, Chapter 31) a).

Deccan Aviation has capabilities to carry out the following NDI /NDT process 1. 2. 3. 4. 5. 6.

3.11.1

3.11.2

3.11.3

Fluorescent- dye penetrant inspection Magnetic particle inspection Eddy Current inspection Ultrasonic inspection. Borescope Inspection Coin Tap test Inspection.

b).

This section outlines the policies and procedures to followed for control of procedures related to the qualification, experience, training and examination of personnel involved in specialized activities such as NDT / NDI

c).

Detailed procedure for control of personnel’s qualification, training requirements, competency assessment is provided in EPM Section-3, Chapter-31.

COMPANY POLICY a).

Qualification requirements for personnel provided in CAR section-2, Series-L, Part XIV will be followed and no deviation will be entertained.

b).

All NDT / NDI inspection will be carried out based on the specific instructions provided in the NDT manual / standard practices manual / maintenance manual.

EXPERIENCE, TRAINING AND EXAMINATION

a).

Experience, training and examination requirements as given in CAR Section 2 Series L Part XIV will be followed and the same are detailed in EPM Section-3, Chapter-31.

b).

Candidate must have minimum of two years of experience in NDT industry, out of which 6 months in aviation industry.

c).

Candidate must have minimum of 3 months (in last one year) of recent experience on the procedure, by using the type of equipment or similar type of equipment owned by the company, before applying for authorization.

ISSUE OF APPROVAL / AUTHORIZATION BY QUALITY MANAGER a).

Candidate having certificate of competency issued by DGCA will apply to the Quality Manager using application for grant / renewal of approval / authorization (Form No. 005), duly signed by the Regional engineering manager / chief engineer.

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3.11.4

b).

Candidate will be subjected to competency assessment for knowledge in use of various type equipments owned by the organization and the standard or specific case to case procedure provided by the TC holder in standard practices manual / NDT manual.

c).

Quality Manager will issue certification authorization to the candidate to carryout the work and certify the aircraft / component for release to service, with respect to the work.

CONTINUATION TRAINING AND TESTING

a).

3.11.5

Procedure given in CAR Section 2 Series L Part XIV will be followed and the same are detailed in EPM Section-3, Chapter-31

AUDITING OF STAFF AND SYSTEM a).

Auditing of staff certifying specialised activities and the system and procedures followed for carrying out the specialised activity will be carried out once every twelve months.

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3.12

3.12.1

3.12.2

CONTROL OF MANUFACTURERS’ AND OTHER MAINTENANCE WORKING TEAMS (Ref: EPM Section -3, Chapter 16)

a).

Maintenance work required to be carried out on an aircraft / engine / component which is beyond the scope of work / capability of the organization, then manufacturer’s or other approved maintenance team’s assistance to carryout and certify will be sought.

b).

This section outlines the brief policies and procedures to be followed by the organization for control of quantum of work, authorization of personnel, control of repair documentation such as drawings, maintenance instructions, certification etc.

c).

Detailed procedure for control of manufacturer’s and other maintenance working team is provided in EPM Section-3, Chapter-16.

COMPANY POLICY a).

If any maintenance work to be carried out in the organization’s base facility or at locations away from base, are beyond the scope of approval / capability of the organization, then assistance from the manufacturer’s / other approved maintenance organization will be sought.

b).

Assistance from manufacture, manufacturer authorized service centre or EASA / FAA /TC or equivalent authorities approved organization will be sought to carryout work and /or certify the work.

c).

Control will be exercised by the organization in verifying the quantum of work, authorization of personnel, materials, maintenance data or instructions, tools & equipments, environmental conditions at the time of carrying out the work to ensure quality work is carried out on the aircraft / component.

SOURCE OF WORK a).

Any major defect or damage requiring repair requiring skilled or precision working, which is beyond the scope of the organization or capability of the personnel will be entrusted to the manufacturer / other maintenance working team.

b).

In such cases, chief engineer will liaise with the manufacturer to obtain recommendations on the scope of work to be carried out and propose the same to the Regional Airworthiness Office for their acceptance.

c).

Manufacturer team may perform design, repair, installation and test with in the scope of their manufacturing / maintenance approval granted by the airworthiness authority of their country. Regional airworthiness Office, Bangalore will be intimated prior to utilizing the service to obtain their acceptance.

d).

Other maintenance working team may perform design, repair, installation and testing with in the scope of their repair design approval / maintenance approval granted by the airworthiness authority of their country.

e).

In both the cases, the Indian Government (Ministry of Civil Aviation) must have bilateral agreement in effect with such airworthiness authority of the country, and accept their approval process. Else, such manufacturer or maintenance working team will not be allowed to carryout work on the organization owned / maintained aircraft.

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3.12.3

3.12.4

3.12.5

AUTHORISATION OF PERSONNEL a).

All work to be carried out by the manufacturer’s working party and other maintenance working teams will be certified by them under their Company authorization if their MOE or equivalent documents and their scope of approval permit them to carryout the work and certify the same.

b).

In case due to various regulatory reasons, if the manufacturer working team / other maintenance team cannot certify the work carried out by them, then the Quality Manager will permit the senior and experienced certifying staff or base engineering manager / chief engineer who is type rated on the model of aircraft to associate with the repair team and certify the repair under approval issued by the company.

c).

In both cases, CRS will be issued by the company authorized certifying staff only.

SYSTEM FOR CONTROL OF MATERIALS, WORKING INSTRUCTIONS AND PROCEDURES a).

All materials/tools/ spares required for the subject work will be supplied by the organization procured as per procedures or the organization may ask the manufacturer / other working team to provide the same.

b).

In such cases, all parts / materials will be subjected to inspection and acceptance procedures as described in MOE 2.2 and then issued for use.

c).

Quality Manager will ensure that the one of the following criteria is fulfilled for control of maintenance instruction and procedures 1.

Use of maintenance instruction and procedures approved by the manufacturer.

2.

Use of maintenance instruction and procedures approved by the Head of Engineering / Quality of the organization, which has supplied the maintenance working team.

3.

Use of maintenance instruction approved by the Quality Manager, based on the recommendation from the manufacturer.

CONTROL OF DOCUMENTATION - MODIFICATION, REPAIR PROCEDURES a).

Base engineering manager / chief engineer will raise a work order i.a.w MOE 2.10 and issue the same to the manufacturer’s / other maintenance working team.

b).

Any modification / repair, recommended by the manufacturer, will also be carried out under detailed work order raised as above.

c).

Work carried out by manufacturer’s / other maintenance working team will be certified in the respective work order and in logbooks by the authorized personnel described in sub-para 3.12.3 of this chapter.

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3.12.6

CERTIFICATION - REPAIR-REPLACEMENT-MODIFICATION-INSPECTION – OVERHAUL

a).

3.12.7

3.12.8

Procedure for certification of repair, replacement, modification, inspection or overhaul will be carried out by the authorized personnel described in sub para 3.12.3 of this chapter.

ENVIRONMENTAL CONDITIONS a).

Work will be carried out in an acceptable environmental condition, which will not hamper the execution of the work or put undue stress on the working personnel.

b).

Work will not be carried out during rain, storm, icing or dusty (dust storm) conditions.

c).

If work is required to be carried out in a place outside the hangar, where the temperature is higher than moderate and acceptable (25°C to 30°C), then the working time per day will be reduced to avoid exceeding human factor limitations.

FINAL CERTIFICATION TO RELEASE BY THE COMPANY

a).

For any work carried out by manufacturers and other maintenance teams, the final Certificate of Release to Service (CRS) will be issued by company authorized certification authorization Holder after satisfying himself that the work is carried out in a proper and complete manner.

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HUMAN FACTORS TRAINING PROCEDURE (CAR & AMC 145.30(e), EPM Section-3, Chapter-24, MOE 2.8.11, Training Manual)

a).

Human factors deal with the relation between the INDIVIDUAL and 1. 2. 3. 4.

3.13.1

3.13.2

b).

This section outlines the policy and procedures to be followed to provide human factors training to all personnel involved in the CAR-145 maintenance organization.

c).

Detailed procedure for control and conduct of human factors training procedure is provided in EPM Section-3, Chapter-24, MOE 2.8.11 & in Training Manual.

COMPANY POLICY a).

Organization’s human factors approach will be based on the improvement of the relation between the following; 1. Individual and Data. 2. Individual and Materials 3. Individual and Environment 4. Individual and Individual

b).

Human factor issues, ways and means to improve and overcome the difficulties faced will be made part of the training syllabus.

CATEGORIES OF STAFF TO BE TRAINED a).

All appropriate Deccan Aviation personnel will receive both initial and recurrent human factors training. This will include: 1. 2. 3.

3.13.3

Data (Maintenance Data / Instructions, Organization procedures, computer data) Materials (Tooling, equipment) Environment (Climate, temperature, lighting, working space, noise, pollution) Individual (family members, supervisors, subordinates, customers)

Managers, supervisors Certifying staff, technicians Planners, technical records personnel

DURATION

a).

Initial training will be provided to the staff within six month of joining to Deccan Aviation, depending on the evaluation for the need of this training for the staff concerned.

b).

The initial training course will be integrated within other training and a set syllabus will be followed. The training syllabus will cover all topics as listed in training manual.

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c).

3.13.4

REQUIREMENT FOR TRAINERS

a).

b).

3.13.5

Human factors training will be made part of continuation training syllabus for all personnel who attend continuation training, every 24 months.

Human factor trainer should meet the following minimum criteria; 1. Must have undergone a formalized training activity and having been assessed and cleared by Quality Manager or already performed trainings. 2.

Must have worked at least 3 years in a maintenance organization

3.

Must have got a detailed initial training on human factors covering the syllabus of Human factors under CAR-145 by Quality Manager or another trainer.

If suitable persons are not available, then the services of general industrial personality development trainer will be utilized for imparting training after a briefing from the Quality Manager about the human factors involved in CAR 145.

TRAINING METHODS AND SYLLABUS a).

Training for Human factors will be given through Audio-Visual Capsules for ease and thorough observation of all personnel. A set syllabus is followed.

b).

The training syllabus will cover all human factors topics. (Ref: AAC 3 of 2000) and the same listed in training manual.

c).

Lecture on Good Maintenance Practice will also be covered. Good Maintenance practices are listed in EPM Section – 1, Chapter – 19.

d).

Human factors training syllabus will cover the following topics, described in brief below;

1.

2.

Improvement of relations between Individual and Data (CAR 145.A.45 & CAR 145.A.65) i).

Procedures are developed taking the human factors related principles into account and a system to report the error or ambiguities noted in Maintenance organization procedures. Use Form No. 006 for reporting error in policies or procedures. Refer EPM Section-3, Chapter-14 for detailed procedures.

ii).

Procedures are developed to report the errors or ambiguities noted on maintenance data / instructions. Use Form No. 027 for reporting error noted in maintenance data / instructions. Refer EPM Section-1, Chapter-18 for detailed procedures

Improvement of relations between Individual and Material (CAR 145.A.40) i).

Human factors associated in management, supply and use of tooling / access means.

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3.

Improvement of relations between Individual and Environment (CAR 145.A.25) Human factors associated in relation to the working environment.

i). 4.

3.13.6

Improvement of relations between Individual and Individual

i).

Human factor training syllabus includes training to all personnel to know about their own and other’s limits. (CAR 145.A.30)

ii).

Human factor consideration in planning, preparation, co-ordination and teamwork (CAR 145.A.47).

iii).

Human factor consideration associated with communication / transmission of instructions and signing of tasks (CAR 145.A.47 and 145.A.65)

iv).

Human factors related to human performance and limitations in the management of individuals (CAR 145.A.47)

INITIAL & CONTINUATION TRAINING

a).

Initial training will address all the personnel of the organization to get to know about the various personnel’s to be dealt with during the course of employment.

b).

Continuation training for human factors will be provided on an ongoing basis with formal training at least once in every two years for the above mentioned personnel in order to ensure that they remain current in terms of human factors.

c).

This training will be an open two way interactive process to ensure that valuable feedback is collected on human factor issues.

d).

Continuation training may be combined with Refresher Training, will be of sufficient duration in relation to the relevant quality audit findings and other internal/external sources of information available on human errors in maintenance.

e).

A register for human factor training programme will be maintained by Training Manager. This register will include frequency, duration and personnel attended the training. Individual personnel records kept in quality cell will be updated accordingly.

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3.14

3.14.1

3.14.2

COMPETENCE ASSESSMENT OF PERSONNEL (Ref: CAR 145.A.30 (e), CAR 145.A.35.f, MOE 1.7.e & EPM Section-3, Chapter-23)

a).

CAR 145.A.30.e requires the organization to establish and control the competence of personnel involved in any maintenance, management and/or quality audits in accordance with a procedure and to a standard agreed by DGCA. In addition to the necessary expertise related to their job function, competence assessment will include an understanding of the application of human factors and human performance issues appropriate to that person’s function in the organization.

b).

CAR 145.A.35.f requires the organization to assess all prospective certifying staff for their competence, qualification and capability to carryout their intended certifying duties in accordance with an established procedure prior to the issue or re-issue of a certification authorization under CAR-145.

c).

This section briefly outlines the policies and procedures adapted by the organization for, various personnel whose competence assessment is required to be assessed, assessment procedures, training & qualification of personnel, management competence assessment and retention of assessment records.

COMPANY POLICY a).

Competence assessment of personnel involved in any maintenance, management and / or quality audits will be carried out in accordance with established procedure and standard agreed by DGCA.

b).

Competence assessment will be carried out as per established procedures and training will be provided to those personnel who fail to qualify in the assessment.

PERSONNEL TO BE ASSESSED IAW CAR 145.A.30(E)

a). Personnel whose competency is required to be assessed as per established procedure are given below; 1.

Personnel involved in any maintenance activity (support / certifying staff, Technicians, Tech. services personnel, logistics / stores personnel, Specialized services staff, Foreman / Supervisors)

2.

Management personnel

3.

Quality audit personnel

b). Competence of personnel involved in any maintenance, management and /or quality audits will be carried out by a board consisting of Quality Manager and relevant technically qualified personnel. c). Competence assessment will include assessment of the individual for knowledge on the specific functional area of employment and an understanding of the application of human factors and human performance issues appropriate to that person’s function in the organization

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3.14.3

3.14.4

ASSESSMENT PROCEDURES

a).

Competency assessment will be done at three stages.

b).

First assessment will be done during pre-induction phase, where a candidate would be assessed for competence by the concerned Head of the Department and HR-Manager. On satisfactory assessment, the individual will be inducted into the organization.

c).

Second assessment will be done at routine basis, when they attend the continuation training. This assessment will be done to ensure whether the individual is up-date with the current happenings related to his field and also to refresh the basic knowledge in the respective field. Competency assessment during continuation training will be done by Training manager or Base engineering manager, where the continuation training is conducted.

d).

Third assessment will be for the support / certifying staff including appropriately qualified persons and task trained persons for issue of approval / authorization. The Quality Manager will constitute an examination board for competence assessment, consisting of Quality Manager, Chief Engineer and/or type experienced certifying personnel. On satisfactory assessment and recommendation from the board, the Quality Manager will issue approval / authorization.

QUALIFICATION a).

3.14.5

3.14.6

TRAINING a).

The Chief Engineer before putting up application for any candidate will ensure that the candidate has undergone proper training as per organization requirement and meet the qualification and training requirement for issue of approval / authorization.

b).

If any employee is assessed to be low on competency to perform the function, the Quality manager / Chief engineer will recommend and organize additional training for the person to cope up with the requirement.

ASSESSORS a).

3.14.7

The Regional engineering manager / Chief Engineer will ensure that all candidates whose applications are forwarded to Quality Manager are suitably qualified and meet the company requirement.

The examination board will consist of the Quality Manager, Chief Engineer and/or type trained or authorized certifying personnel in the relevant category.

MANAGEMENT COMPETENCE ASSESSMENT

a).

All personnel in managing positions in the engineering set up will undergo yearly periodic management competence assessment by the Manager – HR.

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3.14.8

ASSESSMENT RECORDS

a).

Competency assessment will be carried out using competency assessment form (form no. 059)

b).

All Assessment records will be maintained till the time the employee is working with Deccan Aviation and thereafter for a period of one year.

c).

Detailed procedure for competence assessment of maintenance personnel are provided in EPM, Section-3, Chapter-23.

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Qualification, Experience, Training & Competency requirement for Issue of Various approvals / authorization by Quality Manager to support or certifying staff.

Approval to carryout and certify BFF, Transit and ALF (Lay over) inspections without snag rectification

Approval to carry out and certify Minor scheduled line maintenance with simple defect rectification

Approval to carryout and certify Line maintenance higher than weekly check & Defect rectification

Approval to carryout maintenance / inspection ( BASE MAINTENANCE SUPPORT STAFF)

1.

Basic license issued by DGCA in appropriate category or CPL/CHPL on the type aircraft

2.

Minimum of four years of total aircraft maintenance experience including ab-initio training.

3.

7 transit inspections carried out under the supervision of an appropriately qualified approval holder.

4.

Must have passed an exam conducted by Quality Manager / Auditor.

1.

BAMEL in appropriate category. (LA, PE, HA, JE, RA, ES, IS, RN)

2.

Minimum of five years of total aircraft maintenance experience including ab-initio training.

3.

Completion of DGCA approved, internally conducted training course relevant to the inspection on the aircraft.

4.

Completion of minimum of seven weekly or equivalent relevant inspections.

5.

Must have passed an exam conducted by Quality Manager / Auditor.

1.

Full scope authorization / AME Licence issued by DGCA in similar aircraft.

2.

Minimum of five years of total aircraft maintenance engineering experience including abinitio training.

3.

Satisfactory completion of CAR-147 / EASA-147 or equivalent type training on the specific type aircraft at DGCA / Manufacturer approved facility.

4.

Must have passed an exam conducted by Quality Manager / Auditor.

1.

Type rated AME on same / similar aircraft meeting all general requirements.

2.

Minimum of five years of total aircraft maintenance experience including ab-initio training.

3.

Must have passed an exam conducted by Quality Manager / Auditor.

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Requirements for issue of Approval / Authorization

1.

Must have BAMEL in appropriate category.

2.

Must have total of five years of aircraft maintenance engineering experience including abinitio training.

3.

Must have successfully completed internal task training on inspection of controls on specific aircraft type.

4.

Must have passed an oral cum practical test conducted by Quality Manager / Auditor

1.

Must type rating on the specific aircraft and engine.

2.

Must have total of five years of aircraft maintenance engineering experience including abinitio training.

3.

Must have experience of one year as support / certifying staff after obtaining type rating.

4.

Must have passed an exam conducted by Quality Manager / Auditor.

1.

Must have type rating on airframe and engine.

2.

Must have passed an exam conducted by Quality Manager / Auditor.

1.

Must have type rating on airframe and engine.

2.

Must have passed an exam conducted by Quality Manager / Auditor.

Approval to carryout inspection of parts and materials – Stores Inspector & Release Note Signatory approval

1.

Must have passed Paper –I and II of AME examination.

2.

Must have minimum of one year of experience in aviation / aviation related stores.

3.

Must have passed an exam conducted by Quality Manager / Auditor

Approval to pilots to carryout and certify duplicate inspection of controls (valid for line stations only)

1.

Must have CPL / CHPL on the type aircraft.

2.

Must have successfully completed internal task training on duplicate inspection of controls on specific aircraft type.

1.

Must have total of five years of aircraft maintenance engineering experience including abinitio training.

2.

Must have successfully completed internal task training on removal / installation of dual controls on specific aircraft type.

3.

Must have passed an oral cum practical test conducted by Quality Manager / Auditor.

Approval to carryout and certify duplicate inspection of controls including installation / removal of dual controls.

Approval to carryout assembly of major components and issue erection certificate

Approval to carryout engine ground run

Approval to carryout aircraft taxiing.

Approval to carryout and certify duplicate inspection after installation / removal of dual controls

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Requirements for issue of Approval / Authorization

Approval to carryout and certify borescope inspection.

Approval to carryout weighing and preparation of weight schedule

Approval to carryout weight schedule recomputation

Approval to carryout maintenance on components in shop facility – 1.

Battery shop.

2.

Wheels & Brake shop.

3.

Helicopter dynamic components overhaul shop

TASK TRAINED AND AUTHORIZED PERSONS

1.

Must have type rating on the engine or in similar model of engine in appropriate category.

2.

Satisfactorily undergone training on bore scope inspection conducted by manufacturer or the company or completed three bore scope inspection under an authorization holder.

3.

Must have passed an oral cum practical test conducted by Quality Manager / auditor

1.

Must have type rating on the aircraft in appropriate category.

2.

Must have completed atleast one weighing under an approved support staff.

3.

Must have passed an exam conducted by Quality Manager / Auditor.

1.

Must have type rating on the type of aircraft or in similar type of aircraft in appropriate category.

2.

Must have passed an exam conducted by Quality Manager / Auditor.

1.

Person holding BAMEL in relevant category of HA, JE, RA, ES, IS, RN or Diploma in Engineering in the appropriate branch or Degree in Engineering in the appropriate branch.

2.

Person must pass relevant modules of examination as per Annexure 1 of CAR Section-2, Series-L, Part-X, which will be conducted by DGCA.

3.

Person must have undergone training with the manufacturer or with approved firms / organization approved to impart such training or with another person holding (holding approval for 2 years) specific approvals covering the activity.

4.

Person should have one year experience in the overhaul, major repairs, modifications of the systems of components / accessories of aircraft, engines out of which six months must be on the overhaul, maintenance, repairs, modifications of the system etc. of the particular type of aircraft component, engines or systems

5.

Should have 10+2 standard with physics, chemistry and mathematics or equivalent examination and not less than 21 years of age.

6.

successfully completed oral test by board consisting of Representative of Civil Aviation Dept, Quality Manager, Chief Engineer and Head of the particular shop

1.

Must have four years of aircraft maintenance experience, preferably with a 3 year course in relevant category.

2.

Must have Minimum of 1 year experience on the aircraft and out of which, 6 months maintenance experience on the relevant system / task.

3.

Must have completed internal training conducted by the organization on the relevant task.

4.

Must have completed a oral cum practical exam conducted by Quality Manager / auditor.

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Requirements for issue of Approval / Authorization

Requirement for issue of certification authorization

1.

Adequate understanding of aircraft, components, systems and organization procedures provided in MOE and associated procedure manuals.

2.

Involved in maintenance at least six months in the preceding 24 months.(CAR 145.A.35.c refers).

3.

Completed refresher training within preceding 24 months on specific type rating of the aircraft (for renewal only). (CAR 145.A.35.d refers)

4.

Licence remaining valid throughout the validity period of the authorization.

5.

Must have passed an oral examination by the Quality Manager / auditor.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-4

4.1

CONTRACTED OPERATORS PROCEDURES

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CONTRACTED OPERATORS

INTRODUCTION a).

Organization provides maintenance and maintenance management services to various operators and the list of such operators with the following information will be part of the Engineering procedures manual. Section-1, Chapter-20. 1. 2. 3. 4. 5. 6. 7.

Name of the company. Type of aircraft being maintained. Registration No. Scope of Maintenance work contracted with the operator / owner. Whether the operation contract is also entered with the owner of the aircraft. Name & Contact details of the Nodal Officer Scope of work being carried out for the operator as per the contract.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-4

4.2

4.2.1

4.2.2

4.2.3

CONTRACTED OPERATORS PROCEDURES

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CONTRACTED OPERATOR PROCDURES AND PAPERWORK a.

Deccan Aviation provides maintenance services under contract to maintain aircraft operated by various operators.

b.

The maintenance tasks undertaken by the organization includes scheduled and unscheduled line maintenance including rectification of defects and replacement of components and other maintenance tasks required as per AD/ SB issued by regulatory authority/ manufacturers. The following maintenance management task (listed below in sub-paragraph) is also undertaken.

c.

Organization will also provide maintenance service to an aircraft operator who requires their work card / work card system / Maintenance programme & Inspection schedule to be used, then such arrangement of carrying out maintenance as per the operator’s /other agencies approved maintenance programme / inspection schedule will be followed. In this case, all the original completed inspection schedules will be handed over to the operator and a copy of the records will be maintained for a period of two years from the date of completion of the work. (CAR 145.A.45.e refers)

Spares management procedure a.

The responsibility of supply spares for aircraft maintained by the organization lies with the operator. If the operator forwards a request to the organization, then the same will be supplied by the organization as per procedures given in the Stores manual.

b.

The Nodal Officer of the Operator will provide a requisition / purchase order for such spares. All spares supplied by either by the organization directly or by the operator will be routed through the organization stores before they are used on the aircraft.

Engine performance monitoring ( Engine Management Program and Reliability Monitoring) a.

All engine parameters noted by the flight crew in flight are recorded in the tech log book. Parameters will be transferred to the Trend monitoring Book (for Rolls Royce engines only) and corrected as per correction table. Corrected values will then be plotted in graphs.

b.

The engine parameter graphs are monitored on a monthly basis by the certifying staff & Regional or Base engineering Manager.

c.

Periodic Checks of chip detectors will be carried out at manufacturers recommended scheduled Intervals to check the health of the engine.

Control of maintenance programme. a.

Maintenance Programme will be prepared by the type rated or type trained engineer, on the particular aircraft, in association with the Tech. Officer (AMP/Schedules). The same will be verified by the Regional engineering Manager / Chief Engineer or by a person designated by the Chief Engineer (Manager –Technical Services) for the purpose and submitted to the Regional Airworthiness Office, Bangalore.

b.

Copy of Approved maintenance programme will be circulated to all sub-base station approved for maintenance of the type aircraft and one copy will be kept in the aircraft for ready reference.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-4

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4.2.5

4.2.6

4.2.7

CONTRACTED OPERATORS PROCEDURES

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c.

Any changes to component service life / overhaul limit, inspection schedules, SB, AD, Mandatory modifications will be monitored by the Tech. Officer (MPD/Schedules) and the same will be incorporated into the maintenance programme and submitted for approval to Quality Manager.

d.

Copies of revised maintenance programme will be circulated to all control copy holders.

Analysis of pages of technical log a.

All entries made in the Tech Log Pages will be analysed for legible and proper entries of sectors, timings, defect reports, parameters, MEL Releases etc by the Tech. Officer (sub-base / records)

b.

Relevant data will be entered into the FLYPAL system for maintenance monitoring by the Tech. Officer (FLYPAL) at Bangalore base. At all line stations, the data will be entered by the Tech. officer.

Control of deferred maintenance a.

All deferred defects at line stations will be intimated to the Tech. Officer (Directives & Occurrences) at Bangalore.

b.

Tech officer (Directives & Occurrences) will liaise with the type engineer or the chief engineer, who will plan for the rectification action.

c.

Tech. Officer (Directives & Occurrences) will maintain a register aircraft wise to monitor the details of deferred defects and the maintenance action on the same.

Major and repetitive defect control a.

Major defect will be controlled as per procedures given in MOE 2.18.

b.

Any repetitive defect will be intimated by the certifying personnel to the Regional/Base engineering Manager / Chief engineer.

c.

Repetitive defects will be analysed by a team consisting of type qualified engineer and the base / regional engineering manager or Chief engineer. If the defect repeats more than 3 times, manufacturer will be consulted for rectification action.

Aircraft damage - identification and control a.

All damages, observed by maintenance personnel or by the flight crew will be recorded in the Tech. Logbook and suitable action taken for rectification by the certifying persons at line / base station.

b.

If the damage is more and requires major rectification action, chief engineer will be consulted for rectification action.

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Reporting of un-airworthy conditions. a.

4.2.9

CONTRACTED OPERATORS PROCEDURES

PAGE NO : 4

Any un-airworthy conditions reported by the crew or observed by maintenance personnel will be recorded in the Tech logbook and will be rectified prior to releasing the aircraft for further flights.

Control of continuous airworthiness programme. a.

All aircraft either owned by the organization or owned by other parties and maintained by the organization will be maintained under a continuous airworthiness program to ensure that the aircraft is airworthy at all times.

b.

Continuous airworthiness is ensured by monitoring of amendments to manufacturer’s maintenance programme ( or Chapter 4 or 5), SB’s, AD’s etc, timely amendment of the approved maintenance programme and circulation of amended maintenance programme to all controlled copy holders for carrying out continuous airworthiness inspection on the respective aircraft

Control of repair scheme. a.

All repair will be carried out as per repair manual or procedures provided by the manufacturer.

b.

Minor repair scheme will be prepared in accordance with the AC-43 (Standard repair practices manual), in the absence of specific recommendation from the manufacturer in repair manuals.

c.

Minor repair will be carried out by type qualified engineer and copy of all repair drawings will be attached to the work order.

d.

All major repairs will be initiated by the type qualified engineer / regional engineering manager in consultation with the manufacturer.

e.

Repair scheme will be scrutinized by the Quality Manager and forwarded to the Regional Airworthiness Office, Bangalore for approval.

f.

Detailed procedure for carrying out repair on aircraft maintained by the organization is provided in EPM Section-2, Chapter-1.

Load and Trim a.

CAR Section-2, Series-X, Part-II requires that every operator to prepare a load and trim sheet, to indicate the composition and the distribution of total load carried on board the aircraft as well as the calculated C.G. position for take off and landing configurations, before the commencement of the flight.

b.

Preparation of such load sheet will be the responsibility of the pilot-in-command of the flight or persons trained for the purpose. Hence for all operators’ aircraft under maintenance with the

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organization, it will be the responsibility of the pilot-in-command to ensure that proper load and trim calculations are done before commencement of flight. c.

4.2.12

In case of operator, who has entrusted the operation contract of the aircraft to the organization, then it will be the responsibility of the organization’s Pilot (in-command) to ensure that load and trim sheet is filled up before the commencement of the flight.

Nodal Officer – Link Between the AMO and the Owner / Operator a.

CAR Section-2, Series-E, Part-1 requires that every owner / operator who has contracted the maintenance of their aircraft to an AMO, to appoint a Nodal Officer to enhance the airworthiness control system.

b.

Manager – Technical Services will provide the following information to the Nodal officer on periodic basis

Copy of organisation’s approval, scope and capability Request to provide technical literatures as per the terms and conditions of the contract. Intimation about the Inspections and Component replacements falling due on the aircraft Request to provide spares / consumables for inspections

c.

Before commencement of contract and if there is any change in the scope / capability. Once in a year Once in three months Once in three months

Nodal officer will be provided with access to the aircraft and the maintenance bay to enable him to carryout checks / surveillance, while the maintenance is in progress.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-4

4.3

DATE

: Aug 2008

Completion and preservation of maintenance records of operator’s aircraft will be the responsibility of the maintenance organization.

The operator’s logbooks will be updated and certified for maintenance task as per EPM Section-3, Chapter-18.

KEEPING THE OPERATOR'S TECHNICAL RECORDS a).

4.3.3

: 01

COMPLETING OPERATOR'S LOG BOOKS a).

4.3.2

REV NO

CONTRACTED OPERATOR’S RECORDS COMPLETION (Ref: EPM Section-1, Chapter-20) a).

4.3.1

CONTRACTED OPERATORS PROCEDURES

PAGE NO : 6

All other technical records such as completed inspection schedules, task cards, off job sheets, record of completed ADs, SBs, and modifications, pages of technical log, etc., will be maintained and retained by the maintenance organization as per procedures given in EPM Section-3, Chapter-17.

RETENTION OF RECORDS ON BEHALF OF OPERATORS (CAR 145.55c & EPM Section-1, Chapter-20) a).

All log books and technical records belonging to operator’s aircraft will be preserved for two years from the date of completion of the work. However all original log books and other technical records will be transferred to operators on completion of the contracted period.

b).

Detailed company procedure for completion, preservation, handing over and retention of Operator’s records are explained in EPM Section-1, Chapter-20.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION Part -5 Forms

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SAMPLE OF DOCUMENTS

a). MOE and associated procedure manuals refers to use various forms for seamless flow of information and for traceability of the originator, authorising person etc. b). Sample of all documents are provided in forms manual. Each forms are serially numbered (Form Number) in the forms manual for ease of identification. c). Each form will be provided with the details such as no. of copies to be printed and to the concerned to whom the filled up form is supposed to be sent to. d). Forms manual consist of index which list out all forms as per the form number.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION Part -5 Forms

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LIST OF SUB – CONTRACTORS

a.

Presently, no work is being sub-contracted.

b.

List of sub-contactor will be provided in LPM Chapter-14, as when a sub-contractor is approved and designated.

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DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION Part -5 Forms

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LIST OF LINE MAINTENANCE STATIONS a).

Stations approved for Line Maintenance for various aircraft are given below;

CHENNAI

Bell 407 Helicopter

VIZAG

Bell 206L4 Helicopter

KATRA

Bell 206L3 Helicopter

KOPPAL

Cessna Citation CJ1+ airplane Cessna Caravan 208B airplane

TORNAGALLU

Cessna Caravan 208B airplane

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LIST OF CONTRACTED CAR-145 ORGANIZATION AS PER CAR-145.70 (a) (16)

a).

List of CAR-145 organization contracted to obtain services beyond the scope of the organization will be listed in the LPM Chapter-14

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-6 OPERATOR’S MAINTENANCE PROCEDURES

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OPERATOR’S MAINTENANCE PROCEDURES

a).

Organization is issued with a NSOP by the DGCA for operating non-scheduled services.

b).

Since organization is a CAR-145 Approved Maintenance Organization as well as a DGCA Approved Non–Scheduled Operator, it has its own approved quality system and maintenance procedures which are compiled in accordance with the relevant Civil Aviation Requirements issued by DGCA for maintenance and operation of aero planes and helicopters

c).

The details of such approved maintenance procedures are enlisted in this chapter.

BASIC MAITNENANCE PROCEDURES a).

Organization is holding maintenance approval to carry out maintenance of various aero planes and helicopters and the engine’s installed thereon as per the scope of approval granted from Regional Airworthiness Office, Bangalore.

b).

In order to ensure proper and effective maintenance, all maintenance procedure including basic, special and unscheduled maintenance tasks are carried out at main base / sub-base / line stations within the scope of approval granted by the Airworthiness Office.

c).

Higher maintenance activities above the granted scope of approval are carried out at the aircraft / engine manufacturer approved facility.

d).

The basic maintenance procedure as per manufacturer’s guideline ranges from pre-flight inspection to the highest scheduled maintenance inspection, which will be carried out at specified intervals.

e).

Compliance of basic maintenance procedures, do include replacement of calendar time limited items, lifed components, items due for overhaul / bench checks, tests on condition items, in-situ functional checks, lubrication, hydraulic servicing, compliance of modification, etc.

f).

Rectification of flight crew reported/ground crew observed defects are carried out and certified by appropriately approved support staff and aircraft released to service by qualified certifying staff.

g).

Any changes in periodicity or inspection contents as approved by Regional Airworthiness Office will be implemented by additional call-outs which will become part of the monitoring of aircraft maintenance status.

h).

The major maintenance schedule or periodic check as per approved maintenance task is carried out at specific intervals.

i).

The aircraft is subjected to inspection which includes scheduled maintenance task like replacement of life limited items, component due for replacement/overhaul, bench check for on-condition items, special inspection like NDT techniques, major modifications, repairs, structural inspection including ageing airplane program, corrosion prevention and control program (CPCP).

j).

Unscheduled maintenance task are the follow-up actions on inspection observation, carried forward defects, opportunity inspection, replacement of prematurely failed components, compliance of Alert Service Bulletins, inspection after Hard Landing, inspection after Bird Strike etc.

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k).

The periodic checks or major maintenance may be subject to life development program which is normally an escalation within the maximum period detailed in Maintenance planning document of the manufacturers, based on operating experience and will be carried out under the approval of DGCA.

l).

Any approved life development will be carried out for the basic maintenance tasks only and excludes controlled life items, calendar/cycle based specific inspection / replacement, and servicing tasks. ENGINE PERFORMANCE MONITORING (TREND MONITORING) a).

The satisfactory performance of an engine involves monitoring various parameters like, oil consumption, oil temperature, vibration, N1, N2, fuel flow, thrust, EGT, etc within the permissible limits as per engine maintenance manual during operation.

b).

These parameters will be continuously monitored to assess the condition of engine in service. The parameters are monitored in such a way to assess the internal gas path conditions as well as mechanical conditions.

c).

Basically the engine performance/trend monitoring is carried out based on individual engine manufacturer’s recommendation and program.

d).

However, engine parameters normally used to monitor the internal condition of engines in flight covers EGT, Fuel Flow, N1 and N2 (at a particular power / thrust rating) that are indicative of engine gas path performance.

e).

The engine vibration, oil pressure and oil temperature, reflects the engine’s mechanical condition.

f).

Apart from recording the above parameters in cruise flight, the other parameters like Aircraft Forward Speed, the ambient temperature and the altitude of the flight that will have influence on engine performance is also recorded in the Tech. Logbook.

g).

These parameters are scrutinized by support / Certifying Staff and corrective actions taken whenever recorded parameters show performance deterioration.

h).

Similarly performance related defects recorded by the flight crew for each sector are also analyzed by support / Certifying Staff and corrective action taken prior to releasing the aircraft for further flight.

i).

The engine parameters recorded in the tech log book will be scrutinized by the support / certifying staff to assess the degradation and take corrective measures.

j).

The engine oil consumption will also be continuously monitored for any abnormal increase by the support / certifying staff.

k).

The Trend Monitoring program given by the manufacturer evaluates engine performance by computing deviations of observed / recorded in-flight data from baseline values representing typical performance for the particular engine-airframe combination involved.

l).

Detailed procedures of trend monitoring are provided in EPM, Section -4, Chapter-15

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ENGINE OIL CONSUMPTION a).

Oil quantity added to each engine on every occasion is recorded in the tech log book to monitor oil consumption by the support / Certifying Staff.

b).

It will be the responsibility of the certifying staff carrying out inspections above 100hrs /150hrs to add up the total quantity of the oil consumed since last inspection and calculate the average oil consumption as given below.

c).

The average oil consumption is normally given by the manufacturer in the engine operation & maintenance manual which is compared with the average oil consumption calculated from the recording in the tech. log book and corrective actions are taken as per maintenance manual in case of any abnormality is noticed before releasing the engine for further flight.

Oil Consumption =

6.4

PAGE NO : 3

Total Oil Consumption Block Time in Hours

POWER ASSURANCE CHECK

a).

Aircraft manufacturer provides the procedure for carrying out the power assurance check and related charts in the respective flight manual of the aircraft. CAR Section-2, Series-O, Part-1 requires the pilot in command to ensure before take of, that the aircraft develops required power.

b).

Power assurance check will be carried out at the intervals as specified by the manufacturer. Detailed procedures for power assurance check is provided in EPM, Section-4, Chapter-16

CONTINUED AIRWORTHINESS OF AGED AIRCRAFT a).

The DGCA Airworthiness Advisory Circular and relevant Civil Aviation Requirements provide necessary guidelines for ensuring continued air worthiness and maintenance of aged aircraft. Aged aircraft are those defined as aircrafts that have passed 20 years since manufacture.

b).

Normally, the aircraft manufacturer provides ageing aircraft maintenance program to ensure continued air worthiness so that proper adherence of the program in maintenance can take care of the of significant structural items/members before they fail.

c).

Ageing aircraft program document may consist of service bulletins requiring structural inspection of specific areas, Supplemental Structural Inspection Document (SSID) specific to aging aircraft, repair and modification program, and Corrosion Prevention and Control Program (CPCP).

d).

Ageing aircraft program provided by the manufacturers is declared mandatory by the regulatory authorities that need implementation, as per the program laid down at stipulated intervals.

e).

The ageing aircraft program is separate from the normal maintenance program and is to be complied as per the relevant document at the threshold given.

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6.8

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f).

It is very important while carrying out ageing aircraft program, that all minor and major defects will be thoroughly analyzed and investigated and cause established and corrective action taken so that the occurrence of such defects minimized, if not eliminated totally.

g).

All records related to ageing aircraft program will be properly maintained and preserved.

CERTIFICATE OF REGISTRATION

a).

Rule 5 of Aircraft rule requires that no person will fly or assist in flying any aircraft unless it has been registered and bears its nationality and registration marks. CAR Section-2 Series-F Part-1, lists out the procedure for obtaining the certificate of Registration. Organization will follow the requirements provided in the above rule.

b).

Company procedure for obtaining Certificate of Registration for aircraft imported into the country or purchased with in the country are provided in EPM, Section-1, Chapter-1

AEROMOBILE STATION LICENSE a).

Aircraft Rule 9, sub-rule 3 and rule-57 requires that every aircraft will be fitted and equipped with radio apparatus as may be specified according to the use and circumstances under which the flight is to be conducted.

b).

CAR Section-2, Series-R, Part-II, describes the procedures and requirements to be complied with for installation of airborne communication, navigation and radar equipment. Organization will follow the requirements provided in the above rule.

c).

Company procedures for obtaining Aeromobile station license for aircraft imported into the country or purchased with in the country or after installation of radio equipments on Indian registered aircraft are provided in EPM, Section-1, Chapter-2.

ISSUE OF CERTIFICATE OF AIRWORTHINESS a).

CAR Section – 2, Series-F, Part-III, provides information for guidance and compliance by operators for obtaining certificate of airworthiness for aircraft imported into the country or acquired with in India.

b).

Company procedures for obtaining certificate of airworthiness for aircraft are provided in EPM, Section-1, Chapter-3

REVIEW OF CERTIFICATE OF AIRWORTHINESS

a).

Airworthiness Review is required to be carried out once in a year, from the date of issue / renewal / last review. CAR Section-2, Series-F Part-III provides the procedure to be followed for review of C of A.

b).

Company procedures for carrying out the review of C of A is provided in EPM, Section-1, Chapter-4

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-6 OPERATOR’S MAINTENANCE PROCEDURES

6.10

6.11

6.12

6.13

6.14

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RENEWAL OF CERTIFICATE OF AIRWORTHINESS a).

Renewal of Certificate of Airworthiness is required to be carried out 5yr /2yrs /1yr interval based on the life of aircraft since manufacture. Validity of C of A is provided in the C of A document.

b).

Company procedures for renewal of certificate of airworthiness is provided in EPM, Section-1, Chapter-5

ISSUE OF EXPORT C OF AIRWORTHINESS a).

Any Indian registered aircraft when exported out of India should be accompanied with the export Certificate of Airworthiness issued by the DGCA.

b).

Company procedures for obtaining export C of A is provided in EPM, Section-1, Chapter-6

QUALITY CHECK OF FUEL a).

Fuel Uplifted on the aircraft: It will be the responsibility of the pilot in command to check the quality of the fuel being uplifted on the aircraft.

b).

Fuel stored in Barrels / Bowser: It will be the responsibility of the support / certifying staff / Engineering Manager / In-charge of the base / line station to control the quality of fuel uplifted in Barrels / Bowser.

c).

Detailed procedures to be followed to ensure dispensation of quality fuel into the aircraft are provided in EPM Section-4, Chapter-17.

QUALITY CHECK OF OIL a).

Certifying staff / authorized persons releasing the aircraft to service is responsible to check the quality of oil in the components such as MGB, TGB, IGB etc.

b).

Detailed procedure to be followed to ensure quality of oil in the aircraft component is provided in EPM, Section-4, and Chapter-18.

QUALITY CHECK OF HYDRAULIC FLUID a).

Certifying staff / authorized persons releasing the aircraft to service is responsible to check the quality of hydraulic fluid in the aircraft.

b).

Detailed procedure to be followed to ensure quality of hydraulic fluid is provided in EPM, Section-4, Chapter-19.

DECCAN AVIATION LIMITED MAINTENANCE ORGANISATION EXPOSITION PART-6 OPERATOR’S MAINTENANCE PROCEDURES

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6.16

6.17

6.18

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FERRY FLIGHT PERMISSION a).

CAR Section-2, Part-VII specifies the circumstances under which an aircraft without valid / suspended / deemed to have suspended C of A may be permitted by DGCA to undertake ferry flight and the procedure for issue of ferry flight permit. Organization will not fly an aircraft not meeting the airworthiness requirements unless ferry flight permit is obtained.

b).

Detailed company procedures for obtaining ferry flight permit is provided in EPM, Section-3, Chapter-27

WEIGHING OF AIRCRAFT a).

CAR Section-2, Series-X, Part-1 provides the frequency of the weighment and preparation of weight schedule. Organization will follow the requirements provided in the CAR.

b).

Authorization for carrying out weighing and / or computation of weight schedule will be provided by the quality manager after carrying out examination of the personnel.

c).

Detailed company procedures for the frequency of the weighment, format of weight schedule, qualification requirement for the personnel to issue authorization for carrying out weighing and / or computation of weight schedule are provided in EPM, Section-4, Chapter-20

CARRIAGE OF DOCUMENTS ON BOARD THE AIRCRAFT

a).

CAR Section-2, Series-X, Part-VII, provides the documents to be carried on board the Indian registered aircraft. Organization’s maintenance and operation personnel responsible for the flight will ensure that all required documents are on board before commencement of flight.

b).

Detailed company procedures for ensuring that all required documents are carried on board the aircraft are provided in EPM, Section-4, Chapter-13.

CVR / DFDR READ OUTS AND RECORDING INTEGRITY

a).

CAR Section-2, Series-I, Part V and VI provides the fitment and maintenance requirements of FDR and CVR on Indian registered aircraft. Quality Manager will ensure that the aircraft operated by the organization meets the requirements given in the above mentioned CAR.

b).

Detailed procedure for maintenance and read out requirements of CVR and FDR are provided in EPM, Section-4, Chapter-21.

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TEST FLIGHTS a).

CAR Section-2, Series-T, Part-II provides the requirement of flight testing of aircraft for which a C of A has previously been issued.

b).

It will be the responsibility of the certifying authorized personnel to be aware of test flight requirements and release the aircraft for test flight accordingly.

c).

Detailed company procedure for flight testing of aircraft operated by the organization is provided in EPM, Section-4, Chapter-22

FIRST-AID KIT a).

CAR Section-2, Series-X, Part-III lays down the requirement for placement and use of first aid kit on the Indian registered aircraft.

b).

Certifying authorization holder is responsible to ensure that the first aid kit meeting the above CAR requirements is on board before releasing the aircraft for service.

c).

Detailed company procedure for placement and certification of first aid kit is provided in EPM Section-4, Chapter-7.

FURNISHING MATERIALS a).

CAR Section-2, Series-X, Part-IV provides the requirement of use of standard furnishing material in crew, passenger, cargo or baggage compartment.

b).

It will be the responsibility of the Head-Logistics to procure furnishing material meeting the above CAR requirements while placing orders for furnishing materials.

c).

Detailed company procedures for use of furnishing material and testing after dry cleaning of such furnishing material are provided in EPM, Section-4, Chapter-23

MINIMUM EQUIPMENT LIST (MEL) a).

CAR Section-2, Series-B, Part-1 specifies the procedure for framing, approval and the use of acceptable deficiency list (MEL).

b).

Manager-Technical Services in consultation with the type rated engineer & chief pilot will prepare the MEL for each aircraft operated by the organization and submit to the quality manager for scrutiny.

c).

After scrutiny, quality manager will submit the MEL for provisional approval to the Regional Airworthiness Office, Bangalore. Till such time, the approval for MEL is not granted by the DGCA (HQ), the provisional copy will be carried on board and followed.

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Until the provisional approval for MEL is granted by the Regional Airworthiness Office, Bangalore, no aircraft will be released for flight with defects / damage as per sub-rule (5) of rule 60 of Aircraft Rules, 1937.

PROCEDURE FOR CERTIFYING THE COMPONENTS FROM AN ACCIDENTAL AIRCRAFT a).

Organization will follow the guide lines stipulated in Airworthiness Advisory Circular 4 of 2003 dated 30th October 2003 on “Return to Service of Aircraft Items – Recovered from the Aircraft involved in accidents / incidents for use of components from an aircraft that has met with an accident /incident.

b).

When ever there is an occasion for use of such parts, organization will follow guidelines to use such parts on a serviceable aircraft with due permission from DGCA HQ through a request to the Regional Airworthiness Office.

AERIAL WORK OPERATIONS a).

Organization conducts special operations using aircraft which are classified as Aerial work aircraft. Such operations are under slung cargo transportation, survey of area using under slung survey equipments, flower dropping etc.

b).

Chief Engineer and the Certifying authorization holder is responsible for ensuring the following

c).

1.

Equipments having approved (approved by airworthiness authority of the country with which India (Ministry of Civil Aviation) has bi-lateral agreements to accept/validate their type certificate approvals) supplemental type certification for installation on specific model of the aircraft are only fitted as per the instruction installation.

2.

Instructions/ Inspections for continued airworthiness is carried out as specified in the continuous airworthiness instructions provided by the supplemental type certificate holder.

3.

Any weight change due to installation / removal is documented in the weight & balance section of the flight manual.

4.

Necessary flight manual supplement is inserted in the flight manual.

Detailed procedures to be followed for installation of special mission oriented equipments and to ensure continued airworthiness are provided in EPM Section-4, Chapter-24.

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CARRIAGE OF ACCEPTABLE DANGEROUS GOODS a).

Carriage of Dangerous goods as cargo movement will be governed by Operation’s Manual of the operator. Due maintenance reasons, items classified as Dangerous goods may have to be carried on board to facilitate maintenance activities. For example: Sealed battery for engine start at outstations, Adhesives / Compounds required for sealing etc.

b).

In such cases, the quantity allowable for safe carriage will only be carried on board in the cargo compartment. Necessary precautions recommended by Dangerous Goods Manual (ICAO document no. 9284-AN/905) will be undertaken.

c).

Detailed company procedures for carriage of acceptable dangerous goods are provided in EPM Section- 2, Chapter -3.

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