Production Approval Procedures Manual
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Production Approval Procedures Manual VERSION 2.0: AUGUST 2004
CASADOC 79
Production Approval Procedures Manual
This is an internal CASA policy manual. It contains guidance material intended to assist CASA officers and delegates in carrying out their regulatory responsibilities and may be made available to the public for information purposes only. Copies of this manual are available from: http://casa.jsmcmillan.com.au/He/cat. Since this is an uncontrolled version of the manual which will not be updated by CASA, it should not be relied upon for any regulatory purpose. The current manual can be viewed at any time via CASA's website at "www.casa.gov.au". You should always refer to the applicable provisions of the Civil Aviation Act, Civil Aviation Regulations and the Civil Aviation Orders, rather than this manual, to ascertain the requirements of, and the obligations imposed by or under, the civil aviation legislation.
Version 2.0: August 2004
Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Table of Contents
1. Introduction to Production Approval Procedures..........................................................1-1 1.1
About this Manual ..................................................................................................1-1 1.1.1 Review of this Manual..................................................................................1-1 1.1.2 Purpose and Scope of the Manual...............................................................1-2
1.2
Regulatory Framework...........................................................................................1-3 1.2.1 Background..................................................................................................1-3 1.2.2 Legislative Basis ..........................................................................................1-4
1.3
Responsibility for Production Approval ...............................................................1-6 1.3.1 Staff Responsibilities....................................................................................1-6
1.4
Production Approval Process ...............................................................................1-7 1.4.1 Production Approval Flowchart ....................................................................1-7
1.5
Processing Inquiries and Applications for Production Approvals ....................1-8 1.5.1 Advice Provided by CASA for General Enquiries.........................................1-8 1.5.2 On Receipt of an Application .......................................................................1-9
1.6
Production Certification Board (PCB) ................................................................1-11 1.6.1 Production Certification Board (PCB) – Description...................................1-11 1.6.2 PCB Membership.......................................................................................1-11 1.6.3 PCB Member Responsibilities ...................................................................1-11 1.6.4 Conduct of the PCB ...................................................................................1-12 1.6.5 PCB Records .............................................................................................1-14 1.6.6 Administration of Production Approvals Granted .......................................1-15
2. Assessment and Issue of Approvals...............................................................................2-1 2.1
Approved Production Inspection System—Production under a TC ..................2-1 2.1.1 Applicability – Approved Production Inspection System ..............................2-1 2.1.2 Responsibility...............................................................................................2-2 2.1.3 Procedure for APIS Issue ............................................................................2-2 2.1.4 APIS Board ..................................................................................................2-4 2.1.5 TC Holder's/TC Licensee's Responsibility under CASR Part 21, Subpart F .....................................................................................................2-5 2.1.6 APIS Holder’s Facility Location....................................................................2-7 2.1.7 Assessment of an Applicant’s Suppliers ......................................................2-7
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Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
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2.2
Production Certificate (PC)....................................................................................2-8 2.2.1 Applicability – Production Certificate............................................................2-8 2.2.2 PCs Issued for Fabrication In The Course of Maintenance..........................2-9 2.2.3 Responsibility for PCs..................................................................................2-9 2.2.4 Advising the Applicant................................................................................2-10 2.2.5 Preliminary Assessment Procedures .........................................................2-11 2.2.6 Testing Aircraft, Engines and Propellers....................................................2-19 2.2.7 PC Holder's Location(s) .............................................................................2-19 2.2.8 Responsibility for PC Management............................................................2-20 2.2.9 Assessment of an Applicant’s Suppliers ....................................................2-20 2.2.10 Summary of Distribution of Production Certification Documents................2-21
2.3
Australian Parts Manufacturer Approval ............................................................2-22 2.3.1 Applicability of Australian Parts Manufacturer Approval.............................2-22 2.3.2 Responsibility for Australian Parts Manufacturer Approval ........................2-23 2.3.3 Lodgement of an Application for an APMA ................................................2-23 2.3.4 CASA Engineering Assessment ................................................................2-24 2.3.5 Manufacturing Inspector Assessment ........................................................2-29 2.3.6 APMA Approval .........................................................................................2-30
2.4
Australian Technical Standard Order Authorisation (ATSOA) .........................2-33 2.4.1 Applicability – ATSOA................................................................................2-33 2.4.2 Advising the Applicant................................................................................2-33 2.4.3 Lodgement of an Application .....................................................................2-34 2.4.4 ATSOA Issue Procedure............................................................................2-34 2.4.5 ATSOA Holder's Facility Location ..............................................................2-37 2.4.6 Approval of Materials and Processes.........................................................2-37
3. Assessments .....................................................................................................................3-1
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3.1
Assessment of an Applicant's Quality Systems for Manufacture......................3-1 3.1.1 General Principles........................................................................................3-1
3.2
Assessment of an Applicant’s Suppliers .............................................................3-3 3.2.1 Assessment of an Applicant’s Suppliers ......................................................3-3 3.2.2 Assessment .................................................................................................3-4 3.2.3 Stage 1 Quality System Assessment—Desk-top Review ............................3-4 3.2.4 Stage 2 Quality System Assessment – Quality System Evaluation ...........3-23
Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11 3.2.12 3.2.13 3.2.14
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Stage 3 Quality System Assessment—Manufacturer's Corrective Action.........................................................................................................3-24 Manufacturer’s Service Documentation .....................................................3-24 Service Difficulty Reports...........................................................................3-24 Reporting of Failures, Malfunctions and Defects During Manufacture .......3-25 Manufacturer’s Maintenance Facility..........................................................3-25 Supplier Quality Control .............................................................................3-25 Engineering Drawings................................................................................3-26 Use of CASA Form 917 Authorised Release Certificate ............................3-26 Use of CASA Form 917 for Unapproved Parts ..........................................3-27 Export Airworthiness Approvals .................................................................3-27
4. Inspections ........................................................................................................................4-1 4.1
Conformity Inspections .........................................................................................4-1 4.1.1 Introduction to Conformity Inspections.........................................................4-1 4.1.2 Conformity Inspections ................................................................................4-1 4.1.3 First Article Inspection..................................................................................4-3 4.1.4 Materials ......................................................................................................4-4 4.1.5 Processes and Processing ..........................................................................4-4 4.1.6 Automatic Production Processes .................................................................4-5 4.1.7 Non-destructive Inspection (NDI) Method Evaluation ..................................4-6 4.1.8 Critical and Major Characteristics ................................................................4-6 4.1.9 Workmanship...............................................................................................4-7 4.1.10 Adequacy of Drawings and Related Change Records .................................4-7 4.1.11 Adequacy of Inspection Records ...................................................................4-7 4.1.12 Material Review Action ..................................................................................4-7 4.1.13 Software ........................................................................................................4-8 4.1.14 Conformity Inspections of Test Articles .........................................................4-8 4.1.11 Structural Test Articles – Aircraft .................................................................4-9 4.1.12 Flight Test Articles—Aircraft ........................................................................4-9 4.1.13 Endurance Test Articles—Engines and Propellers ......................................4-9
4.2
Final Inspection and Flight Test..........................................................................4-11 4.2.1 Applicability — Final Inspection and Production Flight Test.......................4-11 4.2.2 Preliminary Ground Inspection...................................................................4-11 4.2.3 Final Ground Inspection.............................................................................4-11 4.2.4 Flight Inspection.........................................................................................4-12
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Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
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5. Sample Letters ..................................................................................................................5-1 5.1
Sample APMA Application Letter..........................................................................5-2
5.2
Sample CASA APMA Approval Letter...................................................................5-3
5.3
Sample CASA APMA Supplement without Licensing Agreement......................5-5 5.3.1 Sample CASA APMA Supplement (Design Approval) Test and Computation ................................................................................................5-5
5.4
Sample CASA APMA Supplement with Licensing Agreement ...........................5-6 5.4.1 Sample CASA APMA Supplement (Design Approval) Identicality ...............5-6
5.5
Sample Australian Parts Manufacturing Approval Supplement.........................5-7
5.6
Sample CASA APMA Design Rejection Letter .....................................................5-8
5.7
Sample ATSO Authorisation Application and Statement of Conformance .......5-9
5.8
Sample ATSO Authorisation................................................................................5-10
5.9
Sample APIS Approval Letter ..............................................................................5-12
6. Definitions .........................................................................................................................6-1 Revision History .................................................................................................................. RH-1 List of Effective Pages ...............................................................................................................v Forms Form 724
Statement of Conformity
Form 849
Production Approval—Application
Form 882
Conformity Inspection Record
Form 883
Production Approval Assessment Control Document
Form 1248 Request for Conformity Inspection (Note: The above forms are only those available to the industry/public via the CASA Website. Forms and templates used internally are available to CASA staff only, via CASAconnect, and are not listed here.)
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Production Approval Procedures Manual List of Effective Pages Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
List of Effective Pages
No. of Pages
Version
Date of Issue
Cover and verso
2
2.0
08/2004
Table of Contents List of Effective Pages and Abbreviations
6
2.0
08/2004
1.
Introduction to Production Approval Procedures
16
2.0
08/2004
2.
Assessment and Issue of Approvals
38
2.0
08/2004
3.
Assessments
28
2.0
08/2004
4.
Inspections
14
2.0
08/2004
5.
Sample Letters
12
2.0
08/2004
6.
Definitions
4
2.0
08/2004
2
2.0
08/2004
Part
Revision History
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Production Approval Procedures Manual List of Abbreviations Approved by Executive Manager, Aviation Safety Standards List of Abbreviations
Abbreviations AC AD APIS APMA ARC ARN ASCD ATSOA AWE CoA ESS FIS FITCOM IPC MI MRB NAA PAH PA PC PCB PLR PO RMU SB SDR STC TC
vi
Advisory Circular Airworthiness Directive Approved Production Inspection System Australian Parts Manufacturer Approval Authorised Release Certificate Aviation Reference Number Aviation Safety Compliance Division Australian Technical Standard Order Authorisation Airworthiness Engineer Certificate of Airworthiness Engineering Support Section Fabrication Inspection System Fabrication in the Course of Maintenance Illustrated Parts Catalogue Manufacturing Inspector Materials Review Board National Airworthiness Authority Production Approval Holder Production Approval Production Certificate Production Certification Board Production Limitation Record Project Officer Record Management Unit Service Bulletin Service Difficulty Report Supplementary Type Certificate Type Certificate
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.1 About this Manual Approved by Executive Manager, Aviation Safety Standards 1.
Version 2.0: August 2004
Introduction to Production Approval Procedures
1.1
About this Manual
1.1.1
Review of this Manual
Production Approval Manual Review Team This Production Approval Procedures Manual will be reviewed as required and within 12 months of issue or review. The Production Approval Manual Review Team will comprise: ●
Executive Sponsor – Executive Manager, Aviation Safety Standards
●
Technical Sponsor – Head of Airworthiness Standards
●
Chair – Central Office Manufacturing Specialist
●
Two Airworthiness Engineers
●
Three Manufacturing Inspectors
●
Administrative Support.
Recommending Changes to the Manual If any information in this manual needs to be amended or new information added, notify the technical sponsor. Use Form 476 Manual Amendment Request, when making suggestions, including additional sheets if necessary. Definitions See 6. Definitions.
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1-1
Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.1 About this Manual Approved by Executive Manager, Aviation Safety Standards
1.1.2
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Purpose and Scope of the Manual
Purpose The purpose of this manual is to provide CASA staff with procedures for assessing applications for Production Approvals (PAs) under CASR Part 21 and for issuing those CASA approvals.
CASR Part 21
Scope CASR Part 21
This manual applies to PAs under Part 21 including but not limited to the following:
CASR Part 21. Subparts F, G, K, O, and Q
●
Production under Type Certificate (TC) (CASR Part 21 Subpart F)
●
Production Certificate (PC) (CASR Part 21 Subpart G)
●
Australian Parts Manufacturer Approval (APMA) (CASR Part 21 Subpart K)
●
CASR Part 21.305 (e)
Australian Technical Standard Order Authorisation (ATSOA) (CASR Part 21 Subpart O)
●
Identification of Aircraft and Aeronautical Products (CASR Part 21 Subpart Q)
●
Other approvals under CASR 21.305(e).
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.2 Regulatory Framework Approved by Executive Manager, Aviation Safety Standards 1.2
Regulatory Framework
1.2.1
Background
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An outline of the background to this manual is as follows: CASR Part 21 CAR 30
a. Version 1 of this manual was introduced in May 2000 to address manufacture under CASR Part 21 and for transition from previous approvals issued under regulation 30 of CAR 1988. b. CASR Part 21 provisions were developed with the intent of reflecting the corresponding provisions in US FAR Part 21, but only where these were appropriate to Australian requirements. c. The result has been regulations that harmonise with international best practice while at the same time meeting Australia's obligations as a contracting state to the ICAO Convention.
CASR Part 21
d. Audit of manufacturing approvals is conducted under CASA’s surveillance procedures. e. Amendment 2.0 is introduced to clarify procedures in the light of experience gained since the introduction of CASR Part 21.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.2 Regulatory Framework Approved by Executive Manager, Aviation Safety Standards
1.2.2
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Legislative Basis
Civil Aviation Act 1988 Section 11 CAA 1988 CAR 1988 CASR 1998 Part 21
Australia, as a contracting state to ICAO, has an obligation to ensure that functions carried out in Australia are performed in accordance with international agreements. The Civil Aviation Act (1988) section 11 refers. CAR1988 and CASR Part 21 are consistent with the provisions of the Act.
Civil Aviation Act 1988 Section 31 and Civil Aviation Safety Regulations 1998 Part 201.4 CAA 31
Section 31 of the Act makes all decisions to refuse to grant, vary, suspend or cancel an approval appealable to the AAT.
CASR 201.4
CASR Part 201.4 makes appealable any condition imposed on an approval, authorisation, authority, certificate or permit.
Civil Aviation Act 1988 Section 97 If a fee is prescribed for the grant of an approval then the approval need not be granted until the fee is paid (section 97 of the Act).
CAA 97
Civil Aviation Safety Regulations Part 1 CASR Part 1
Part 1 describes legislative links to other aviation legislation and practices.
Civil Aviation Safety Regulations Part 21 Subpart A Subpart A defines the applicability of CASR Part 21, including provisions dealing with falsification of applications, suspension and cancellation actions and reporting of failures by production approval holders.
CASR Part 21
Civil Aviation Safety Regulations Part 21 Subpart F CASR Part 21 Subpart F
Subpart F prescribes the requirements for approval of production under a TC only. It contains the requirements for establishing a production inspection system and a Materials Review Board (MRB). This approval does not provide the same degree of flexibility as a Production Certificate.
Civil Aviation Safety Regulations Part 21 Subpart G CASR Part 21 Subpart G
Subpart G prescribes the requirements for issue of a Production Certificate and the rules governing the production of aircraft, aircraft engines and propellers and certain parts.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.2 Regulatory Framework Approved by Executive Manager, Aviation Safety Standards
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Civil Aviation Safety Regulations Part 21 Subpart K CASR Part 21. Subpart K,
Subpart K prescribes the requirements for issue of an Australian Parts Manufacturer Approval. This approval requires the establishment of a Fabrication Inspection System (FIS) in addition to design approval.
Civil Aviation Safety Regulations Part 21 Subpart O CASR Part 21. Subpart O.
Subpart O prescribes the requirements for issue of an Australian Technical Standard Order Authorisation. This approval is both a design and production approval.
Civil Aviation Safety Regulations Part 21 Subpart Q CASR Part 21. Subpart Q
Subpart Q prescribes the requirements for part identification and marking.
Civil Aviation Safety Regulations 21.305 (e) CASR Part 21.305 (e)
Section 21.305(e) authorises approval of items not otherwise covered by other approval mechanisms.
Civil Aviation Safety Regulations Part 201 CASR Part 201
Part 201 prescribes the appointment of authorised persons.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.3 Responsibility for Production Approval Approved by Executive Manager, Aviation Safety Standards 1.3
Responsibility for Production Approval
1.3.1
Staff Responsibilities
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Executive Sponsor The Executive Sponsor has responsibility for the overall control of this manual. Technical Sponsor The Technical Sponsor assumes technical responsibility for this manual and manages its development through to completion, or its amendment as and when required, in accordance with the Manual of Controlled Documents. Managers Managers ensure that CASA staff correctly implement the procedures in this manual. CASA Officers CASA officers are to: ●
●
Adhere to the procedures in this manual Bring to the notice of the Sponsor the need for amendments to the manual, in accordance with the instructions for Recommending Changes to the Manual.
CASA Project Officer The Head of the Engineering Support Section (ESS) appoints a Project Officer (PO) for a particular production approval, who ensures that the production approval application is assessed effectively and that all aspects of the approval are complete and in accordance with this manual. When satisfied, the Project Officer recommends the issue of the approval. The PO for PC and APIS applications will be a Manufacturing Inspector (MI). The PO who evaluates the APMA and ATSOA applications will be an Airworthiness Engineer (AWE).
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.4 Production Approval Process Approved by Executive Manager, Aviation Safety Standards 1.4
Production Approval Process
1.4.1
Production Approval Flowchart
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Initial advice to applicant
Receive application Conduct onsite evaluation/ audit of QC system Set up project files
Does applicant follow approved procedures?
Acknowledge application
ESS assigns a Project Officer
Is this the facility's first approval?
No
Notify applicant to take corrective action
Yes
Is PC board involved?
No
No
Yes Convene PC board
Yes Establish PC board if the application is for a PC
Yes
Is there a major change in the facility's procedures?
No
Has applicant met all requirements?
No
Notify applicant to take corrective action
Yes
Review data for compliance
Issue the approval
Do procedures comply? Yes
No
Notify applicant to revise procedures
Complete files and enter approval details on CASA Internet database
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.5 Processing Inquiries and Applications for Production Approvals Approved by Executive Manager, Aviation Safety Standards 1.5
Processing Inquiries and Applications for Production Approvals
1.5.1
Advice Provided by CASA for General Enquiries
AC 21.14, 21.16, 21.20, 21.27, 21.601
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When people make inquiries about production approvals, provide them with relevant advice and request that they read the appropriate Advisory Circular (AC) for the particular approval, including: ●
AC 21.14
Production Certificates
●
AC 21.16
Australian Parts Manufacturer Approval
●
AC 21.20
Production Under TC
●
AC 21.27
Manufacturing Approval — Overview.
●
AC 21.601
ATSOA (Yet to be issued)
Should the person wish to proceed, advise that a formal written application to CASA is required before the application can be processed. Enquirers must be advised that cost recovery procedures are applicable. Regardless of which production approval is sought, it should be stressed to the applicant that it is the applicant’s responsibility to demonstrate conforming products and parts. It is a CASA responsibility to find that conforming parts have been demonstrated as a basis for issue of the approval sought. A non-conformed proof-of-concept product is not a basis for CASA assessment and subsequent approval. The CASA officer should advise the applicant of the advantages of obtaining a PC. The advantages of being a PC holder, compared to production under a TC only, include the following: ●
●
●
CASR 21.325
●
No requirement to submit a Statement of Conformity to CASA, for each conformed product Reduced CASA involvement, relative to conformity inspections An Authorised Person within the Approved Production Inspection System (APIS) will be able to issue airworthiness certificates and approvals for completed products without reliance on CASA inspections The issue of export approvals for small aircraft without assembly or flight test (CASR 21.325).
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.5 Processing Inquiries and Applications for Production Approvals Approved by Executive Manager, Aviation Safety Standards
1.5.2
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On Receipt of an Application
Administrative Procedures 1. All correspondence is to be recorded and controlled in accordance with Record Management Unit (RMU) guidelines. 2. All actions to be properly documented and filed as appropriate. 3. All other administrative processes to be in accordance with local ESS internal procedures. Cost Recovery Procedures The cost recovery procedures for production approvals are similar to those described in the Type Certification Procedures Manual. Engineering Manager The Engineering Manager or Team Leader is to monitor the progress of the application. If it becomes evident that the application will not be processed within the normal timeframe, ensure that the applicant is notified accordingly. Project Officer 1. Raise Form 883 Production Approval Assessment Control Document and place it on the appropriate file. 2. Check that Form 849 Production Approval Application and covering letter are complete and on file. 3. Check the LARP database for any current enforcement actions pending or proceeding in relation to the applicant or whether any exclusion periods have been imposed. Refer any of these to the Office of Legal Counsel for advice. 4. Prepare a cost-recovery estimate within 7 days. 5. Forward the file with the attached cost-recovery details to Administration. 6. Liaise with Central Office personnel, as applicable, to advise them of the application and, if the application is for an APIS or PC, to arrange the establishment of a Production Certification Board (PCB). Refer to 1.6.1 Production Certification Board. The ESS and Central Office managers will allocate resources.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.5 Processing Inquiries and Applications for Production Approvals Approved by Executive Manager, Aviation Safety Standards
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7. Send the applicant a letter of acknowledgment when notified that the applicant has accepted the estimate for service and/or the prescribed fee has been paid. If a PCB is required, pre-PCB (CASA) and pre-PCB (applicant) meetings may now be convened (refer to 1.6.1 Production Certification Board), to prepare both CASA officers involved in the assessment and the applicant for the requirements of the assessment. A PCB is required for Class 1 items, and may be required for other items, at the discretion of the Head of ESS, depending upon the complexity and investigations required. 8. If the application does not require the establishment of a PCB, proceed as for the preliminary assessment only. Administration Officer 1. Complete the cost recovery documentation in accordance with the Financial Procedures Manual. 2. Return the file to the Project Officer.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.6 Production Certification Board (PCB) Approved by Executive Manager, Aviation Safety Standards 1.6
Production Certification Board (PCB)
1.6.1
Production Certification Board – Description
Version 2.0: August 2004
A Production Certification Board (PCB) is a CASA panel established for the purpose of facilitating the assessment of a production approval PCBs should be convened for initial production approvals covered by production under TC or Production Certificate, or when entire facilities have been relocated or are to be added to the production approval. PCBs should not be convened for the addition of new models to the production approval or for relocation of a portion of a facility, unless significant changes in production technology or processes apply. In these instances, follow the procedures in Chapter 2.
■ 1.6.2
PCB Membership The PCB will include a Chairperson nominated by the ESS manager, the Project Officer and any other nominated specialists. These members will assist in evaluating the applicant's production, engineering, flight test procedures, and other related functions. The Project Officer may be, or act as, the Chairperson of the PCB and will coordinate activity through the Head of ESS.
■ 1.6.3
PCB Member Responsibilities
PCB Chairperson The PCB chairperson is responsible for: ●
●
●
●
●
●
Assigning board members, as deemed appropriate for the particular product, and notifying members of the pending PCB schedule in sufficient time to permit adequate planning and preparation Notifying the applicant of the PCB schedule Selecting a representative number of the applicant's supplier facilities for evaluation to determine whether or not the applicant's quality system provides for satisfactory supplier control Conducting pre/post-PCB meetings with CASA officers and/or the applicant Reviewing and analysing the PCB findings and ensuring that appropriate corrective actions have been or will be taken by the applicant Completing, signing, and distributing the PCB minutes.
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Project Officer The Project Officer is responsible, using administrative assistance as appropriate, for: ●
Establishing schedules
●
Making arrangements for meeting rooms
●
Obtaining sufficient copies of quality system data
●
Making all other arrangements necessary for convening and conducting the PCB in the most expeditious manner
●
Ensuring that all agreed-upon corrective actions have been taken by the applicant
●
Preparing the minutes of the PCB.
Certification Specialists The Certification Specialists are responsible for: CASR 21.127, 21.128, 21.129, 21.143 (1)(c)
●
●
●
Evaluating and approving the applicant's production engine/propeller test procedures, as required by CASR 21.143(1)(c), 21.127, 21.128 or 21.129 Evaluating and approving the applicant's flight test procedures and check-off lists as required by CASR 21.143(1)(c) Reporting and making recommendations to the Project Officer (rather than making direct communication with the applicant).
■ 1.6.4
Conduct of the PCB A PCB is generally conducted as follows: ●
Initial CASA personnel meeting
●
Pre-PCB meeting
●
PCB meetings
●
Review of the PCB process and conduct.
Initial CASA Planning Meeting A meeting of CASA personnel is held to plan the preliminary assessment, ESS Office recommendations, and related correspondence between CASA and the applicant. This meeting is also used to plan the PCB schedule for subsequent meetings; and establish agenda items for the pre-PCB meetings.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.6 Production Certification Board (PCB) Approved by Executive Manager, Aviation Safety Standards
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Pre PCB Meeting A Pre-PCB meeting may be held with the applicant's representatives upon receipt of the production approval application. This meeting should include the Chairperson and any other specialist as necessary. The purpose of this meeting is to advise the applicant of the purpose of the CASA PCB and of CASA's evaluation plans. CASR 21.125, 21.135, 21.137
Inform the applicant that the PCB is a fact-finding body convened to determine whether or not the applicant is in compliance with CASR 21.125 or 21.135 and, that in making this determination, the PCB will thoroughly evaluate the applicant’s quality system, data, organisation and production facilities. It is at this point that the Chairperson determines whether or not the location of the applicant’s facilities poses an undue burden on CASA, as specified in CASR 21.137. PCB Assessment of Applications Following the pre-PCB meeting with the applicant, the PCB evaluates the applicant's quality system data and performs an on-site evaluation of the applicant's quality system, organisation production facility and suppliers, as appropriate. PCB Meetings PCB meetings attended by all board participants are conducted as needed to discuss and evaluate each unsatisfactory condition and related recommendation submitted by each member. All unsatisfactory conditions are recorded as findings on Form 883 Production Approval Assessment Control Document. A final meeting, attended by all PCB members and representatives of the applicant, is held to advise the applicant of the PCB findings. Each unsatisfactory condition and recommendation should be presented and briefly discussed. Corrective Action In those instances where a product is being produced under a TC, the PCB must request that the applicant commence immediate corrective action on those items that directly involve the product and related quality practices. A reasonable time may be allowed for correcting deficiencies in the quality system data. However, the applicant must be advised that the PCB cannot recommend that an approval be issued until all applicable regulations are complied with and the ESS Office has evaluated all corrective actions and found them to be satisfactory. Formal Confirmation The applicant must also be advised that the applicant will receive an official letter confirming the verbal presentation of the list of unsatisfactory conditions and recommendations. This formal notification should be prepared and signed by the PCB Chairperson, within ten working days of the final meeting with the manufacturer.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.6 Production Certification Board (PCB) Approved by Executive Manager, Aviation Safety Standards
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Violations CASR Part 21 Subpart F
If the applicant is manufacturing a product under a TC, and any of the unsatisfactory conditions are determined to be violations of CASR Part 21, Subpart F, appropriate enforcement actions should be initiated by the ESS Office.
Final Phase of the PCB The final phase of a PCB is the evaluation by the ESS Office of the corrective action taken by the applicant. The results of any re-inspection should be reported to the Chairperson of the PCB and, if satisfied, the Chairperson will make a recommendation to the ESS Manager and sign off on Form 883 Production Approval Assessment Control Document. PCB Conclusion CASR 21.123, 21.135
The ESS Office will formally advise the applicant in writing, as soon as practicable, that based on a demonstrated compliance with CASR 21.123 or 21.135, an approval will be issued. Conversely, if compliance has not been demonstrated, the applicant will be formally advised that an approval will not be issued, and a statement of reasons must be advised to the applicant.
■ 1.6.5
PCB Records The Project Officer shall prepare the PCB minutes for the signature of the Chairperson. The minutes should contain a concise record of the entire PCB proceedings, including the names and titles of all participants. All correspondence and forms relating to the PCB, including letters to the applicant, the applicant’s replies, etc, are considered to be part of the minutes and should be attached as appendices. Once accepted by the Chairman, the PCB minutes should be distributed as follows: ●
Original to the applicant’s file
●
One copy to Certification Support Services Section
●
Copies to the members of the PCB.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.6 Production Certification Board (PCB) Approved by Executive Manager, Aviation Safety Standards
1.6.6
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Administration of Production Approvals Granted
Approval Numbers All PA numbers incorporate the Aviation Reference Number (ARN) of the organisation. PC Numbers A PC’s number consists of the letters PC- followed by the ARN of the applicant—for example, PC-123456. It is unlikely that there would be more than one PC issued to an organisation because the PLR can list multiple activities. For PCs issued for Fabrication in the Course of Maintenance (FITCOM), -1 is added after the ARN, for example PC-123456-1. APIS Numbers An APIS number consists of the letters APIS- followed by the ARN of the applicant—for example, APIS-123456. The specific products are specified on the Type Certificate. APMA Numbers Only one APMA is likely to be issued to an organisation. An APMA number consists of the letters APMA- followed by the ARN of the applicant—for example, APMA-123456. The specific products and parts are listed on the supplement, which is re-issued to add or delete products and parts. The first and any additional supplements are numbered consecutively from 001. ATSOA Identification CASR 21.865, 21.870
An ATSOA is expected to be a discrete issue, and an organisation is likely to have multiple ATSOA approvals. The Letter of Approval identifies the specific item(s). The applicant’s ARN will be quoted in the letter. The articles must be marked in accordance with CASR 21.865 or 21.870. ESS PA Database After each PA is issued, the ESS administration staff are to enter the details of the specific approvals given into the MS Excel spreadsheet of PAs. Either weekly or as required, a copy of the complete database is to be forwarded to the CASA website controller in Canberra. The website controller will update the CASA external website and the intranet.
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Production Approval Procedures Manual 2. Assessment and Issue of Approvals 2.1 Approved Production Inspection System—Production under a TC Approved by Executive Manager, Aviation Safety Standards 2.
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Assessment and Issue of Approvals
2.1
Approved Production Inspection System—Production under a TC
2.1.1
Applicability – Approved Production Inspection System
CASR Part 21, Subpart F
This section provides guidance on the assessment and issue of an Approved Production Inspection System (APIS), under CASR Part 21, Subpart F. It applies to a holder or licensee of a TC who wants to manufacture complete aircraft, aircraft engines or propellers and parts thereof under an APIS prior to obtaining a Production Certificate (PC).
AC 21.20, 21.27
Additional guidance is contained in AC 21.20 and AC 21.27. Applicants should be aware that CASA considers an APIS an interim production stage, and they should be encouraged to achieve a PC for their activities. This is because, from the date of issue of the Type Certificate (TC) and prior to the issue of an APIS, CASA provides the resources to determine whether the product, and parts manufactured by the applicant, conform to the type design and are in a condition for safe operation. Because there is a six-month deadline from date of issue of a TC to the time when an applicant must have an APIS in place, the applicant should signal his or her intention to produce duplicates at the start of the type certification process. The regulations require the APIS holder to have process specifications, materials review records, test procedures and flight check forms that are acceptable to CASA, and the applicant should have started developing these data concurrently with other data relevant to type certification requirements.
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Responsibility Subsequent to the date of issue of the TC and prior to the issue of an APIS (or PC), CASA has full responsibility for determining whether the product and parts thereof conform to the type design and are in a condition for safe operation. The ESS is responsible for managing all aspects of progression to an APIS or PC and for the relevant surveillance activities once an APIS or PC has been issued. The Project Officer performs detailed inspections of all incoming materials (at the source, if necessary), installations, operations, processes, detail parts, sub-assemblies and completed products. These inspections must be documented as prescribed in section 4.1 Conformity Inspections, so that there is a complete inspection record for each product/part. The ESS Office maintains the complete inspection record of each product/part thereof.
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Procedure for APIS Issue
Preliminary Assessment Procedures CASR 21.123
An applicant for an APIS must show compliance with CASR 21.123. This preliminary assessment consists of an evaluation of the applicant’s: ●
●
Production inspection system data Facilities, equipment, processes, personnel, control of suppliers, stores, etc, to ensure that they are adequate for the purpose.
The assessment of the data will require a number of visits to the applicant’s facilities and suppliers, as necessary; to evaluate and confirm that the procedures provide control for the conformity of detail parts, sub-assemblies and completed products. In other words, the Project Officer must evaluate the adequacy of the quality system by personally observing the control of each stage of production, and all supporting functions such as document control. In the preliminary assessment, use the appropriate sections of this manual to assess: ●
Suppliers
●
Supplier control
●
All quality systems.
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Project Officer 1. Make arrangements to conduct the preliminary assessment only after the applicant has accepted the CASA estimate of costs and has the capability to comply with the regulatory requirements. 2. Assess the applicant's quality system assisted by specialists, as required. 3. Carry out the assessment concurrently with conformity inspections of first articles prior to the issue of an APIS. That is, assess the applicant’s inspection system for adequacy on a progressive basis. 4. As parts of the system are found to meet the regulatory requirements: ❍ Maintain a record of those portions of the system considered satisfactory on Form 883 Production Approval Assessment Control Document ❍ Reduce conformity inspections to spot-checks for articles covered by those parts of the system found satisfactory ❍ Place increasing emphasis on securing corrective actions on the parts of the system where procedural discrepancies or nonconformities are found, or where the system is found to be inadequate, as recorded on Form 883 Production Approval Assessment Control Document. Assessing the Applicant's Progress Project Officer 1. Periodically assess the applicant's progress in obtaining approval of the APIS. CASR 21.123(1)(c)
2. If it appears that the applicant may not be eligible for the APIS by the deadline date (six-month period specified in CASR 21.123(1)(c)), advise the applicant in writing of all known deficiencies. Also, caution the applicant that after the deadline date, CASA will not issue any airworthiness certificates or any other approvals unless an extension of the time period is authorised by the delegate. Keep the delegate informed if such a situation becomes inevitable. 3. Extension of six-month period: An application for extension of the six-month period must take into consideration the impact the extension would have on CASA staff, resources and safety.
CASR 21.123(3)
CASR 21.123(3) allows CASA to grant an extension when there are unusual or extenuating circumstances which would preclude the establishment of an APIS within the six-month limitation. 4. Forward requests for extension, together with a detailed summary of the ESS Office inspections and assessment results during the six-month period to the delegate.
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Failure to Establish APIS: When an applicant fails to establish an APIS by the end of the six-month period (except as otherwise extended as above), CASA will no longer make conformity determinations. Discontinue all inspections. Do not issue airworthiness certifications and approvals. Provided that manpower resources allow, CASA may continue to counsel and advise the applicant to the extent necessary to assist in obtaining an APIS as soon as practicable. Notifying the Applicant Project Officer 1. On completion of the preliminary audit, formally notify the applicant of any corrective actions needed. Further advise the applicant that these items only represent CASA’s preliminary findings and that additional requests for corrective actions can be anticipated as a result of subsequent findings by the APIS Board, future routine audits and surveillance activities.
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APIS Board
Conduct of the APIS Board and Records of Its Findings The APIS Board is conducted in a manner similar to a PCB, including the use of a Chairperson. The PCB procedures in 1.6.1 Production Certification Board (PCB) should be followed, as appropriate, by the Project Officer. Also, the APIS Board findings should be documented in the same manner as the findings of a PCB, as applicable to the particular situation. Preparation and Delivery of the APIS Approval Letter Project Officer CASR Part 21
When the APIS Board has determined and documented that the manufacturer's complete production inspection system complies with CASR Part 21, prepare a letter of approval for the signature of the delegate. (A sample letter is provided in section 5.9.) Note: When an APIS is based on a licensing agreement for a specific period of time, the same period of time must be indicated on the APIS approval letter as a limitation to the approval. ESS Administration Officer 1. Forward the APIS approval letter to the applicant and retain a copy in the ESS file.
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Revision of an APIS Approval Letter If, subsequent to the issue of the original letter, the manufacturer applies to add another type-certificated product or a new model to the manufacturer's APIS, the ESS Manager or team leader must appoint a Project Officer to evaluate any required changes to the APIS resulting from new technology change to the facilities and staff. Project Officer 1. If the change is considered to be significant, you may re-convene the APIS Board to make the determination, and process the application in accordance with this section. 2. If an APIS Board is not required, a Project Officer may carry out an assessment, issue the revised APIS approval letter and request the manufacturer to return the original approval letter to the ESS Office ESS Admin Officer 1. Mark the returned APIS approval letter "superseded" and retain it in the ESS Office files.
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TC Holder's/TC Licensee's Responsibility under CASR Part 21, Subpart F
CASR Part 21, Subpart F, 21.130.
Manufacturers producing aircraft, aircraft engines or propellers under a Type Certificate Only (CASR Part 21, Subpart F) are required to submit to CASA a Statement of Conformity (Form 724) for each completed aircraft, aircraft engine or propeller. The Statement of Conformity is required before aircraft produced only under a Type Certificate can be issued with a Certificate of Airworthiness or, in the case of engines and propellers, before an Authorised Release Certificate can be issued. The Statement of Conformity submitted by the manufacturer is a certification that the product conforms to its type design and is in a condition for safe operation. See form 724, the Statement of Conformity required by CASR 21.130.
CASR 21.125
Subsequent to the issue of an APIS, the TC holder/licensee is additionally responsible for maintaining the APIS in accordance with CASR 21.125 to ensure that each product conforms to the type design and is in a condition for safe operation. The manufacturer must also comply with any terms or conditions as prescribed in the APIS approval letter.
CASR 21.003
A TC holder/licensee is responsible for reporting any failures, malfunctions, and defects as required by CASR 21.003.
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Note: The manufacturer must report to CASA for serious occurrences as listed in CASR 21.003 (4) that have occurred.
CASR 21.003
The manufacturer does not need to report to CASA for things as listed in CASR 21.003 (4) that might occur unless the product is outside the manufacturer’s control. Normal manufacturing problems can be fixed and not reported to CASA if the product has not left the manufacturer’s control or can be readily retrieved. The manufacturer does not have to report to CASA on an occurrence that is of a kind listed in CASR 21.003 (5) (21.10 refers) ie, improper maintenance or usage, or has already been reported.
CASR Part 21, Subparts F and Q.
Products manufactured under the provisions of CASR Part 21, Subpart F, must be marked in accordance with the requirements of CASR Part 21 Subpart Q.
Testing (aircraft, engines, propellers). CASR Part 21, Subpart F, 21.127, 21.128, 21.129
Each person who produces a completed product (except rocket engines) under CASR Part 21, Subpart F, must flight test and/or functional test that product. ●
●
Aircraft: Each aircraft produced under CASR Part 21, Subpart F, both prior to and subsequent to the issue of an APIS, must be flight-tested by a CASA approved flight test pilot in accordance with an approved production flight test procedure and flight checklist as required by CASR 21.127. Engines and Propellers: Each engine or propeller produced under CASR Part 21, Subpart F, both prior to and subsequent to the issue of an APIS, must be subjected to an acceptable test run or functional test in accordance with the requirements of regulations 21.128 or 21.129, as appropriate.
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APIS Holder’s Facility Location An APIS holder's manufacturing complex may consist of a principal facility and associate facilities using the same quality system approved by CASA for the particular type certificated product(s). The APIS is issued to the principal manufacturing facility that controls the quality of the product(s) for which the approval was granted. The principal facility and associate facility addresses are listed on the APIS. A post office box address is not acceptable for a facility because the actual location must be identified. However, post office boxes may be used as postal addresses for correspondence. When CASA surveillance is required at an associate facility located outside the geographical area of the ESS Office controlling the APIS, the ESS Manager may arrange for surveillance in accordance with the procedures contained in the Surveillance Procedures Manual. When an APIS holder moves the principal manufacturing facility to a new location the APIS is no longer effective. When the APIS holder moves an associate facility or adds a new plant, the ESS Office must be notified of the changes. Before the new plant or moved facility is approved for production it must be subjected to a satisfactory audit or be assessed by an APIS Board if the change is significant. The APIS must be amended to reflect this change.
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Assessment of an Applicant’s Suppliers See 3.2 Assessment of an Applicant’s Suppliers for supplier evaluation procedures.
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Production Certificate (PC)
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Applicability – Production Certificate
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CASR Part 21, Subpart G
This section provides guidance on the assessment and issue of a Production Certificate (PC) when an applicant complies with CASR Part 21 Subpart G.
AC 21.14
Additional guidance is contained in AC 21.14.
CASR 21.135,
The following persons may be issued with a PC when CASA finds, after examination of supporting data, inspection of the organisation and production facilities, that the applicant has complied with CASR 21.135:
21.021 21.029
●
The holder/licensee of a CASR 21.021/21.029 TC
●
The holder/licensee of a Supplementary Type Certificate (STC)
●
The holder of a PC who wishes to apply for an STC, may include the production approval for the STC on the PLR. Note: STC holders who only desire to produce the modification parts/kit should apply for an Australian Parts Manufacturer Approval (APMA).
CASR 21.025, 21.031 CASR 21.133 (2B)
●
●
The holder/licensee of a CASR 21.025 TC, when the TC issue was based on submission by the TC applicant and CASA approval of the type design data required by CASR 21.031 The holder of a PC issued for the fabrication of components specific to a particular aircraft undergoing maintenance in accordance with CASR 21.133 (2B).
A PC may not be issued to: CASR 21.027, Part 21, Subpart C
●
●
The holder of a TC issued under CASR 21.027, or CASR Part 21, Subpart C (provisional TC) An organisation whose manufacturing facilities are located outside Australian territory, unless it has been determined that such location(s) would place no undue burden on CASA.
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PCs Issued for Fabrication In The Course of Maintenance
CASR 21.133
This procedure has been introduced to assist industry in obtaining aeronautical products, required as part of the maintenance of an aircraft, from other organisations qualified to fabricate those products. Thus, Fabrication in the Course of Maintenance (FITCOM) is facilitated by utilising the facilities and expertise of suitably approved manufacturing organisations. A PC for this purpose may be issued under CASR 21.133(2B). The approval is limited to the fabrication of components for supply to a maintenance organisation, the owner of an aircraft or the operator of an aircraft for the installation in or on an aircraft, engine or propeller in the course of maintenance activities.
CASR 21.133
A PC issued under CASR 21.133 (2B) can be issued in accordance with the procedures in this manual, with the following limitation entered on the PLR in the Limitations section: “Limited to the fabrication and supply of parts to be consumed in the course of maintenance for the supply to: ❍
A maintenance organisation
❍
An owner/operator of the aircraft or component”
The requirements on the fabricator are the same as those requirements for any PC, other than an MRB process is not permitted. All parts fabricated must conform to the approved data and be in a condition for safe operation. CASR 21.151
The PLR may include generic instructions eg for cables and hoses, by material specification, length and fittings. The PAH is expected to receive an application to fabricate each part, identifying the aircraft in which the part will be installed. Note that CASR 21.151 (c) requires the PLR to have a description of each product to be fabricated. However, note that specific replacement parts for general sale (including cables & hoses) are required to be manufactured under an APMA or ATSOA. Note: The use of CASA Form 917 Authorised Release Certificate for a one-off PC is given in 3.2.12. (Form 917 is available at http://casa.gov.au/manuals/regulate/misc/form917.pdf and can also be purchased from J.S McMillan at http://casa.jsmcmillan.com.au/He/cat.
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Responsibility for PCs ●
●
The Project Officer, supported by an AWE, is responsible for managing all aspects of an application for a PC The Head of ESS is responsible for ongoing certificate management.
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Advising the Applicant As part of the assessment, CASA must ensure that the PC applicant understands that the holder of a PC is responsible for: ●
●
CASR 21.147
CASR 21 Subpart Q CASR 21.003
●
●
●
Maintaining the quality system in accordance with the regulations, data and procedures approved for the PC Ensuring conformity with the Type Design or Product Design, as applicable, and condition for safe operation of each completed product or part Notifying CASA of any changes to the quality system in writing to the responsible CASA ESS Office that may affect the inspection, conformity, or airworthiness of the product or part—CASR 21.147 requires the holder of a PC to notify CASA immediately. These changes include: ❍ Relocation of a part of a facility or addition to existing facilities ❍ Discontinuing production for an extended period of time for other than normal reasons such as scheduled holidays ❍ Resumption of production after discontinuance ❍ Significant curtailment/resumption of production operations ❍ Significant reduction/reassignment of quality system personnel ❍ Changes or revisions to quality system data and related procedures Marking products in accordance with the requirements of the regulations (CASR 21 Subpart Q) and approved design data Reporting all failures, malfunctions, and defects as required by CASR 21.003.
Project Officer 1. Advise the applicant that: AC 21.14 CASR Part 21, Subpart G
a. AC 21.14 provides an acceptable means of compliance with CASR Part 21, Subpart G. Where an applicant proposes to use a different means of compliance to that published in the AC, the delegate will assess this and the applicant advised accordingly.
AC 21.27,
b.
The data required to be submitted is described in appendix 1 of AC 21.27.
2. A title must be provided for the quality system manual for positive identification. In addition, a revision page or similar control is required to ensure that the original approval date and the date of each revision is recorded. A number or letter, and date of the revision must identify each revision. CASR 21.143
3. Where an applicant has existing quality control procedures for other purposes, the applicant must identify those parts that comprise the quality system that show compliance with CASR 21.143.
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Preliminary Assessment Procedures The application Form 849 Production Approval - Application is recorded at the ESS office is accordance with local procedures. ESS Administration Officer 1. On receipt of the application, issue a letter of acknowledgment. 2. Provide an estimate of costs for assessment of the application in accordance with CASA cost-recovery procedures, advising the applicant that CASA cannot proceed with the assessment until his or her payment/acceptance, in writing, of the estimate of costs.
Preliminary Assessment Project Officer 1. Plan for the establishment of the PCB and a pre-PCB meeting with the applicant so that the meetings can proceed on payment/acceptance of the estimate of costs. 2. Before the preliminary assessment, convene a pre-PCB meeting, if necessary. 3. After acceptance of the estimate of costs make arrangements to commence the preliminary assessment. This assessment consists of an evaluation of the applicant's: ❍ Quality system data ❍ Facilities, equipment, processes, personnel, control of suppliers, stores, etc, to ensure that they are adequate for the purpose. The assessment of the quality system data may require a number of visits to the applicant’s facilities and suppliers as necessary, to evaluate and confirm that the procedures are in fact adequate to control the conformity of detail parts, subassemblies and completed products. The MI must evaluate the adequacy of the quality system by personally observing the control of each stage of production and all supporting functions. Establishing the PCB and Holding Meetings of the PCB Project Officer Establish the PCB and meet, as appropriate, in accordance with the procedures in 1.6.1 Production Certification Board (PCB) – Description.
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Notifying the Applicant On completion of the preliminary assessment, formally notify the applicant of any corrective actions needed. Further advise the applicant that these items only represent CASA’s preliminary findings and that additional requests for corrective actions can be anticipated as a result of subsequent findings of the PCB, future routine audits and surveillance activities. Issuing the PC and Production Limitation Record (PLR) The PC and PLR certificates are prepared using the CASA templates for the Production Certificate (Form 737) and the Production Limitation Record (PLR) (Form 002). (The templates are available on CASA's Intranet). PCs and PLRs are printed on the official CASA certificate quality paper No 401 CERTIFICATE PAGE 1 – LOGO & BORDER (refer to the McMillan catalogue on the CASA Intranet for supply). See sample Production Approval Templates on page 2-15 (Production Certificate) and page 2-16 (Production Limitation Record). When issued, the original PC and PLR are given to the applicant. Copies of the PC and PLR are kept on the project file and on the master folders of PCs and PLRs issued or amended. The details of the PC and PLR are entered on the PC and PLR Register held as a shared drive in the Certification Support Services (CSS) Section. Electronic copies are also held on the shared drive. ESS Office CASR Part 21
1. When the PCB has determined and documented that the manufacturer's quality system and procedures comply with CASR Part 21, prepare the PC and PLR, together with a draft letter of approval for the signature of the appropriate delegate. When preparing the PLR, list: ❍ The TC number or Design Data Reference of each product authorised for production ❍ The model numbers and the date on which production was authorised ❍ Any limitations (eg limitation to parts only). Note: When a PC is issued and based on a licensing agreement for a specific period of time, the PC must terminate on the same date. The approval letter to the applicant must refer to this date.
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Additions to the PLR If a PC holder wants to add a new TC, or a new model or new parts, the holder must apply in the same manner as for the original issue. ESS Office 1. Normally it is not necessary to establish a PCB. However, in place of the PCB, conduct an audit to the extent necessary to determine whether the quality control system is adequate or has been appropriately changed to ensure positive control of the product/parts to be added to the PLR. However, if changes to the quality control system are substantial, establish and convene a PCB to make the determination. 2. If the revisions to the PLR are to include new products/models, prepare and issue the revised PLR, together with a draft approval letter for the delegate’s signature. 3. After the PLR has been approved and signed by the delegate, forward the revised PLR to the applicant with a request to return the superseded PLR to the ESS Office. Deletions to the PLR Responsible ESS Office 1. Where production of a type-certificated product has been discontinued, and more than one TC is listed on the PLR, the following applies: a. If neither the complete product nor spare parts are being produced, delete the discontinued product or model from the PLR. b. If production of the complete product has ceased, but spare parts are still being produced, revise the PLR to reflect this: CASR 21.147
❍
❍
CASR Part 21, Subpart G
❍
❍
Ensure that the manufacturer remains in compliance with CASR 21.147 and continue to advise CASA of any changes in the organisation, systems, procedures or processes Continue surveillance, in accordance with established procedures, of those facilities that are still active, paying particular attention to determine whether: The quality control data adequately covers the remaining procedures and processes involved The PC holder continues to comply with the requirements of CASR Part 21, Subpart G.
2. The revised PLR supersedes all previous issues of the PLR and is now the current approval for production.
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STC Modifications Incorporated by the PC Holder There are two means available: ●
●
The TC holder may apply to CASA to have the STC entered on the TC. The PC holder as either the TC holder or licensee of the TC may then incorporate the STC during production; or The PC holder may apply to CASA to have the STC entered on the PLR.
The production inspection system must be revised to address the incorporation of the STC during production.
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Sample Production Approval Templates Sample Production Certificate
CIVIL AVIATION SAFETY REGULATIONS 1998
Production Certificate Number PC-123456 In accordance with regulation 21.134 of the Civil Aviation Safety Regulations 1998, this certificate including the associated production limitation record(s) authorises: Planemaker Aircraft Pty Ltd ABN 91 123 456 789
to manufacture Class 1 Products
at the following manufacturing facilities: 2A Industrial Place Werribee, Victoria 3030
This certificate terminates on: 15/06/2004 This certificate is subject to the condition that the holder must notify CASA in writing of any change to the business address of the holder. (signed) A. G. Citizen Date Issued:
15/06/2003
Original Issue:
22/05/2002
Delegate of CASA
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Sample Production Limitation Record
Production Limitation Record The holder of Production Certificate No. PC-123456 may produce: Aircraft and Parts
manufactured in accordance with the following design data. Design Data
Model or Parts
VA999 ASR028SY
Airhawk 132B ACME R12
Date Production Authorised 1 December 2003 12 December 2003
Conditions and Limitations: None.
(Signed) 12/12/2003
A. G. Citizen
Date Issued: (dd/mm/yyyy)
Delegate of CASA
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Sample Production Certificate for Fabrication in the Course of Maintenance
CIVIL AVIATION SAFETY REGULATIONS 1998
Production Certificate Number PC-123456-1 In accordance with regulation 21.134 of the Civil Aviation Safety Regulations 1998, this certificate including the associated production limitation record(s) authorises: Planemaker Aircraft Pty Ltd ABN 91 123 456 789
to fabricate Class III Products
at the following manufacturing facilities: 2A Industrial Place Werribee, Victoria 3030
This certificate terminates on: 15/06/2004 This certificate is subject to the condition that the holder must notify CASA in writing of any change to the business address of the holder. (signed) A. G. Citizen Date Issued:
15/06/2003
Original Issue:
22/05/2002
Delegate of CASA
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Sample Production Certificate for Fabrication in the Course of Maintenance
Production Limitation Record The holder of Production Certificate No. PC-123456-1 may produce: Class III Products
manufactured in accordance with the following design data. Design Data Design data approved by CASA or a CASR 201.001 Authorised Person, specific to an individual aircraft
Module or Parts Sheet metal parts as defined by the design data
Date Production Authorised 1 December 2003 12 December 2003
Conditions and Limitations: Limited to the fabrication and supply of parts to be consumed in the course of maintenance (FITCOM), for the supply to: • a maintenance organisation • an owner/operator of the aircraft.
(Signed) 12/12/2003
A. G. Citizen
Date Issued: (dd/mm/yyyy)
Delegate of CASA
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Testing Aircraft, Engines and Propellers
Aircraft. CASR 21.197(1)(c)
All aircraft produced under a PC must pass an approved production flight test as part of the inspection procedure required for issue of an airworthiness certificate. A Special Flight Permit is issued to authorise production flight-testing under CASR 21.197 (1)(c).
CASR 21.325
Small aeroplanes and gliders manufactured under a PC and being exported without assembly or flight test under the provisions of CASR 21.325 are exceptions. However, in these instances the manufacturer, as a condition of the PC, must provide CASAapproved assembly and flight test procedures.
Engines and Propellers CASR 21.143(1)(c)
Engines and propellers produced under a PC must pass a production test approved as part of the quality system data required by CASR 21.143(1)(c).
■ 2.2.7
PC Holder's Location(s) A PC holder's manufacturing complex may consist of a principal facility and associate facilities using the same quality control system approved by CASA, for the particular type certificated product(s). The PC is issued to the manufacturing facility that controls the final assembly, testing and airworthiness release. The principal facility, and all associate facility addresses are listed on the PC. A post office box address is not acceptable for a facility because the actual location must be identified. However, post office boxes may be used as postal addresses for correspondence.
CASR 21.155, 21.159
A PC is not transferable—CASR 21.155. If the PC holder relocates any part of the manufacturing complex, the PC holder is required to apply for a new PC, as per CASR 21.159. A new PC under the same number will be issued to reflect the change.
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Responsibility for PC Management On receipt of an application for a PC, the ESB Manager assigns responsibility for coordinating progress of the application to a Manufacturing Inspector (MI). The assigned MI is responsible for: ●
Coordinating any PCB activities and chairing the PCB meetings during the evaluation phases of the application
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Carrying out the preliminary assessment of the quality system data and facilities
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Assessing the inspection/quality system for manufacturing and special processes
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Assessing the applicant’s quality system for compliance with regulatory provisions
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Approval of quality system data and review of all changes to the quality system that may affect the inspection, conformity or airworthiness of the product Conducting conformity inspections on prototype and production products and parts, as necessary Providing guidance and assistance to the PC holder as necessary. Investigating non-conformities, rejected products and Materials Review Board (MRB) activities Ensuring that appropriate corrective actions are taken for all unsatisfactory conditions reported, such as non-conformance notices issued during the company’s internal audits Monitoring the PC holder's supplier facilities, and conducting audits at those facilities as necessary to ensure conformity of the TC product Issuing airworthiness and export approvals as necessary Advising the assigned AWE whenever technical data is found to be inadequate for producing duplicates—eg, material/process specifications not listed or inadequate; drawings and drawing lists not approved etc.
■ 2.2.9
Assessment of an Applicant’s Suppliers See 3.2 Assessment of an Applicant’s Suppliers for supplier evaluation procedures.
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2.2.10 Summary of Distribution of Production Certification Documents The Project Officer is to distribute the PC documents as indicated below. Application for PC, CASA Form 849 ●
Original retained by the ESS Office, together with: ❍ Copies of the applicant’s legal identity ❍ Licensing agreement(s) ❍ Documented quality control system when approved.
Prepared PC, PLR and Draft Letter of Approval ●
The ESS Office prepares these documents after the satisfactory completion of the assessment, completion and acceptance of the PCB findings, and approval of the quality system data. The Project Officer forwards the documents to the delegate.
Approved PC, PLR and Draft Letter of Approval The delegate when satisfied signs and forwards: ●
The originals to the applicant
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Copies to the Project Officer for filing.
Request for Amendment to the Production Certificate CASR 21.153
The applicant is to submit the Production Approval Application form (Form 849). An ESS Project Officer will assess the application for amendment in accordance with these procedures for revised PC and for its compliance with CASR 21.153. The PC and PLR will be re-issued to reflect the amendment.
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Australian Parts Manufacturer Approval
2.3.1
Applicability of Australian Parts Manufacturer Approval
CASR Part 21, Subpart K, 21.303
Version 2.0: August 2004
This section covers the assessment and issue of an Australian Parts Manufacturer Approval (APMA) for replacement and modification parts for installation on a type certificated product, in accordance with CASR Part 21, Subpart K, regulation 21.303. Note: AN APMA is not issued for production of parts for installation on non-type certificated aircraft or products. The section provides guidance for CASA to be satisfied that the applicant has shown compliance with airworthiness requirements on the basis of tests and computations, or in certain cases, on the basis of identicality.
CASR 21.303
CASR 21.303 requires that any person producing replacement or modification parts for sale for installation on a type-certificated product must obtain an APMA. An APMA must be obtained for replacement or modification parts for an STC if they are not being produced under a PC. CASA does not approve manufacturing inspection procedures, materials or special processes such as heat treatment, plating, shot peening etc. If such processes are required in the manufacture of parts, the APMA approved data will specify the requirement. Note: The part or parts for a STC, which carry or carries a one-time only limitation, may be manufactured under maintenance approval for the one aircraft involved.
CASR 21.303(2)(e)
Note:
Standard parts conforming to an established industry or Australian specification—eg, AN bolts and nuts are not eligible for an APMA (CASR 21.303(2)(e)).
Imported Products CASR 21.502, 21.502A
If, in producing a part under an APMA, imported parts are to be used, they must be imported parts in accordance with CASR 21.502 and 21.502A.
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Responsibility for Australian Parts Manufacturer Approval
Applicant The applicant must show that the design meets the applicable airworthiness standards. The applicant shows compliance in two ways: ●
●
The applicant demonstrates that the design of the part is identical to the design of a part covered under a TC or STC; or The applicant demonstrates through tests and/or computations that the design of the part meets the airworthiness requirements applicable to the product on which the part is installed. The applicant must assure that no interference with mating or adjacent hardware occurs and that the part performs its intended function.
Applicants intending to demonstrate that the design is identical must produce evidence of any licensing agreement held with original equipment manufacturer or STC holder. The applicant must establish and maintain a Fabrication Inspection System (FIS) that meets the requirements of CASR 21.303(11).
CASR 21.303(11),
Assigned Engineer and Manufacturing Inspector CASR 21.303 (3)
The assigned AWE assesses the design data, any test reports and computations for compliance with the applicable airworthiness requirements – CASR 21.303 (3).
CASR 21.303
The MI assesses the APMA applicant’s facilities, process, documentation and fabrication inspection system for compliance with the airworthiness requirements – CASR 21.303.
■ 2.3.3
Lodgement of an Application for an APMA Applicants should be advised to submit an application for an APMA in a letter complete with Form 849 Production Approval – Application to the Manager, ESS.
CASR 21.303
The suggested format of the application and a list of required attachments are shown in 5.1 Sample APMA Application Letter in Chapter 5 Sample Letters. The applicant must comply with CASR 21.303. Note: The applicant must have produced conforming parts in support of the application. A non-conformed proof-of-concept part is not a basis for CASA assessment and subsequent approval.
Initial Assessment The AWE and MI should jointly assess the application. If the application or Form 849 does not contain all the relevant information the ESS Office will advise the applicant.
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CASA Engineering Assessment
Design Assessment 1. Ensure that the applicant’s engineering design data package meets the applicable airworthiness design standards and complies with the relevant certification regulations. This may require the AWE to refer aspects of the design package to other engineering specialists. CASR 21.303(c) 21.303 4)
2. Design data as defined in CASR 21.303(c) that has been approved by an Authorised Person for CASR 21.303(4) is to be reviewed at the discretion of the AWE, commensurate with the knowledge and experience that /casa has of the Authorised Person. 3. Determine whether the application for the APMA establishes that the part meets the relevant airworthiness requirements applicable to the type certificated product on which the part is to be installed. Also verify the eligibility for installation of the part on the type-certificated product. 4. If the applicant's design does not meet all the above design considerations, advise the applicant accordingly. Do not process application any further. A revised application may be required to resolve outstanding issues. Note: The Issue Paper process as described in the Type Certification Procedures Manual may be used for documenting items requiring further discussion.
Compliance Considerations Applicant The applicant must submit: AC 21.16
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A Compliance Statement listing the applicable regulatory requirement (refer AC 21.16)
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The means or documents showing compliance
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A 'yes' or 'no' compliance statement.
Assigned Engineer 1. Irrespective of the method by which an applicant chooses to show compliance as listed on the Compliance Statement, prior to issuing APMA approval, carefully review the application, in coordination with the MI, as appropriate, to determine whether the applicant can ensure: a. Compliance with the applicable airworthiness requirements. b. That materials conform to the specifications in the design. c. That the part conforms to the drawings in the design.
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d. That the applicant has demonstrated that the fabrication processes, construction and assembly conform to those specified in the applicant's design (CASR 21.303 (8)(d) refers).
CASR 21.303 (8)(d) CASR 21.865
e. That part marking requirements are satisfactory and in accordance with CASR 21.865.
CASR 21.003
f.
Continued airworthiness under the applicable airworthiness requirements, including reporting requirements under CASR 21.003, for the manufactured part and the product upon which the part is installed.
Verification of Installation Eligibility Project Officer The applicant’s claim of installation eligibility must be verified. This may be one or more of the following: ●
Licensing agreement with TC or STC holder
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TC Data Sheet
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Training notes
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Maintenance manuals
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Service Bulletins
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Technical Publications
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Flight Manuals
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Airworthiness Directives
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Illustrated Parts Catalogues (IPCs).
While some of these sources may not be NAA approved, they may be used carefully in conjunction with other data to provide verification. Service History Considerations Project Officer 1. Consider the service history of the part in question and verify that it is not the subject of an Airworthiness Directive (AD), other continued airworthiness problems, or subject to an incident/accident investigation.
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2. If the part is subject to one of the above, and the design is identical to the original part and produced under a licensing agreement, use the following guidelines: a. If there is an AD that removes the original part from service, immediately or in the future, the APMA application should be rejected unless the application includes design changes that satisfactorily address the AD problem. b. Consult with the Section Head, Airframes or Systems Section to ascertain whether CASA is currently developing or considering development of an AD to remove the original part from service. CASR 21.303(4)(a)
c. If CASA and/or ATSB are investigating an incident/accident where the original part may be causal, CASA may delay or suspend the processing of the APMA application until the part is cleared. (Refer CASR 21.303(4)(a).) d. If an AD calls for repetitive inspections but prescribes no terminating corrective action—eg, no modification or replacement of the part provided—and if the repetitive inspections are intended to catch failures that may occur before the part reaches the published service life, CASA should reject the application for an identical part APMA. CASA should always strive for terminating corrective action; an APMA to produce and distribute identical parts only complicates and prolongs the problem. If the part is subject to Service Difficulty Reports and CASA is pursuing corrective action with the TC holder, the application for APMA should be rejected. In these cases an improved replacement part should be sought. e. The fact that the TC holder issues an Alert Service Bulletin (ASB) to remove a part from service does not, in itself, exclude issue of an APMA.
Life-limited Parts Irrespective of the method under which an applicant seeks an APMA, the applicant must establish the life limit of that part. The required substantiating data must include tests on components produced by the applicant. Special Considerations – Identicality Engineering design data can be accepted for approval when the applicant shows, and CASA finds, that the design of the part for which the APMA is requested is identical in dimension, tolerances, materials, processes, and specifications to the design of the part covered under a TC or STC. Some part designs may contain features that may have nothing to do with form, fit, or function or being airworthy. Some of these features may include tooling holes, colour, tighter tolerances, location/type of part marking, etc. It may not be necessary that these features be identical, however these will require engineering assessment and acceptance.
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Engineering Review of Data Package Review the data package as necessary with Engineering specialists in conjunction with CASA type certification personnel to determine whether manufacturing processes specified in the design data are appropriate and acceptable. For critical parts, coordination with CASA technical specialists is required. Reverse Engineering The process of reverse engineering is one way to develop the design of a part. However, reverse engineering will not produce a design that is identical to a type certificated part. While an applicant could establish the use of identical materials and dimensions, it is most unlikely that a showing could be made that the tolerances, processes, and manufacturing specifications are identical. The Test and Computation method is the only practical means of demonstrating compliance with the applicable regulations. Rejecting an Application CASR 21.002B
CASR 21.002B refers. Project Officer CASA in general does not have access to the commercial in confidence original certified data in order to make a determination of identicality. Therefore, in practice, identicality can only be established for parts manufactured to design data supplied under licensing agreement with a TC or STC holder. 1. When the design data submitted is based on showing identicality (including the manufacturing processes) and the data does not show that the part is identical to a part covered under a TC, return the application to the applicant with a notification that it does not show the applicant's part to be identical. See 5.6 Sample CASA APMA Design Rejection Letter.
CASR 21.303(8)
Note: An APMA may be granted if the applicant resubmits and shows, on the basis of Test and Computations, that the part meets all applicable airworthiness requirements in accordance with CASR 21.303(8).
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2. You may also require that the applicant submit inspection and test reports to substantiate that the design and manufacturing data will produce a part that meets the airworthiness requirements and is safe for installation on applicable type-certificated products. If you determine that the airworthiness of a part cannot be assured solely by the showing of equivalence to the design covered under a TC or the design cannot be shown to comply with the original TC design standard, also send the applicant a letter of design rejection. See 5.6 Sample CASA APMA Design Rejection Letter. Tests and Computations Considerations for the Project Officer 1. Review and evaluate the test schedule submitted prior to any CASA test to determine if it is appropriate for the part. 2. Ensure the part conforms to the design data and/or the test proposal before testing. 3. For critical parts, coordination with technical specialists may be required. Evaluate the Data Package 1. Evaluate each applicant's capabilities to reproduce a part on a case-by-case basis. 2. Coordinate with the appropriate MI to assure that the manufacturing process produces replacement and modification parts according to the approved design. All applications should include: ❍ Detailed design criteria, including drawings, technical data necessary to establish structural strength, part marking information, and process specifications necessary to define the configuration. CAR 35, 36
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❍
For engineering design modifications approved under CAR 35, the depth of assessment may be varied at the discretion of the engineer. Other data necessary to establish the pertinent characteristics of the part. The applicants must identify detail drawings as their own unless evidence of a licensing agreement is submitted. In evaluating any data package, consider the following: ❍ Manufacturing and Process Specifications: Manufacturing procedures and process specifications may affect the airworthiness of the part. If the applicant's detail drawings reference the TC holder's process specifications, those specifications must be submitted. As the data package is reviewed, coordination with the CASA type certification personnel may be necessary to determine what effect these specifications may have on the airworthiness of the design or to a finding of identicality (see Special Considerations – Identicality). For critical parts, coordination with the relevant specialist is required.
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Master Control Drawings: Master control drawings or their equivalent must be carefully evaluated to determine whether the applicant has appropriate control over the configuration and manufacture of the part. The applicant must submit all applicable detail drawings and specifications for acceptable evaluation of the sources listed on master control drawings. The applicant must have satisfactory and verifiable control procedures included in the Fabrication Inspection System (FIS) for vendor supplied items prior to the issue of the APMA. Drawing Notes: The Project Officer, with particular reference to any drawing notes or process specifications identified on the drawing, should check the applicant’s ability to produce conforming parts before issuing APMA approval.
■ 2.3.5
Manufacturing Inspector Assessment The following procedures are performed when the MI receives a copy of the APMA application letter and the relevant FIS data from the Project Officer. See 5.1 Sample APMA Application Letter.
Fabrication Inspection System MI CASR 21.303(11) AC 21.27
1. Ensure that the APMA applicant has advised CASA that the Fabrication Inspection System required by CASR 21.303(11) has been established and is ready for assessment. If part production is under a license agreement, CASA is to receive a copy of the licensing agreement and to sight the original. The data from the design/production holder should be nominated and confirmed as controlled data. 2. Carry out an assessment of the FIS in accordance with 3.1 Assessment of Quality Systems for Manufacture and 3.2 Assessment of an Applicant's Suppliers. 3. When these data have been found to be acceptable, notify the Project Officer in writing.
CASR 21 Subpart Q
4. Ensure the FIS includes procedures for the marking of parts in accordance with CASR 21 Subpart Q requirements.
Facilities Inspection MI 1. Conduct an evaluation of the applicant's facility, including any supplier's facilities as appropriate, to determine whether the facilities are suitable for manufacturing the nominated parts and that the applicant's FIS is operating effectively. CASR 21.303(5)
This evaluation, in accordance with CASR 21.303(5), should be coordinated with the Project Officer.
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Validation of the Applicant’s Conformity Inspection MI CASR 21.303(8)
1. Conduct validation conformity checks, as necessary, to ensure conformity of the parts to the approved design drawings and data as undertaken in accordance with the applicant's FIS in compliance with CASR 21.303(8). Validation conformity checks include incoming materials and processes used in producing the conformed part. Parts inspected for conformity are to be recorded on the Conformity Inspection Record (Form 882), together with comments regarding identified non-conformities. 2. An agreement must be reached with the applicant as to how the identified nonconformities will be addressed and, if necessary, the FIS re-presented to CASA
Manufacturing Procedures MI CASR 21.303(8) 21.303(11)
When satisfied that the manufacturing facilities, procedures and processes and inspection system comply with CASR 21.303(8) and (11), complete the relevant section of Form 883 Production Approval Assessment Control Document.
■ 2.3.6
APMA Approval
Design Acceptance/Approval Project Officer 1. Confirm design compliance. 2. Confirm with the MI that satisfactory manufacturing processes, material control and FIS have been assessed and are acceptable. 3. Ensure that a master drawing list or similar has been prepared and dated at the revision level. 4. Ensure that all drawings and data required are listed. Make sure that a copy of the submitted data package is retained on the project files.
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Final APMA Approval Project Officer CASR 21.303
1. Draft an APMA approval letter (pursuant to CASR 21.303) together with an APMA Supplement for approval for the appropriate delegate’s signature. Ensure that both the letter of approval and Supplement document are identified with the same APMA approval number. See: ❍ 5.2 Sample CASA APMA Approval Letter ❍ 5.3 Sample CASA APMA Supplement without Licensing Agreement ❍ 5.4 Sample CASA APMA Supplement with Licensing Agreement. Note: Form 1142 is used for portrait APMA Supplement and Form 1143 is used for landscape APMA Supplement. (Forms available to CASA staff only.) 2. Finalise costing charges by CASA in accordance with CASA’s cost-recovery procedures. 3. Forward all relevant documents to the delegate 4. Forward the original documents to the applicant and retain copies on file. 5. Advise the ESS Administration Officer of the approval details for entry onto the database of production approvals, and for inclusion in the ESS audit program.
Assessment of Data An assigned Airworthiness Engineer (Project Officer) will carry out the assessment of the application, together with an MI if necessary, in a similar manner to the APMA procedures for parts approval. Approval Processing and final approval of an application for a material or process will be similar to the procedure for APMA approval described in this section. A letter of approval shall be issued in a similar manner to that of an APMA. Design Changes CASR 21.303 (3)(c)
CASR 21.303 (3)(c) refers.
AC 21.16 7.1(a)
Design changes to the part for an APMA granted on the basis of identicality and under a licensing agreement with the TC or STC holder may be carried out as minor modifications to the part under the APMA, provided that TC or STC holder agreement has been obtained. Refer AC 21.16 7.1(a).
CASR 21.303 (4)
For an APMA based on test and computation, all the design changes must be submitted to CASA or an Authorised Person for CASR 21.303 (4) for assessment.
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Changes to an Existing APMA The MI should conduct or arrange for an evaluation, as appropriate, when additional parts are approved to an original APMA approval or when the manufacturer makes changes to the FIS or relocates a facility. Advice to CASA of Changes to a FIS or Location CASR 21.303 (4)
A Production Approval Holder (PAH) is required to notify CASA within 10 days of any change to the manufacturing facility (CASR 21.303 (13)), and within 2 days of any change to the FIS (CASR 21.303(13A)), however, the MI response to that advice may differ in each situation.
CASR 21.303(12)
On advice that a facility has been expanded or relocated, the MI is to determine the likely airworthiness impact. If the same procedures are still applied, and a satisfactory first article conformity inspection is conducted and documented, then it may be sufficient to file the notification and use the advice to focus the next audit to the changed areas. If the PAH does not conduct a satisfactory first article conformity inspection after the facility is expanded or relocated, the MI is to advise the PAH that the APMA is no longer in force (ie, suspended) (CASR 21.303(12)) until this is achieved or the facility is re-evaluated by the MI with the intent of re-issuing the APMA or authorising continued production. If the PAH has changed the FIS without prior advice to CASA, the inspection process may not ensure conformity, and the MI needs to evaluate the APMA. When issuing an APMA the applicant should be encouraged to include suitable procedures in the procedures manual for having changes to the FIS approved by CASA before implementation so the approved system can be maintained. If conformity is affected, the APMA holder is required to quarantine production until the change is approved.
APMA Data Package AC 21.16
The recommended content of an applicant’s data package is given in AC 21.16. Provision of this information will assist assessment of the application.
Statement of Conformity The use of CASA Form 724 Statement of Conformity by the applicant is recommended for first article Statement of Conformity. Use of the form prompts for the information required to process the application. APMA Letter of Approval A template for the APMA Letter of Approval is provided (Form 1202, accessible by CASA staff via CASAconnect).
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Australian Technical Standard Order Authorisation (ATSOA)
2.4.1
Applicability – ATSOA
Version 2.0: August 2004
An ATSOA is a CASA design and production authorisation, issued to a specific manufacturer of an article which has been found to meet or exceed a specific Australian Technical Standard Order (ATSO) performance standard, or other performance standard accepted by CASA. CASR Part 21 Subpart O
An ATSOA must be obtained by persons who want to manufacture ATSO articles under CASR Part 21, Subpart O, Australian Technical Standard Order System. An ATSOA holder is a manufacturer who controls the design and quality of an article produced under the ATSO system, including all related parts, processes or services obtained from an outside source. The ATSOA system does not apply to parts produced under an APMA, TC only, or a PC. A letter of ATSO design approval for an appliance may be issued to foreign manufacturers located in countries with which Australia has an agreement which provides for the acceptance of appliances, provided that: ●
●
The NAA of the country in which the appliance will be manufactured certifies to CASA that the design of the particular appliance meets the pertinent design requirements of the specific ATSO The NAA is advised that each appliance that is produced under the provisions of the ATSO design approval and exported to Australia must be accompanied by an airworthiness approval issued by the NAA of the foreign country certifying that the article conforms with the appropriate ATSO and is in a condition for safe operation.
■ 2.4.2
Advising the Applicant
Project Officer 1. Advise the applicant that: AC 21.27
a. AC 21.27 contains guidance on what is an acceptable quality system. b. An ATSOA consists of the design and production approval. c. An ATSOA can only be obtained for the current ATSO for the particular article.
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Lodgement of an Application The applicant (or the applicant’s authorised agent) must submit an application for an ATSOA to the Manager, Engineering Support Branch. See 5.7 Sample ATSO Authorisation Application and Statement of Conformance.
CASR 21.605
The application must be accompanied by those documents required by CASR 21.605, and any documents required by the performance standard.
CASR 21.617
Foreign manufacturers who want to obtain a letter of ATSO design approval, (as provided for in CASR 21.617) must submit their application through their NAA to the Head of Airworthiness Standards, Civil Aviation Safety Authority, GPO Box 2005, Canberra, ACT 2601, Australia.
■ 2.4.4
ATSOA Issue Procedure
Design Approval Administration Officer 1. On receipt of the application, forward it to the ESS Team Leader at the appropriate geographical location. Project Officer CASR 21.605
1. On receipt of the application, check all incoming material to determine that documents and all data conform to the requirements of CASR 21.605. 2. If the data are incomplete, advise the applicant by letter that no further work will be done until the missing data are supplied.
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Assessment of Design Data Project Officer CAR 35
The design and production approval must be carried out by CASA. Data submitted with a CAR 35 Authorised Person’s approval still needs to be assessed by the CASA Project Officer. 1. Examine the technical data to ascertain that the technical requirements of the ATSO are met. The examination should include: ❍ A check of the adequacy and validity of technical data and test results
CASR Part 21.605
❍
Drawings and prescribed equipment installation information, and specified limitations should be checked for completeness and adequacy since such data are important to evaluation of aircraft type designs as well as for determination of the ability of the applicant to produce duplicate articles per CASR 21.605(4).
2. Notify the applicant in writing of any omissions. 3. Visit the applicant’s facility for the purpose of appraising the applicant’s competence to certify conformance with the ATSO. This visit should be in company with the assigned MI responsible for production approval compliance who should determine that compliance tests, as prescribed, are being realistically conducted. 4. When the authorisation is granted, add ATSOA holders to the engineering Surveillance Procedures Manual (SPM) audit pan to verify holders continue to comply with the performance standards of the ATSO. Quality System Data Compliance CASR 21.143, 21.144
The applicant for an ATSOA must submit, along with the application, a written description of the quality system in the detail specified in CASR 21.143 and 21.144. The quality system data compliance is determined in the following manner: Project Officer 1. Request an ESS MI to carry out a thorough evaluation of the quality system data submitted by the applicant. 2. If the MI advises of any quality system deficiencies, ensure all unsatisfactory conditions are addressed.
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MI CASR 21.143 AC 21-27(0)
AC 21-27
CASR 21.605
1. Carry out the procedures detailed in 3.1 Assessment of an Applicant’s Quality Systems for Manufacture, to determine compliance with CASR 21.143 and 21.144. The quality system data must include an acceptable test procedure meeting the ATSO requirement to which each production article will be tested. Guidance on an acceptable quality system is in AC 21-27 Manufacturing Approval Overview. 2. Advise the Project Officer as to whether or not these data comply with CASR 21.605. 3. In those instances when the quality system is found to be unsatisfactory, note the deficiencies on the Form 883 Production Approval Assessment Control Document and advise the applicant.
CASR 21.605
4. When satisfied that the data is in compliance with CASR 21.605, notify the Project Officer.
Issue of the ATSOA Project Officer 1. When satisfied that both the design approval aspects and quality control data aspects are compliant, forward a recommendation for the issue of an ATSOA to the Head of Certification Support Services Section through the ESS Manager. 2. Advise the ESS Administration Officer of the approval details for entry onto the database of production approvals, and for inclusion in the ESS audit program 3. Normally a separate letter of ATSOA approval will be issued for each article complying with the performance standard. Post-issue Compliance CASR 21.143 CASR 21.144
Subsequent revisions to the quality system must be submitted by the ATSOA holder to the responsible ESS Office to determine compliance with CASR 21.143 and 21.144.
CASR 21.143 CASR 21.144
The assigned MI is to advise the ATSOA holder as to whether or not the revisions comply with CASR 21.143 and 21.144.
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2.4.5
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ATSOA Holder's Facility Location An ATSOA holder's manufacturing complex may consist of a principal facility and associate facilities using the same quality control system approved by CASA. The ATSOA is issued to the principal manufacturing facility which controls the design and quality of the product(s) for which the approval was granted. The principal facility, and all associate facility addresses are listed on the ATSOA. A post office box address is not acceptable for a facility because the actual location must be identified. However, post office boxes may be used as postal addresses for correspondence. If an ATSOA holder moves a manufacturing facility to a new location, CASA must conduct an assessment at the new location to ensure that the ATSOA holder continues to comply with CASR 21.605 and 21.607.
CASR 21.605, 21.607
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Approval of Materials and Processes
Introduction CASR Subpart K
CASR 1998, Subpart K also provides for approval of the use of materials and processes.
CASR 21.305
Under the provisions of CASR 21.305, the use of a particular material or process may be approved:
CASR 21.502 CASR 21.305
●
If it is included as part of an APMA or ATSOA
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In conjunction with type certification for an aircraft engine or propeller
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If it meets the requirements of CASR 21.502 (1) (a) and (b) for imported materials
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In any other manner approved by CASA.
Application CASR 21.305
Applicants seeking CASA specific approval of the use of a material or process under CASR 21.305 (e), should be advised to lodge their application by letter to the Manager, ESS. This letter of application should include details regarding: ●
●
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The identity of the type certificated product or part on which the material or process will be utilised The name and address of the material manufacturing or process application facility Material or process specification details, including test reports showing the material’s physical and chemical properties
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Reports and computations necessary to show that the use of the material or process is compatible with, and does not in any way compromise, the design of the type certificated product or part on which it is utilised
The applicant may be required: ●
●
To carry out any other tests considered necessary to verify material or process specifications To carry out appropriate tests to show the effect of the material or process in service.
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Production Approval Procedures Manual 3. Assessment of an Applicant's Quality Systems for Manufacture 3.1 General Principles Approved by Executive Manager, Aviation Safety Standards Version 2.0: August 2004 3.
Assessment of an Applicant's Quality Systems for Manufacture
3.1
General Principles
3.1.1
General Principles
CASR Part 21, Subparts F, G, K or O
The purpose of this part is to assist in assessing quality systems of applicants seeking production approvals under CASR Part 21, Subparts F, G, K or O (APIS, PC, APMA, ATSOA). Not all the functions/elements specified in this part are necessarily applicable to every applicant's system, and the assessing MI/AWE before undertaking this assessment should, therefore, ensure a good understanding of the applicant's organisation and the extent of the manufacturing work to be undertaken. All aspects of the intended manufacturing activity must be clearly and adequately specified in the applicant's quality system.
Assessment Stages Assessment of any quality system is normally a three-stage process. Stage 1 Quality System Assessment—Desk-top Review Conduct a "desk top" review of the applicant's system to ensure that all the required procedures are included and adequately address the regulatory requirements. Stage 2 Quality System Assessment—Quality System Evaluation Evaluate the system at the manufacturing facility or facilities to ensure that the procedures have been documented, implemented and effectively control the work. Stage 3 Quality System Assessment—Manufacturer's Corrective Action The manufacturer rectifies any noted deficiencies and discrepancies by amending documented procedures or correcting discrepancies at the manufacturing facility or facilities. Quality Systems Documentation All production approval applicants are required to establish and maintain a quality system. It follows that the documented system must contain adequate procedures for the maintenance of the approved system. The documented system should identify the person who is responsible for CASA liaison, and will approve and implement quality system changes within the entity. For APMA and APIS formal CASA approval of a proposed quality system change is necessary before the change is implemented.
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Quality systems for PC and ATSOA applicants are required to comply with CASR 21.143 and 21.144. The quality system must be documented in a manual, and must include procedures for the following functions.
CASR 21.143, 21.144
1. Organisation Structure, Authority and Responsibility of Appointed Persons. 2. Technical Data Control. 3. Manufacturing Processes. 4. Special Processes. 5. Non-destructive Inspection. 6. Tool and Gauge Control. 7. Receiving Inspection/Supplier Control. 8. Inspection and Testing. 9. Material Review Procedure (Except for a CASR Part 21.133(2B) PC). 10. Stores Control. 11. Certification and Release. 12. Service Difficulty Reporting and Control. CAR 1998 21.123(1), 21.303(11)
The requirements for an APIS and APMA quality (fabrication inspection) system must also address items (1) to (12) above. The regulations covering APIS and APMA do not contain a specific requirement for the applicant's organisational structure to be included. However, CAR 1998 21.123 (1)(c) and 21.303 (11) require the applicant to establish and maintain a system which ensures that each completed product or part conforms to its design and is safe for operation or installation. To satisfy this requirement the applicant's organisational structure must also be included in such quality systems.
Establishment of Evaluation Teams The Project Officer shall coordinate with the appropriate ESS Team Leader to conduct an evaluation of an applicant's quality system. When the application is for manufacture of aircraft, the flight test personnel from Airworthiness Standards Branch are required to evaluate the relevant sections of the data and approve the production flight test schedule.
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Production Approval Procedures Manual 3. Assessment of an Applicant's Quality Systems for Manufacture 3.2 Assessment of an Applicant’s Suppliers Approved by Executive Manager, Aviation Safety Standards Version 2.0: August 2004 3.2
Assessment of an Applicant’s Suppliers
3.2.1
Assessment of an Applicant’s Suppliers
Preliminary and Ongoing Audits of the Supplier’s Facilities CASR Part 21
This section provides guidelines for CASA’s assessment of an applicant’s supplier production facility to ensure that the supplier control system implemented by the Production Approval Holder (PAH) meets the intent of CASR Part 21. The PAH has initial and on-going responsibility for control of suppliers. CASA may undertake audit of the facilities.
CASR Part 21, Subparts F, G, K, and O
CASR Part 21, Subparts F, G, K, and O, require the establishment of a quality system as a prerequisite to the issue of CASA a production approval. A critical part of such a system is to establish and maintain procedures for ensuring that components and materials produced by suppliers conform to the approved design data and are in a condition for safe operation. It is the PAH's responsibility to ensure that each completed product, part or appliance, including supplied components and materials, conforms to the approved design data and is in condition for safe operation. When suppliers are located outside of Australian territory CASA may request assistance from the NAA of the foreign country to act on its behalf, to perform assessment (and audit) activities. Such assistance may come under the terms of formal state agreements, memorandums of agreement between the authorities, or requests for assistance on a case-by-case basis. A PAH may utilise any supplier as long as the PAH’s quality control system provides assurance that all parts or services, including engineering services, furnished by a supplier are in compliance with its production approval. The PAH should place special emphasis on controlling those suppliers that it authorises to deliver parts/materials directly to a user/operator of the PAH’s completed product. Each PAH must make available to CASA a list of its direct ship suppliers. The PAH should have objective evidence that the suppliers have been notified that their facilities are subject to CASA audit. Emphasis is placed on the PAH's control of its suppliers, since the PAH is totally responsible for all of its supplier-furnished parts and services. CASA may evaluate the PAH's quality system implementation at selected suppliers.
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Assessment The same procedures and criteria used to accomplish and record assessment of the PAH quality system and facilities are to be used for evaluating suppliers, even though not all elements may be applicable to individual suppliers. MIs are to exercise their judgment and experience in performing supplier assessments. These procedures and criteria are detailed in 3.3 Quality System Assessment. Note: When a supplier to multiple PAHs is evaluated, it is of the utmost importance to ensure that the quality control requirements for the applicant being currently evaluated are met by the supplier.
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Quality System Assessment
3.3.1
Stage 1 Quality System Assessment—Desk-top Review
System Data Evaluation This stage is a thorough evaluation of a manufacturer's data (including any referenced procedures, policies, standards, instructions, processes), which describes the quality system required for a particular production approval. Note: All applications to CASA for production approval, conformity inspection, certificates of airworthiness or special flight permits must be signed by a legally empowered company principal or a letter of agency must accompany each application. Data Evaluation Method 1. It is of the utmost importance that the Project Officer critically evaluates the submitted data to ensure that: a. The described quality system will adequately provide for the consistent acceptance of only those products/parts that conform with the approved design data. b. The manufactured products/parts are in a condition for safe operation. 2. The prime objective of all quality system data is to ensure that it describes the procedures that meet the intent of the pertinent regulations, and can be realistically implemented. Applicants must understand that penalties can apply to non-compliance with the approved system, therefore the system described must reflect ‘local’ operations rather than ‘generic’ procedures. 3. All data must be positively identified by title, revision, and date; and must be approved for use by an authorised management representative (often the Quality Manager). 4. The initial evaluation of a manufacturer's quality system data must be thorough and comprehensive. However, any subsequent evaluation of a particular manufacturer's data may consist of: a. A cursory review of previously submitted data to determine whether or not it has remained adequate. b. A thorough review of any data that has been revised since the last evaluation. c. A thorough review of any new data that has been developed and implemented since the last analysis—for example, review of the quality assurance provisions of a new bonding process introduced subsequent to the last analysis.
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5. When evaluating the data, inspectors should flag: a. Any ambiguous data that may be subject to misinterpretation. b. Any overly complex or cumbersome inspection procedures that may be difficult to implement, be disregarded or even circumvented. Consistency of Compliance Standards CASR Part 21
Although the CASR Part 21 production approvals require different types of production control systems, this does not mean that less stringent standards are acceptable for manufacturers of like products or parts. Notwithstanding the type of production approval held, the product or part must, when completed, conform to its approved design and be in a condition for safe operation. For example, there is no need for an APMA holder who is authorised to produce a replacement part, to have the sophisticated quality management system required of a PC holder. However, the APMA holder must have the same manufacturing and quality control procedures in place, appropriate to the production of the part in question that would be required of a PC holder producing the same part. Some variance in requirements is balanced by the extent of CASA oversight. For example, an APIS holder is normally subjected to a greater degree of CASA involvement than a PC holder since the production inspection system does not provide for the same assurance of control as that provided under a PC.
Quality System Elements The system elements detailed below are common to all production approvals, although the level of detail required to ensure control of any particular element may vary between the different types of approvals. Evaluating inspectors must be satisfied that the applicant has adequately addressed each necessary requirement and the procedures are satisfactory to ensure the product or part conforms to the approved design. The following tables include the essential elements and evaluation criteria. Note 1: In describing the quality system, references to other documents or data maintained by the applicant may be used, provided that a brief description is included in the quality system. All referenced documents must be submitted for evaluation. Note 2: In the tables the ‘Esential Elements’ define the breadth of requirements under each sub-title. The ‘Evaluation Criteria’ column briefly outlines criterion that satisfy the requirements The Essential Elements and Evaluation Criteria in the following tables are not meant to directly correlate across the table.
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1. Organisation Structure, Authority and Responsibility of Appointed Persons Essential Elements
Evaluation Criteria
1. Management has responsibility for the quality system.
1. A concise statement that describes the assigned responsibilities and delegated authority of senior management for the quality system including maintenance of the system.
2. Clearly described responsibilities for control of production and quality functions, including internal audit responsibilities.
2. (i) An organisation chart that shows the functional relationship of the QC organisation to management and to the other organisational components. 2. (ii) A concise statement that describes the authority and responsibilities of each Appointed Person, including CASA Authorised Persons, within the production and quality functions.
3. Management responsibility for training of personnel.
3. A description of the chain of authority and responsibilities within the organisation for task-specific training and maintenance of operator approvals.
4. Personnel performing critical operations, inspections, special processes etc, or certifying for inspections and/or stages of work are adequately trained and approved.
4. Procedures for incorporating changes to the quality system and outlining the authority of those authorised to make such changes.
5. Ensure that each tag, form or other document used under the approved system is described by sample in the approved manual and has instructions for correct use.
5. (i) Procedures to ensure that any change to the quality system that may affect inspection, conformity, or airworthiness of the product are forwarded immediately to CASA in writing. 5. (ii) Procedures to ensure that any change to the production location results in a first article inspection following start-up production at the new location, and advice to CASA within 10 days of the re-location.
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Essential Elements
Evaluation Criteria
6. Ensure procedures exist for keeping 6. Procedures for establishing and a technical master file and record of maintaining all controlled documents all current and superseded identified in the quality system. approved design and production system documentation to ensure the complete production history of product and parts is available. 7. Management has and applies procedures for inspection record retention compliant with the applicable regulatory provision. Record retention includes back-up and security provisions.
7. Procedures that provide for an adequate method of self-audit by the manufacturer of the entire QC system, including supplier facilities. (The prime objective of the self-audit is for the manufacturer to determine compliance with their own procedures and to ensure that management is aware of any existing system deficiencies.)
8. Ensure inspection stamps are controlled and procedures exist to cover stamp loss or absence of the stamp holder. 2. Technical Data Control Essential Elements
Evaluation Criteria
1. Technical data (drawings, specifications, software and changes thereto) must be approved only by authorised personnel.
1. Procedures for drawing, engineering and software change control including drawing and specification lists necessary to define the configuration of the CASA approved design.
2. Technical data must be approved prior 2. Procedures for informing company to release, and should contain the date inspectors of approved changes in of effectivity and the signature and engineering data, specifications and the position of the person authorised to quality system. release the data. 3. Distribution of technical data is controlled to ensure that current data is readily available to production and inspection personnel.
3. Procedures that require all process changes to be submitted to CASA for evaluation and incorporation into the approval. Process specification changes are deemed to be major changes.
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Essential Elements
Evaluation Criteria
4. Inapplicable, inappropriate, or obsolete technical data must be removed from use.
4. Procedures to ensure that major changes to the design and data are approved by CASA prior to being incorporated in the product or part.
5. Current approved technical data must be used for inspection acceptance.
5. Procedures to ensure that design changes generated as a result of Airworthiness Directives (ADs) are immediately incorporated in the design data to ensure that the design change is incorporated on production products.
6. Drawings and specifications bearing unauthorised changes or unauthorised notations must not be used for inspection acceptance purposes. 7. Ensure procedures have been properly implemented to adequately provide for immediate incorporation of design changes resulting from ADs. 8. Where appropriate, ensure procedures are applied to incorporate production changes back into the applicable Instructions for Continued Airworthiness and Flight Manual. 9. Ensure a determination of major or minor change is made and recorded for each design change. CASR Part 21 21.093 21.132A(2) 21.303 (3)(c) 21.611
Part 21.093 applies to APIS and TC designs only. Part 21.132A(2) defines Class ll and III product designs, 21.303(3)(c) defines APMA designs and 21.611 applies to ATSOA designs. Ensure procedures acceptable to CASA are applied to approve minor design changes.
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3. Manufacturing Processes Essential Elements
Evaluation Criteria
1. Production facilities should be arranged to preclude contamination of products and parts—for example, isolation of grinding, painting, or sanding areas from a critical assembly area.
1. Procedures for generating, validating and approving manufacturing and inspection function recording sheets. These should list the approved data to be used, together with methods of inspection by tooling, characteristics, and sampling quantities, and also identify the persons performing the manufacturing work, and those conducting the inspection and certification.
2. Products and parts must be properly handled and stored to prevent corrosion, damage or contamination.
2. Procedures for suitable identification and inspection marking of products and parts throughout the manufacturing cycle—that is, part number, serial number, acceptance, rejection, NDT, process and material identification.
3. Shop travellers, checklists, or similar media should be used to ensure the proper movement, handling, and storage of products and parts from one station to another through all phases of the manufacturing process.
3. A description of actions required, or a flow chart, for processing all products and parts through the manufacturing cycle.
4. Inspection records must be maintained and used as required.
4. Procedures that will provide for the selection of appropriate inspection methods and plans for each product and part to ensure that all parts will be inspected as required to eliminate discrepancies and to ensure that the end item will be in conformity to the design.
5. The degree of protection afforded by any sampling plan used should be known and the associated conditions for its satisfactory use enforced by the manufacturer.
5. Procedures for establishing and maintaining the qualifications of personnel appropriate to the various processes, tests, and inspection functions.
6. Technical data must be appropriately authorised and must reflect the proper revision for the particular manufacturing process.
6. Procedures to control material lot splitting to ensure complete accountability—that is, action to be taken when a lot or batch contains more or less pieces than recorded on the shop traveller or routing sheet.
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Essential Elements
Evaluation Criteria
7. Inspection stations must be located at points in the manufacturing process where accurate quality determinations can be made.
7. Procedures to control the movement of products and parts throughout the manufacturing process showing production and inspection status at all times.
8. Inspection equipment being used must be adequately controlled for accuracy. 9. The facilities and equipment must be adequate for the manufacture and inspection of the products and parts. 10. Planning methods must ensure the complete inspection of the in-process product or part up to its completion. 11. Inspection sequences must be established and inspections accomplished at intervals where accurate quality determinations can be made. 12. Nonconforming products or parts thereof must be segregated and identified to preclude incorporation into the end product or part. 13. An operator verification program (production personnel performing inprocess checks) if used, should have adequate controls so that final acceptance responsibility remains with the quality control organisation. 14. The degree and timeliness of training that production personnel receive should be commensurate to the skill level necessary to perform the assigned duties. 15. The conditions in environmentally controlled areas must be established and maintained through appropriate procedures and calibrated controls.
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4. Special Processes Essential Elements
Evaluation Criteria
1. All special processes being performed should be covered by appropriate and approved specifications.
1. Procedures for the control of special process characteristics that affect safety.
2. Special process specifications should 2. Procedures that require all special contain inspection/quality assurance process changes to be submitted to criteria that will ensure that all products CASA for evaluation and approval. and parts that are processed and accepted, conform to the particular specification. 3. Current special process specifications should be readily available and be used by operator and inspection personnel.
3. Procedures for special processes to address necessary controls related to personnel qualifications, equipment, and testing methods.
4. Equipment such as tools, gauges, instruments, timers, ammeters, voltmeters, should be readily available and continuously maintained for accuracy.
4. Procedures for the inspection and quality assurance provisions of the special process specification should be approved as part of the quality system data, when applicable.
5. Processes, equipment, and operators should be qualified and approved by the manufacturer in accordance with the specification/manufacturer's procedures.
5. Procedure for the qualification of special processes and the re-testing should changes be implemented.
6. Products and parts should be properly handled throughout the area to prevent damage, contamination, rust, etc. 7. Records should be maintained to accurately reflect compliance with the special process specification requirements. 8. The degree and timeliness of training production personnel received is commensurate to the skill level necessary to perform the assigned duties.
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5. Non-destructive Inspection Essential Elements
Evaluation Criteria
1. Operators should be qualified, and approved by CASA, or by the manufacturer when authorised by CASA.
1. Procedure for training, qualification and periodic re-qualification of personnel.
2. Operators' qualifications must be kept current.
2. Procedure for periodic calibration of test equipment, and validation of processes and materials.
3. The operator must always work to the current, applicable process specifications.
3. Procedure for performance of each NDT method utilised, including use of approved data, and certification of completed NDT inspection together with a record of inspection results.
4. Equipment must be inspected and calibrated periodically to ensure accuracy. 5. Realistic acceptance criteria must be established. 6. Inspection acceptance/rejection criteria must be established to conform with the current design data. 7. Records must be maintained to accurately reflect compliance with the specification requirements.
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6. Tool and Gauge Control Essential Elements
Evaluation Criteria
1. All equipment used for inspection purposes must have the degree of accuracy necessary to determine conformity of the characteristic being inspected.
1. Procedures to ensure that calibrations are traceable to national standards recognised by NATA.
2. Tool and gauge controls should include procedures for protecting, maintaining, and updating this equipment as required, to ensure product conformity to approved design data.
2. Procedures that provide adequate instructions for the operation, inspection, and testing of all equipment and tooling used for the acceptance of dimensional characteristics.
3. The quality system should require identification, inspection acceptance and periodic reinspection of all inspection equipment.
3. Procedures that ensure adequate control of tools and gauges including initial approval and periodic inspections. The procedures should define acceptable methods of tool and gauge rework and reinspection.
4.
4. Procedures to ensure quarantine until re-calibration of tools or gauges identified as out of tolerance or of unknown calibration status.
Control of inaccurate inspection tools, gauges, instruments, and jigs, must ensure their identification and removal from use until repair, rework, or recalibration has been accomplished.
5. Calibration records must be maintained of all equipment used for inspection purposes. These records should contain the nomenclature, serial number, location, details of all repair or rework accomplished and date next inspection is due.
5. Procedures to ensure compensation factors are applied to calibrated tooling to account for environmental conditions that may affect accuracy in use.
6. Calibration intervals may be adjusted where analysis of reliable data indicates no adverse effect on safety.
6. Procedures must be established to uniquely identify and account for calibration of personally owned tools and gauges used for product acceptance.
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7. Receiving Inspection/Supplier Control Essential Elements
Evaluation Criteria
1. Any holder of a production approval 1. Procedures relative to the who has delegated inspection duties or manufacturer's periodic evaluation, relies on suppliers for controlling surveillance, and control of supplier conformity should ensure by evaluation produced raw materials, purchased and/or surveillance that those suppliers items, parts and assemblies. Purchase are continuously in compliance with his Order documents must be reviewed for approved QC system. accuracy and completeness by an appointed person. 2. Each manufacturer must make information available to CASA regarding all delegation of authority to suppliers to make major inspection of any products/parts thereof.
2. A description of any delegation of authority to suppliers to make inspections or conduct tests of products or parts on behalf of the manufacturer.
3. The manufacturer must advise CASA, in writing, of any authority granted the supplier to ship directly to the user.
3. Procedures for advising CASA of any suppliers performing inspections of products or parts that cannot or will not be completely inspected by the manufacturer.
4. The supplier control function should ensure that all material review actions and design changes taken on supplierfurnished parts and services are approved by the manufacturer, prior to use.
4. Procedures outlining inspection acceptance of raw materials, purchased items, parts and assemblies, including independent verification of material specification.
5. The manufacturer's receiving 5. Procedures to ensure that suppliers inspection function must ensure that all submit all design changes for approval supplier furnished parts/services and are provided with the latest conform to the approved design. applicable revisions to the design data.
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Essential Elements
Evaluation Criteria
6. Procedures to ensure that all incoming 6. The manufacturer's receiving inspection function must ensure that all material is supplied with appropriate documentation or details of verification incoming raw material is properly testing to be carried out. identified by batch, specification and verification test results for the batch to Shelf-life limited materials and products the specification. must have life verified to specification. Parts received under cover of an First article inspection is required on Authorised Release Certificate (ARC) parts from a new supplier. (Form 917) and marked ‘Conformity only’, a Statement of Conformity, or equivalent document from a recognised authority would be acceptable in lieu of providing verification test results. If verification test results, an ARC from a CASA approved distribution house or a ‘Statement of Conformity’ from a supplier are not provided the manufacturer must undertake verification testing to the material specifications. 7. The manufacturer's purchase order or equivalent must reflect the current design data, and the pertinent quality system requirements.
7. Procedures for ensuring inspection acceptance, identification, proper segregation, protection and issuance of product and parts in storage areas, including controls for incorporation of applicable design changes in stored items.
8. Parts that are damaged in transit or parts that are waiting certification must be properly segregated until dispositioned. 9. Supplier quality system data, procedures, certificates, reports required for CASA review must be translated to English. 10. Receiving inspection records must be generated and maintained to establish final conformity of products and parts.
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8. Inspection and Testing Essential Elements
Evaluation Criteria
1. The manufacturer must establish and comply with test procedures applicable to products or part design data.
1. Procedures to ensure that the inspection of products or parts will be performed and properly recorded at points in production where accurate quality determinations can be made.
2. For aircraft, the manufacturer must establish and ensure compliance with the approved flight test procedures and flight test check-off form.
2. Procedures to properly perform, control, record, and identify all inspection processes.
3. Test equipment must be controlled and 3. Procedures to ensure that the use of calibrated to ensure accuracy. any statistical sampling inspection plan will not result in an unsafe condition in a product or part. 4. Products and parts subjected to adjustment or rework after inspection must be retested to approved test procedures.
4. Procedures that provide adequate instructions for recording information in inspection records.
5. Where sampling inspection tests are 5. Procedures for the control, issuance, used, other inspections and tests and use of all inspection stamps, and should be implemented, as required, to other in-process marking equipment. ensure the acceptance of only those products or parts that conform to the design data and are safe for operation. 6. Records of all tests conducted must be maintained in accordance with the manufacturer's approved procedures.
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9. Material Review Procedure (Except for a 21.133(2B) PC). Note 1: The material review process is only permitted to disposition minor changes to the CASA approved design. A major change to design must be approved by CASA before formal disposition of parts through the MRB. CASR 21.133
Note 2: A 21.133 (2B) PC holder is ineligible to apply MRB processes. A disposition of ‘Scrap’ is the only available response to non-conformities unless the design data is changed and re-approved to extinguish the non-conformity. Note 3: Parts from assemblies dispositioned as ‘Scrap’ may be recovered only if the MRB determines those parts do not contain the identified non-conformances.
Essential Elements
Evaluation Criteria
1. Except for APMA and a 21.133(2B) PC 1. Procedures that require corrective a Material Review Board (MRB) must action (in-plant, at suppliers, and inbe established and must include service) where processes or procedures representatives from the Inspection result in a nonconforming product/part and Engineering departments. thereof. 2. The MRB procedures must outline the complete MRB system including requirements for obtaining CASA engineering approval on any nonconformities to the product/part thereof which constitute a major change to the approved design data, prior to final acceptance of the product or part.
2. A description of the Material Review Board System (MRB) including the procedure for recording MRB decisions and disposing of nonconforming products or parts—that is, use as is, rework, scrap, return to supplier.
3. The MRB procedures must provide controls for identification, segregation, and disposition of nonconforming products or parts.
3. Procedures for the identification and segregation of products or parts set aside for MRB review.
4. As part of the decision recording requirements the manufacturer should list the MRB members present.
4. MRB delegation procedures to a similar standard as the manufacturer when the manufacturer relies upon or delegates MRB duties to supplier facilities.
Note: ‘Use as is,’ is not an option unless the design data is changed.
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Essential Elements
Evaluation Criteria
5. Nonconforming products/parts thereof must not be released by MRB until they have been properly dispositioned and suitable reinspection and retest procedures determined.
5. Procedures for the review of inspection and service records for evaluation and corrective action on repetitive discrepancies.
6. MRB withheld products or parts must be quarantined to prevent their unauthorised removal. 7. The MRB records must as a minimum include part number, quantity, date, adequate description of nonconformance including a determination of major or minor, disposition, and authorised MRB signatures. 8. The MRB procedures must provide a system for obtaining effective corrective action in-plant, at suppliers or in-service to prevent recurrence. The procedures must provide for monitoring corrective action response, implementation and effectiveness.
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10. Stores Control Essential Elements
Evaluation Criteria
1. The system must ensure that only conforming, accepted and identified products or parts are placed in production storage. Non-conforming items must be suitably identified and quarantined.
1. Procedures for each of the essential element items 1 to 5.
2. The system must ensure that products and parts that are subject to deterioration from prolonged storage are periodically reinspected and dispositioned and controlled.
2. Procedure for the traceability of incoming material, parts and standard parts, including their matching records and certification or specification documents.
3. The system should assure the protection from damage and deterioration of products and parts that are in process or in transit or stored.
3. Procedures to quarantine and identify non-conforming parts, parts awaiting conformity inspection or materials, including those shelf life expired, awaiting MRB disposition.
4. The system must ensure that required design changes are incorporated on products or parts in storage prior to their release. 5. The system must ensure that only those products or parts, identified as having passed company conformity inspection are issued from stores.
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11. Certification and Release Essential Elements
Evaluation Criteria
1. All engineering data used for the acceptance of the product or part must be CASA approved.
1. Procedures to identify completed products and parts.
2. The product or part must conform to the approved engineering data.
2. Procedures to ensure that all required inspections and tests are satisfactorily accomplished prior to final acceptance of the completed products or parts.
3. All required inspections and tests necessary to ensure that the end product or part conforms to the approved design data and is in a condition for safe operation must be accomplished before the product or part can be certificated as airworthy.
3. Procedures that ensure products or parts are in conformity with approved design data and are in a condition for safe operation.
4. The aircraft, engine, or propeller logbooks and records should have inspections and operating time properly recorded, signed and dated.
4. Procedures to ensure that certifications for completed work are only made by appointed or authorised personnel.
5. Each product or part must be properly identified.
5. Procedure to ensure that the final certification for completion of the manufacture of the product or part is made pursuant to the applicable CASR.
6.
A Statement of Conformity under APIS 6. Procedures to ensure that the must be properly documented, signed, Authorised Release Certificate, (ARC dated, and submitted to CASA. Form 917), or other approved document is properly completed, signed and issued by appointed personnel, and that this document provides traceability for the applicable part.
7. Applications for conformity inspection, Certificate of Airworthiness (CoA) or Special Flight Permit (SFP) issue should be properly executed, signed, and submitted to CASA, or where appropriate, an authorised person.
7. Procedures to ensure that completed aircraft, engines and propellers are released with appropriate Log Books, Instructions for Continued Airworthiness and for aircraft, a Flight Manual.
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Essential Elements
Evaluation Criteria
8. Personnel making final certifications are appointed in the quality system.
8. Procedures to ensure that all pre-CoA issue work on type certificated products is properly certified. For an aircraft, CoA issue or acceptance by CASA of a Statement of Conformity under APIS marks the end of the production cycle.
9. The system must ensure that before final release, all required ADs are incorporated or accounted for (for aircraft) that all post flight test adjustment has been certified, and the approved flight test completed.
9. Procedures for airworthiness certification of products or parts to be exported, includes appointment of personnel authorised to make such certifications.
10. Persons approving export of products or parts are identified in the quality system and are appropriately authorised. For export approval of aircraft a CASA instrument of authorisation must be held. 12. Service Difficulty Reporting and Control
CASR 21.003
Essential Elements
Evaluation Criteria
1. The system should ensure that service problems are investigated and the manufacturer takes corrective actions.
1. Procedures that define the manufacturer's responsibilities and corrective actions relative to service difficulties involving products or parts inplant, or in-service, including spares in storage or shipped to a user.
2. The system should have a means for keeping users of the product or part informed of service difficulties and resultant CASA-approved changes to the type design.
2. Procedure to ensure reporting of failures, defects and malfunctions to CASA as required by CASR 21.003.
3. The system should provide for receiving feedback on service problems from users of the product or part.
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3.3.2 CASR 21.123(1), 21.135, 21.303(5), 21.605(4)
Stage 2 Quality System Assessment – Quality System Evaluation This stage of the assessment consists of an evaluation of the quality system at the production facilities to determine that the applicant has satisfactorily implemented and is capable of maintaining the required quality system. During this stage inspect parts applicable to the application in order to assess the applicant's ability to produce conforming parts or products. CASR 21.123(1), 21.135, 21.303(5) and 21.605(4) refer.
System Assessment An adequately described system is useless if not properly implemented and maintained. The project officer must therefore ensure that the manufacturer practices rigid system discipline. CASA does not dictate to a manufacturer the specific manner in which a product will be produced. However, once a manufacturer commits to a specific system that is approved by CASA, the manufacturer is obligated to adhere to every facet of the system without deviation. Whenever a change to the system is necessary, the manufacturer must make the change in accordance with the provisions of his approved system prior to implementation. The following guidelines should be utilised during the course of evaluating a manufacturer's quality system functions: 1. Use the standards described under the Essential Elements columns in the preceding tables—as applicable—as the basis for conducting the evaluation. 2. Use the information detailed under the Evaluation Criteria columns in the preceding tables as an aid in conducting the evaluations of the applicable quality system elements. 3. Be alert to any inadequacies in the system, such as a lack of necessary instructions or procedures, or, more commonly, repetition of regulatory requirements instead of proper procedures. It is virtually impossible during the desk-top review of Section 3.2.2 to determine whether the submitted system complies with all regulatory requirements and provides the necessary safety assurances. Findings When a non-conformance to the design or design data is noted, the inspector(s) must continue with the evaluation to determine whether the condition is a symptom of a quality system deficiency or breakdown. When a quality system deficiency or breakdown is indicated, the inspector must evaluate the system to determine the cause. Necessary corrective action must be taken by the applicant to ensure the quality system remains compliant and effective. Stage 3 Quality System Assessment—Manufacturer's Corrective Action refers (see next section below).
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3.3.3
Stage 3 Quality System Assessment—Manufacturer's Corrective Action Before CASA can approve the application, the manufacturer must complete corrective action to address all deficiencies or discrepancies arising from assessment of an initial application or change to an existing system. This stage is completed when the inspector finds that the manufacturer's corrective actions and quality system amendments comply with all pertinent Part 21 requirements and conforming products or parts have been produced following the final form of the quality system submitted for approval.
■ 3.3.4
Manufacturer’s Service Documentation The PAH may need to issue Service Bulletins (SBs), Service Letters or other continuing airworthiness information. CASA only approves the relevant technical content of a Service Bulletin if a SB is required to address an Airworthiness Directive. The PAH is to submit such a proposed SB to the ESS for engineering assessment and approval of the technical content in the form of a letter to the PAH authorizing the issue of the SB by the PAH.
AC 21.095
The PAH is permitted to issue any other SBs or Service Letters etc without reference to CASA. However, changes to a design must be approved in accordance with the PAH’s Procedures Manual. For further information refer to AC 21.095 section 10.
■ 3.3.5
Service Difficulty Reports In-service Service Difficulty Reports (SDRs) received by CASA relating to production item issues will be processed in accordance with CASA’s SDR procedures, and referred to the ESS as well as technical specialists.
CAR 50
The Manufacturing Inspector is to be involved in any follow-up actions (CAR 50).
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3.3.6
Reporting of Failures, Malfunctions and Defects During Manufacture
CASR 21.003(4)
The holder does not have to report to CASA all failures, defects or malfunctions that might cause an occurrence (as listed in CASR 21.003 (4)) unless the defective part has left the holder’s control by the time the defect is discovered.
CASR 21.003(4) CASR 21.003(10)
The holder must report to CASA all failures, defects or malfunctions that have resulted in an occurrence [as listed in CASR 21.003(4)]. However, failures, malfunctions and defects caused by improper maintenance or improper usage, or which have been reported to CASA by another person, may not have to be reported to CASA by the holder. See Subregulation 21.003(10). Manufacturing errors and irregularities can be rectified. Parts found to be defective by the holder’s quality system can be repaired, scrapped or quarantined. These defects do not have to be reported to CASA if the parts have not left the holder’s control, or can be reliably retrieved.
■ 3.3.7
Manufacturer’s Maintenance Facility Which Division of CASA issues the maintenance approval is an administrative matter. If the maintenance approval is limited to maintenance of the company’s own products then provided the MI has the delegation and training, the MI may issue the approval and conduct surveillance on this restricted MMF. This would be subject to ESS resource limitations, on occasions the task would need to be delegated to Aviation Safety Compliance Division (ASCD). If the organisation intends to conduct general maintenance on other than its own products, then this is the province of the Aviation Safety Compliance Division
■ 3.3.8
Supplier Quality Control The last production quality system is that for suppliers. Suppliers may not have a CASA production approval, however, suppliers make up the bulk of the manufacturing effort in producing aircraft, aircraft engines, and propellers. Suppliers are controlled by the PAH that they work for, ie, PC, APIS, APMA and ATSOA. Suppliers are not required to have a quality manual, and have no regulatory privileges or responsibilities. However, they may not sell production parts on the open market without their own production approval.
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3.3.9
Engineering Drawings Drawings reviewed by CASA ESS engineering and used by MIs in the conduct of conformity inspections must meet a level commensurate with the minimum standards of the CASRs, which assures safety. CASA regulations require that an applicant submit sufficient drawings, special process documents, specifications and test reports to identify and substantiate the product for which CASA approval is sought. CASA ESS reviews this data for minimum compliance with the airworthiness standards. That data is then used for inspecting the product. The CASA MI utilizes the data to witness a conformity inspection of the product at the applicant’s facility, or at an agreed upon location, and reports the results of that conformity inspection to ESS engineering. Provided all of the drawing requirements have been met, the product is then tested. If the test is acceptable, the product is approved, and the applicant proceeds to manufacture the part/assembly. Once a CASA approval is issued, the drawings used to inspect the original product are considered to be the approved CASA baseline. That baseline never changes unless there is a modification to the drawings after the approval is issued. Any deviations from the drawings for a part or assembly must be documented, dispositioned, and approved in the same manner as the original drawings were. CASA will accept drawings that meet some recognised drawing standard that can produce a quality part within a minimum tolerance range when the manufactured part has been inspected and tested and has shown to meet the minimum CASR requirements.
■ 3.3.10 Use of CASA Form 917 Authorised Release Certificate CAR 42 CAAP 42W2(3)
CAR (1988) 42 WA sets out the requirement for Form 917, and CAAP 42W2(3) provides guidance as to the use of the form. Manufacturers holding a PA may sign a Form 917 to accompany a finished part. However, suppliers to the PAH can only issue some form of conformity statement with clear delivery documents. They are not entitled to issue a Form 917.
CASR 21.133(B)
For use by the holder of a PC issued for the support of a FITCOM activity in block 13 ‘Remarks,’ add the words “This ARC is issued under the provisions of CASR 21.133(B).” Additionally, a statement qualifying Block 14 is to be entered in Block 13, “This part is manufactured for certificate of Approval Holder number xxx (or owner/operator by name, as appropriate) per order number yyy.
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3.3.11 Use of CASA Form 917 for Unapproved Parts These are parts produced (and to be conformed) to certain controlled design data that has not yet been approved to be part of the Type Design, Usually, these parts are for use in a ground or flight test development or certification program, ie usually a prototype. Neither the manufacturer nor CASA can sign a release for fitment to a certificated aircraft for such a part. However, the manufacturer or CASA (if requested by a foreign NAA) can do the administrative function of signing a Form 917 limited to conformity only and referring to the particular controlled data against which the product is conformed. This fulfils the function of communication between NAAs in a standardised form.
■ 3.3.12 Export Airworthiness Approvals A person must be included in the class of persons of the appropriate CASA Instrument of Appointment, to issue a Form 917 as an Export Airworthiness Approval.
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Inspections
4.1
Conformity Inspections
4.1.1
Introduction to Conformity Inspections This Chapter provides procedures and methods to be followed by the inspector when conducting inspections to determine that parts, appliances and products (aircraft, aircraft engines, propellers or parts) conform to the approved design drawings and specifications. Conformity inspections are carried out during the certification phase in obtaining a Type Certificate (TC) or during initial production to verify that parts and products conform to design data.
■ 4.1.2
Conformity Inspections The depth of conformity inspections may vary depending on the particular manufacturer. In the case of a manufacturer with well-established policies, quality system procedures, experience, inspection personnel, equipment and facilities and who has previously demonstrated first article acceptability, the inspector may choose to reduce the depth of conformity inspection by a form of sampling inspection of the manufacturer’s product and procedures. In the case of a manufacturer whose ability is unknown—eg, during the initial production period by a manufacturer producing under a TC only—it will be necessary to conduct in-depth conformity inspections until the inspector is confident that reducing the degree of assessment will not compromise safety. The Project Officer is recommended to use CASA Form 1248 Request for Conformity Inspection as a positive means of documenting those particular inspections required.
Inspector 1. Regardless of the manufacturer’s ability, the initial parts or products inspected for conformity for issue of a production approval need to be inspected to a level which conforms all detail parts and processes specified by the design data. 2. When the degree of conformity inspection required has been determined, develop an appropriate conformity verification plan. The plan should focus on: ❍ Verifying the conformity of the critical and major characteristics of materials, parts and assemblies. ❍ Evaluating process controls to assure production of consistent and uniform products. For other than initial conformity statistical quality control methods may be utilised for process evaluation. Complete descriptions of such statistical methods should be documented. ❍ Observing tests of important functional parameters of systems, modules, components and completed products.
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3. Regardless of the manufacturer’s experience, CASA is responsible for determining that the manufacturer has carried out a complete article conformity inspection and that the results of that inspection are properly recorded, before carrying out the conformity inspection (Refer to 4.1.3). In the case of a manufacturer producing under a TC only prior to the issue of an APIS, CASA holds full responsibility for the conformity inspection 4. Record all conformity inspections conducted or tests witnessed on Form 882 CASA Conformity Inspection Record and include all discrepancies, non-conformities and corrective actions. 5. Retain these records on the applicable CASA file at the ESS Office. 6. Where design non-conformities or discrepancies are found, forward a copy of the applicable documents to the Head of ESS. 7. Address the following issues when undertaking a conformity inspection as described in sections 4.1.4 through 4.1.16 as follows: ❍ 4.1.4 Materials ❍ 4.1.5 Processes and Processing ❍ 4.1.6 Automatic Production Processes ❍ 4.1.7 Non-destructive Inspection (NDI) Method Evaluation ❍ 4.1.8 Critical and Major Characteristics ❍ 4.1.9 Workmanship ❍ 4.1.10 Adequacy of Drawings and Related Change Records ❍ 4.1.11 Adequacy of Inspection Records ❍ 4.1.12 Material Review Action ❍ 4.1.13 Software ❍ 4.1.14 Conformity Inspections of Test Articles ❍ 4.1.15 Structural Test Articles—Aircraft ❍ 4.1.16 Flight Test Articles—Aircraft ❍ 4.1.17 Endurance Test Articles—Engines and Propellers. Should discrepancies be found, you may require the manufacturer to carry out a requalification of the part/product. 8. Following any re-qualification of the manufacturer, carry out a further conformity inspection, considering the previous results as appropriate.
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First Article Inspection (Reference Standard SAE AS 9102.) The purpose of First Article Inspection (FAI) is a physical and functional inspection process commonly used to provide objective evidence that all engineering design and specification requirements are properly understood, accounted for, verified and documented. The first conforming article is intended to be a ‘standard’ that verifies conformance and one that provides a yardstick for corrective actions and problem resolution. FAI shall be performed for a new part representative of the first production run including all detail parts and sub assemblies that constitute the end item ordered. The FAI record is not complete until all non-conformities are resolved. Note: Prototype parts or parts made using different methods or processes cannot be considered part of the first production run. The FAI requirement applies even after initial production compliance and CASA approval. Depending on the degree to which characteristics are affected partial or complete accomplishment of the FAI is required for the following events: 1. A change of design affecting form, fit or function of the part. 2. A change in manufacturing source(s), processes, inspection method(s), location, tooling or materials with the potential of affecting the form, fit or function of the part. 3. When required as part of a corrective action for a part with repetitive rejection history. (Typically with three repeat rejections). 4. A change in the numerical control program or translation to another media. 5. A natural or man-made occurrence that may adversely affect the process. 6. A lapse in production of two years. All documented FAI reports are considered a quality record under the CASR record keeping requirements. Inaccessible characteristics shall be evaluated as early in the process as possible provided they are not affected by subsequent operations. Naturally, tooling used to verify a design characteristic must be qualified by FAI verification back to national standards. Where feasible, FAI measurement equipment and/or personnel shall be independent of the equipment or personnel utilized for the final product acceptance inspection. It should be noted that where FAI results are near limits of tolerances, additional parts should be inspected to verify hardware conformance.
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The FAI process for a given part initially includes identification of the original source documents and their respective revision status. Purchase orders or equivalent documents must be examined to determine the basic requirements and the validity of the data called up by the customer. Relevant drawings and specifications must be subject to source substantiation to ensure that the current complete data is available for the inspection.
4.1.4
Materials ●
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Were raw materials used in the fabrication process in conformity with the design data? Is evidence available to assure that chemical and/or physical properties were identified and checked as appropriate? Is there documented evidence to show traceability from the raw material to the completed part? Are there any parts or process deviations recorded against the submitted design data (including material review dispositions)?
■ 4.1.5
Processes and Processing Production approval regulations require fabrication methods that consistently produce conforming parts and all methods requiring close control to attain this objective must be covered by approved process specifications. In evaluating processes, the MI is primarily concerned with performance and conformity. Process performance should be capable of consistently producing articles that meet the specified requirements. Process conformity is determined by checking the articles being processed to determine that they are being processed in accordance with the process specification and that the materials, tools, and equipment called for are being utilised. Since the end results depend on strict adherence to the process instructions, any deviation or discrepancy should be corrected on the initial runs. Product conformity is determined by inspecting the processed articles. The manufacturer should make a determination that the process operations are capable of consistently producing articles in conformity with the design requirements. The method used in determining this fact should be measurable, as required by the process specification, and recorded.
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Automatic Production Processes
Background Modern production methods involve many automatic machines such as: ●
Milling machines
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Lathes
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Work Centres
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Riveters
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Routers
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Fabric cutters
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Lay-up placers
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Electronic component placers, etc.
Traditionally, conformity inspection has been against clearly defined Type Design (TD) data, in the form of drawings and specifications. With numeric- or computer numeric-controlled (NC or CNC) machines, traditional conformity inspections may be difficult due to the non-existence of traditional TD data. Nevertheless, conformity must be achieved. TD data that may now be in the form of Computer Aided Design (CAD) models or other computer instructions must achieve and demonstrate conformity. That is the regulatory requirement and nothing less is acceptable. Conformity is evidence that the automatic machine software is performing correctly. Conformity Inspection Requirements The CASA inspector must be satisfied that the applicant has the systems and ability to produce conforming parts. The CASA inspector should ensure that the applicant has a system in place that ensures that: ●
The approved TD data is permanently stored and available for conformity inspections. The TD may be in the form of drawings and specifications or computer generated models or instructions
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Any software used is identifiable as to the package and the version
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Computer programs such as CAD programs used are of proven validity
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Operators of CAD programs have demonstrated competencies in the use of the particular CAD package Computer Aided Manufacturing (CAM) programs used are of proven validity Operators of CAM programs have demonstrated competencies in the use of the particular CAM program Operators of NC or CNC machines have demonstrated competencies in the use of the machine(s) Manually-inserted CNC machine instructions are related to approved drawings Conformity is performed against the approved TD data, which may be held electronically. The conformity inspection may be in any form acceptable to CASA that achieves the result, eg; a. Comparison against drawings printed out from the relevant CAD package, or from other approved drawings or sketches. b. Use of calibrated “go” and “no go” gauges developed from the TD data, for specified dimensions. c. Use of a Computer Coordinate Measuring Machine (CCMM) for comparison with the computer-held model.
■ 4.1.7
Non-destructive Inspection (NDI) Method Evaluation The procedure for evaluating an NDI method must provide for the manufacturer to demonstrate to the MI’s satisfaction that the NDI method used has the capability to detect the allowable defect size and location specified by the engineering data, that the inspection results are repeatable, and that instruments required to perform the inspection meet the procedural acceptability requirements.
■ 4.1.8
Critical and Major Characteristics ●
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Has the manufacturer identified and inspected all the critical and major characteristics? Does the manufacturer have a record of these inspections? Does witnessing the re-inspection and surveillance indicate that the above inspections were accurate and adequate? Are there any deviations recorded against the approved design data (including material review disposition)?
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Workmanship ●
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Does workmanship contribute to the safety of the product? Have criteria been established to identify acceptable production techniques and practices?
■ 4.1.10 Adequacy of Drawings and Related Change Records ●
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Can the part be produced and inspected using the information on the drawing? Are drawing tolerances practicable and attainable under production conditions? What evidence supports this? Have all of the changes been correctly made to drawings submitted for CASA approval or MRB approval in the case of minor changes? What procedure is used to ensure the incorporation of an engineering change in the production part, on the relevant drawing/s and on completed parts in store? Does the drawing include all the characteristics necessary to inspect the part, the material to be used, the treatment of the material such as hardness, finish and special process specifications? Does the drawing (or associated engineering data) include applicable test specifications?
■ 4.1.11 Adequacy of Inspection Records ●
Do the inspection records show all inspections that are conducted?
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Do they show who conducted the inspection?
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Do they indicate the results of the inspection and disposition of unsatisfactory conditions? Are procedures adequate to ensure re-inspection of any parts that are reworked?
■ 4.1.12 Material Review Action ●
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Is the material review procedure documented and adequate to ensure disposition of non-conformities? Is there adequate corrective action for observed non-conformities to prevent recurrence?
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4.1.13 Software ●
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Are all software products (version description document, source code, object code, documentation, test procedures, loaded hardware/firmware etc) properly identified, including revision levels, when compared to the hardware and software engineering drawings? Have all software problem reports been properly actioned? Do the records indicate that all software products, including support software and procedures, have been placed under configuration control? Have the verification and acceptance tests been successfully executed to approved test procedures and results recorded? Are there records that indicate that the object code was compiled from released source code by approved procedures? Do records indicate technical acceptance of the software prior to loading into the system or product? Are there any indications of non-compliance with the software manufacturer’s procedures?
■ 4.1.14 Conformity Inspections of Test Articles ●
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Prior to initiating conformity inspection activity for test articles, it is essential that the manufacturer and the MI establish and document the parameters of the test article configuration and test equipment configuration. The conformity of the test article and test set-up such as for static, endurance, operational, pressure, environmental etc tests, should be established by an MI or AWE as appropriate to determine conformity. In all cases, the approved engineering data should include: ❍ Appropriate instructions ❍ Reference to the manufacturer’s agreed test plan. When witnessing tests, the MI should determine that the instructions and test schedule described in the agreed test plan are followed.
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4.1.15 Structural Test Articles – Aircraft CASR 21.033
CASR 21.033 requires the manufacturer to allow CASA to perform or witness conformity inspections. This includes structural tests during fabrication and assembly. The final design submitted for CASA inspection must reflect all changes that have been found necessary as a result of previous tests. CASA must ensure that such changes are incorporated into the production drawings. Only then can CASA be certain that subsequent production articles conform to the tested articles. It is strongly recommended, due to the different effects of non-conformities on structural test articles versus flight articles, that parts and assemblies destined for structural testing should be clearly identified. This should be necessary only in those cases where structural test articles are being fabricated concurrently with prototype flight articles. Once parts and assemblies have been subjected to structural testing beyond limit load they must be clearly and permanently identified to prevent their use in production.
■ 4.1.16 Flight Test Articles—Aircraft Determining conformity of flight test articles, including system checks, should begin during fabrication. It is important that flight test articles conform to the data specified in the design data on which the manufacturer’s statement of conformity is based.
4.1.17 Endurance Test Articles—Engines and Propellers In addition to conformity of production, endurance test conformity will also be required. These tests will be part of the CASA approved specifications, and the inspector should coordinate with the CASA engineers before undertaking conformity of endurance tests. CASR Part 33 Part 35 CASR 201.001
At the conclusion of the endurance test, during the teardown inspection, the MI should spot-check conformity of major and critical parts by witnessing the manufacturer’s inspections, paying particular attention to critical characteristics. Teardown inspection of test articles after endurance testing is a specific requirement of CASR Part 33 and Part 35. These activities should be witnessed by the MI, a CASA engineer or a CASR 201.001 appropriately authorised person. The manufacturer should not clean or disassemble the test article until the independent inspector is present, at which time the manufacturer’s inspection should be conducted as follows.
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Inspector 1. Verify that the manufacturer carefully notes the appearance of subassemblies during the teardown and before complete disassembly. The manufacturer should specifically note any abnormal leakage in valves, seals, fittings, etc; indication of excessive or lack of lubrication; excessive coking; metal or foreign particles in the oil screens or passages; sticking or breakage of parts; lack of freedom of moving parts; breakaway torques; and any other condition which may not be noticeable after complete disassembly and cleaning. 2. Verify that all parts are thoroughly cleaned and visually inspected for indications of galling, metal pickup, corrosion, distortion, interference between moving parts, and cracks. Highly finished surfaces should be checked for condition and any discolouration due to excessive heat and lack of lubrication. Special attention should be given to bearings, gears, and seals. Engine pistons, cylinder heads, and turbine assemblies should be carefully inspected for indications of cracking, burning or local collapse. 3. Verify that both ferrous and nonferrous stressed parts are inspected for incipient failures by suitable non-destructive testing methods such as magnetic particle inspection, x-ray, penetrant, ultrasonics, etc, in accordance with the test plan. 4. Verify that all parts subject to wear of distortion are dimensionally inspected to determine the extent of change during the test. This may be done by pre-test and post-test dimensional comparisons. The manufacturer should record the results in a suitable manner. 5. On completion of the above steps for certification of an engine or propeller, the manufacturer’s inspection report, verified by the independent inspector, is submitted to the Section Head, Certification Support Services Section. This report should contain the results of the inspection, giving a comprehensive description of all defects, failures, wear or other unsatisfactory conditions including photographs as required. Since the report is used for evaluation, its importance cannot be overemphasised. 6. Ensure that non-conforming parts are identified and retained by the manufacturer in safe storage for review by CASA.
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Final Inspection and Flight Test
4.2.1
Applicability — Final Inspection and Production Flight Test
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The basic purpose of the ground inspection is to physically determine that the aircraft readied for flight test: ●
Conforms with the technical data
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Is safe for the flight tests intended.
The results should be recorded for the project file, together with any other data requested by CASA engineering and flight test personnel. The ground inspection is normally a progressive inspection of parts and assemblies culminating in the aircraft being finally readied for its initial test flight.
■ 4.2.2
Preliminary Ground Inspection Preliminary ground inspection includes all inspections of the first production unit that can be performed satisfactorily in the course of construction.
Manufacturing Inspector 1. Require the manufacturer to notify the MI whenever changes are made to components, systems, or installations previously cleared. 2. Witness such re-inspection as necessary.
■ 4.2.3
Final Ground Inspection The final ground inspection is the final inspection of the complete aircraft and should be performed just prior to first production flight test. Detailed procedures for conducting inspections and test for the assembled product should be included in the approved production procedures. They should also be coordinated by the manufacturer to preclude unnecessary delays and duplication of effort and to assure that all required inspections and tests are properly accomplished before flight.
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Production Approval Procedures Manual 4. Inspections 4.2 Final Inspection and Flight Test Approved by Executive Manager, Aviation Safety Standards
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Inspector Notify CASA flight test personnel when the initial flight test phase is to commence. Make sure that flight test personnel have sufficient time to prepare for the flight test program. The manufacturer should provide all necessary assistance, equipment, and data essential for the flight test. Flight Test and Manufacturing Inspector 1. Carry out the inspection: ❍ Witness the operation of all ground operable systems by the manufacturer’s personnel. ❍ Witness the weighing of the aircraft and verify scale accuracy. ❍ Verify equipment installed, including test equipment, during each flight test to determine flight loadings. ❍ Verify the weight and balance report, showing the actual empty weight centre of gravity together with the list of equipment installed. Retain a copy of these records and make sure flight test personnel have a copy. ❍ If necessary during this phase, verify weights and moment arms of equipment items. 2. Determine what other inspections remain, such as instrument markings, placards, unusable fuel, etc. These inspections must be completed prior to issue of the Statement of Conformity by the manufacturer.
■ 4.2.4
Flight Inspection
Manufacturing Inspector 1. Establish with the Flight Test Pilot a mutually agreeable system for informing the Manager, Engineering Support Section of changes to the aircraft and any problems encountered during flight test. Cooperation with the Flight Test Pilot is crucial to the safe and professional completion of the flight-testing. 2. Prior to the flight test, determine that the manufacturer carries out the various loading conditions specified by the flight test specialist. This includes a determination that the ballast used is accurately weighed, located, and safely secured.
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3. Throughout the flight test program, determine that the manufacturer has a plan to ensure that the aircraft is adequately inspected to reveal any unsafe conditions that may develop and to require their correction prior to further flight tests. The frequency and extent of such checks should be coordinated with CASA. Participate in the checks whenever practicable to determine compliance. The MI and the flight test specialist should have a system of informing each other of changes made to the aircraft and problems encountered during any flight test. Flight Test Pilot The Flight Test Pilot is not to fly a test aircraft without coordinating with the Project Officer or Head of Engineering Support Section to be assured that the aircraft is released for flight. The final acceptance of the test aircraft as it relates to the operation of the aircraft and the integrity of the test is the responsibility of the CASA Flight Test Pilot. Instruments, gauges, recording devices, etc., which are used in the official flight test for flight, should be in current calibration by a qualified agency and calibration reports furnished. The Flight Test Pilot is to be given copies of the reports prior to flight.
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Production Approval Procedures Manual 4. Inspections 4.2 Final Inspection and Flight Test Approved by Executive Manager, Aviation Safety Standards
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Production Approval Procedures Manual 5. Sample Letters 5.1 Sample APMA Application Letter Approved by Executive Manager, Aviation Safety Standards
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Contents of this Chapter This chapter includes the following sample letters: 5.1
Sample APMA Application Letter
5.2
Sample CASA APMA Approval Letter
5.3
Sample CASA APMA Supplement without Licensing Agreement 5.3.1
5.4
Sample CASA APMA Supplement (Design Approval) Test and Computation
Sample CASA APMA Supplement with Licensing Agreement 5.4.1
Sample CASA APMA Supplement (Design Approval) Identicality
5.5
Sample Australian Parts Manufacturing Approval Supplement
5.6
Sample CASA APMA Design Rejection Letter
5.7
Sample ATSO Authorisation Application and Statement of Conformance
5.8
Sample ATSO Authorisation
5.9
Sample APIS Approval Letter.
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Production Approval Procedures Manual 5. Sample Letters 5.1 Sample APMA Application Letter Approved by Executive Manager, Aviation Safety Standards 5. 5.1
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Sample Letters Sample APMA Application Letter
Senior Manufacturing Inspector Engineering Support Section CASA (See Address of nearest CASA Manufacturing Office below) Dear Sir, Request for Australian Parts Manufacturer Approval Applicant:
THOMAS MANUFACTURING P/L 12 Aviation Street, TULLAMARINE, VIC 3043
Manufacturing Facility Address: As Above Contact Person: John Thomas, Managing Director Telephone (03) 1234 1234 Part for which APMA is requested: Part Description: Spring Part P/N: THOMAS 7654321 For Installation on: General Aircraft Models T210, 315, 327 and Jonkers 234 Replacement for Original Part P/N: Bendix BS 89 Design Data: Drawing No 7654321 Licence Agreement: Nil (See enclosed documentation for application design data and manufacturing procedures.) The following are enclosed: ❍ Two copies of the spring drawing No 7654321 ❍ One copy of the procurement Bill of Material ❍ One copy of heat treatment process specifications ❍ One copy of technical justification supporting a finding of test and computation and other supporting documentation. ❍ A compliance statement for design and manufacturing against the regulatory requirements. ❍ A statement that Thomas Manufacturing P/L has established the Fabrication Inspection System in compliance with CASR 21.303(11). ❍ CASA form 849 Application for a Production Approval and CASA form 724 Statement of Conformity ❍ One conforming ‘first article’ spring. It is our understanding that if the APMA is granted, one copy of the drawing (stamped approved) will be returned to Thomas Manufacturing P/L and that this approved drawing is to be kept on file at the Thomas Manufacturing P/L manufacturing facility. I look forward to a positive CASA response to this application. Yours faithfully,
John Thomas 5 August 1999 CASA Manufacturing Office Postal Addresses Melbourne Sydney Brisbane
PO Box 558 Collins St. West, Vic. 8007 PO Box CP57 Condell Park, NSW 2200 39 Navigator Place, HENDRA QLD. 4011
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Sample CASA APMA Approval Letter
File Ref:04/9999-1 ARN: 123456 CIVIL AVIATION SAFETY AUTHORITY AUSTRALIAN PARTS MANUFACTURING APPROVAL APMA No: APMA-123456 Mr John Thomas Managing Director Thomas Manufacturing P/L 12 Aviation Street TULLAMARINE VIC. 3043 Dear Mr Thomas, I refer to your APMA application to CASA dated 5 August 1999. In accordance with the provisions of CASR 21.303, CASA has found the drawings, specifications and processes submitted as design data by Thomas Manufacturing P/L (the Manufacturer) on 5 August 1999 meet the airworthiness requirements of the Civil Aviation Safety Regulations (1998) applicable to the products on which the part(s) is to be installed. That design data is hereby approved. CASA has determined that the Manufacturer has established the documented Fabrication Inspection System required by CASR 21.303(11). The documented system is identified as Revision 2, dated 30 July 1999 of the Thomas Manufacturing P/L Quality System Manual. The Manufacturer must maintain the documented system in continuous compliance with the requirements of CASR 21.303(11). The attached Supplement defines the extent of approval given under this APMA and is to be read in conjunction with this approval. Manufacture in accordance with the established Fabrication Inspection System, and the attached Supplement, is approved at the following locations: 12 Aviation Street TULLAMARINE VIC 3043. In accordance with CASR 21.303(9), this APMA is granted to the Manufacturer to produce the part(s) listed in the attached Supplement in conformity with the CASA approved design. This APMA is not transferable and, unless suspended, continues in force until cancelled. Subject to due process, CASA may suspend or cancel this APMA by written notice if the holder ceases to comply with the relevant parts of CASR Part 21. This APMA is issued subject to the following conditions: 1. The Manufacturer must produce all parts in accordance with the documented (Manufacturer’s name) … quality system manual, Revision …, dated ……….., the approved system, or later CASA approved revision. 2. The Manufacturer’s Fabrication Inspection System, methods, and procedures documented in the approved quality system manual, together with the Manufacturer’s facilities, are subject to CASA audit or investigation. As CASA does not separately approve suppliers, the Manufacturer must advise any suppliers or contractors that their facilities and processes are also subject to CASA audit in assuring the Manufacturer’s system is being properly maintained. 3. The design and process data listed on the attached Supplement is approved data. This data is not to be altered unless permitted and approved by CASA.
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4. Changes to the Fabrication Inspection System that may affect inspection or conformity to the design data or airworthiness of the part are considered major changes to the APMA. CASA must be advised in writing of the changes within 2 days of implementation. 5. Relocation, or expansion of the manufacturing facilities to include new facilities, must be notified to CASA in writing within 10 days of the date the relocation or expansion takes place. 6. Parts produced under this approval must be permanently marked with APMA identification in the detail required by CASR 21.865. If an APMA is granted for an assembly, detail parts of the assembly sold separately must also be marked in accordance with the requirements of CASR 21 Subpart Q. 7. CASR 21.003 requires the Manufacturer to report to CASA information in the detail and to the timeframe required by CASR 21.003, all defects, failures, and malfunctions in any parts produced, or in processes approved under this APMA. 8. In addition to Item 7 above, the Manufacturer must report to CASA in a timely manner, all information concerning service difficulties on any part produced under this approval. 9. The Manufacturer must make available to CASA, on request, information concerning suppliers who furnish parts or services including; a) a description of the part/s including part name, and part number, b) where and by whom the part or service will be inspected, c) any delegation of inspection functions to the supplier, d) any delegation of material review functions to the supplier, e) name and title of the company contact at the supplier facility, f) inspection procedures required to be implemented by the supplier g) results of the manufacturers internal evaluation, audit and surveillance of suppliers, h) related purchase and work orders i) feedback relative to service difficulties originating from the manufacturer’s suppliers. 10. Parts, appliances or services furnished by any suppliers located in a foreign country may not be used in the production of any part listed in the enclosed APMA Supplement unless: a) That part or service can and will be completely inspected for conformity at the Manufacturer’s Australian facility; or b) CASA has determined that the supplier’s location places no undue burden upon CASA in administering the applicable airworthiness requirements; or c) The parts/services furnished by the foreign supplier are produced under the ‘components’ provisions of an Australian Bilateral Airworthiness Agreement or Bilateral Aviation Safety Agreement, and approved for import to Australia in accordance with CASR 21.502. 11. All technical data required by CASR 21.303(3)(c) for the parts to be produced under this approval, must be readily available to CASA at the facility at which the parts are being produced. 12. CASA must be notified within 10 days if the Manufacturer’s address shown in this approval changes. Yours sincerely, {Signed} Delegate of CASA
Date of original issue: 30 September 1999
Attachment: APMA Supplement
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Production Approval Procedures Manual 5. Sample Letters 5.3 Sample CASA APMA Supplement without Licensing Agreement Approved by Executive Manager, Aviation Safety Standards
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5.3
Sample CASA APMA Supplement without Licensing Agreement
5.3.1
Sample CASA APMA Supplement (Design Approval) Test and Computation
Australian Parts Manufacturing Approval Supplement No. 001 Australian Parts Manufacturing Approval No. APMA-123456 Dated: 30 September 1999 To:
Thomas Manufacturing P/L 12 Aviation Street, TULLAMARINE, VICTORIA 3043
APMA Replacement Part: Part Name: For Installation on: Part P/N: Replacement for Part P/N: Design Data: Approval Means: Licence Agreement:
Spring General Aircraft Models THOMAS 7654321 Bendix BS 89 Drawing No 7654321 Rev 1 Test and Computation Nil
APMA Supplement Revision: 0
Yours faithfully, {Signed} Delegate of the Civil Aviation Safety Authority.
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Production Approval Procedures Manual 5. Sample Letters 5.4 Sample CASA APMA Supplement with Licensing Agreement Approved by Executive Manager, Aviation Safety Standards
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5.4
Sample CASA APMA Supplement with Licensing Agreement
5.4.1
Sample CASA APMA Supplement (Design Approval) Identicality
APMA Production Approval Supplement No. 001 Australian Parts Manufacturing Approval No. APMA-654321 Dated: 14 December 1998 To:
Thomas Aircraft Interiors, Inc., 12 Aviation Street, TULLAMARINE, VICTORIA 3043
APMA Replacement Part: Part Name: For Installation on: Eligibility: Part P/N: Replacement for original P/N: Design Data: Design Approved: Approval Means: Licensing Agreement:
Galley ACE Aircraft Model 700 ACE Aircraft Model 700, S/N 123 and up S101001-101 S101001-301 101001-101 101001-301 Interior Inc STC, drawings per licensing agreement Interior Inc. FAA STC No xxxx Identicality License agreement between Thomas Aircraft Interiors and Interiors Inc. Refer Thomas File No 04/8888 FAA STC No. NN12345 Holder : Interiors Inc. 12 Main Street, Los Angeles Airport, CA 900012, USA
APMA Supplement Rev 1 Yours faithfully, {Signed} Delegate of the Civil Aviation Safety Authority.
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Sample Australian Parts Manufacturing Approval Supplement
AUSTRALIAN PARTS MANUFACTURING APPROVAL SUPPLEMENT Manufacturer Thomas Manufacturing Pty Ltd 12 Aviation St Tullamarine Victoria 3045 Approved Location(s) 747 Mackay Ave. Bowenmango QLD. 4108
Part Name
Approved Replacement Part Number for Part Number(s)
Battery Kit 1
A123
Battery Kit 2
A125
Spacer Block
A126-1
Battery Tray
A126-2
L/H Support Bracket
A126-3
See STC NN555
APMA No:
APMA-599999
Supplement No:
001
ARN:
599999
Date:
30 September 2004
Approval Basis Approved Design/Process Data
Make Eligibility
Model Eligibility
Identicality per STC NN555
Anstrom
Unitsia 204 Series
A126-4
End of Listing
(Signed) Delegate of the Civil Aviation Safety Authority.
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Production Approval Procedures Manual 5. Sample Letters 5.6 Sample CASA APMA Design Rejection Letter Approved by Executive Manager, Aviation Safety Standards 5.6
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Sample CASA APMA Design Rejection Letter
To:
Thomas Aircraft Interiors, Inc., 12 Aviation Street, TULLAMARINE, VICTORIA 3043
14 December 1998 I refer to your APMA application dated 01 November 1998 CASA has reviewed the data you submitted. CASA does not find that compliance with the regulatory requirements for APMA has been demonstrated. Non-compliance in relation to CASR 21.303(3) was found in the following areas: The design data was not found to be compliant with the corresponding end product Type Certificate design standard. or for ‘Identicality’, The design data was not found to be identical with the corresponding replacement part data. The data you submitted is enclosed. Yours faithfully, {Signed} Delegate of the Civil Aviation Safety Authority.
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Production Approval Procedures Manual 5. Sample Letters 5.7 Sample ATSO Authorisation Application and Statement of Conformance Approved by Executive Manager, Aviation Safety Standards 5.7
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Sample ATSO Authorisation Application and Statement of Conformance
{Date} Head of CASA Engineering Support Section
Dear Sir, Subject: ATSO {title of ASTO} for
{model or part number}-( ) Series I am applying for issue of an Australian Technical Standard Order Authorisation (ATSOA). I certify that the article(s) listed below by model, type and part number {use applicable designation} has (have) been tested and meet(s) the performance standards of {ATSO number}. In addition, the applicable provisions of CASR Part 21 have been met. {Model, type or part number} Example:
Model ________-( ) Series.
The technical data required by the ATSO are enclosed. The quality control data required by CASR 21.605(2)(c) are enclosed. CASA form 724 Statement of Conformity is enclosed.
Yours faithfully,
{Signed}
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Sample ATSO Authorisation
Ref: 04/12345 Avia Belts Pty. Ltd. PO Box 578910 Numpytown Qld 4896 For Attention: Mr D Samuelson Subject: Avia Belt Restraint Harness Technical Standard Order C114 Dear Sir, This Letter of Approval refers to your application, dated 01 May, 2003, requesting an Australian Technical Standards Order Authorisation (ATSOA) for your restraint harness Part Number ABPL 5-A1. Based on the data presented and your statement certifying that the article meets in full the minimum performance standards of TSO C114 as applicable, and the requirements of Civil Aviation Safety Regulations Part 21, Subpart O, authorisation is granted. Effective from the date of this authorisation you are authorised to manufacture the restraint harness P/N ABPL 5-A1 and mark the articles with the identification marks required in CASR 21.607(c) and, if applicable, any additional marking requirement. All ATSO articles must be manufactured at the authorised location in accordance with the Avia Belts Pty. Ltd. ATSOA Quality Assurance and Procedures Manual, Initial Issue dated 27 July, 2003 or later CASA-approved revision. Revisions must be passed to CASA for review before implementation. Your production authorisation methods, and procedures documented in the approved quality system manual, together with the manufacturing facilities, are subject to CASA audit or investigation. As CASA does not separately approve suppliers, you should advise any suppliers or contractors that their facilities and processes are also subject to CASA audit in assuring CASA your system is being properly maintained. The authorised design data may be changed, however the requirements of CASR 21.611 apply. Minor design changes must be forwarded to CASA at intervals not exceeding six months. Major design changes require a new ATSOA application to CASA. You are required to report to CASA information in the detail and to the timeframe required by CASR 21.003, all defects, failures and malfunctions in any parts produced, or in processes authorised under this ATSOA. Reports are to be forwarded to your CASA controlling office. The production location is identified as: 9 Markus Street, Numptytown QLD 4896
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This authorisation is not transferable to another location or person and continues in force until it is surrendered, suspended or cancelled. Subject to due process, CASA may suspend or cancel this ATSOA by written notice if the holder ceases to comply with the relevant parts of CASR Part 21. Parts, appliances or services furnished by any suppliers located in a foreign country may not be used in the production of any ATSOA article unless: a)
That part or service can and will be completely inspected for conformity at the authorised manufacturer’s Australian facility; or
b)
CASA has determined that the supplier’s location places no undue burden upon CASA in administering the applicable airworthiness requirements; or
c)
The parts/services furnished by the foreign supplier are produced under the provisions of an Australian Bilateral Airworthiness Agreement or Bilateral Aviation Safety Agreement, and approved for import to Australia in accordance with CASR 21.502.
Should you cease to manufacture the subject ATSO article, you are required to send to CASA copies of the complete and current technical data file for the article including design drawings and specifications in accordance with CASR 21.613(1)(a). This ATSOA is a design and manufacturing authorisation, not an installation approval. Therefore, to address end user/installer responsibilities and in accordance with the applicable TSO requirements, the following text must be supplied with each article: “The conditions and tests required for ATSO approval of this article are minimum performance standards. It is the responsibility of each person intending to install the article on or within an aircraft to determine that the conditions in which the article will be installed are not more onerous than those specified in the ATSO. The article may only be installed in accordance with installation data approved by CASA or an appropriately authorised person.” Yours faithfully,
Delegate of the
Date issued: ………………..
Civil Aviation Safety Authority
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Production Approval Procedures Manual 5. Sample Letters 5.9 Sample APIS Approval Letter Approved by Executive Manager, Aviation Safety Standards 5.9
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Sample APIS Approval Letter
Ref: 04/12345 Avia Belts Pty. Ltd. PO Box 578910 Numpytown Qld 4896 Dear , Production Inspection System Approval Your production inspection system established and maintained at {facility address} has been evaluated and found to be in compliance with CASR 21.125. You are now authorised to produce the following Aircraft/Engines/Propellers and their associated parts in compliance with the requirements contained in CASR Part 21, Subpart F, and in conformity with the type design data forming the basis for the following type certificate(s): Type Certificate
Make
Model
Subject to due process, CASA may cancel this approval by written notice if the holder ceases to comply with the relevant parts of CASR Part 21. 1.
The Manufacturer must manufacture all products and parts in accordance with the documented …(Manufacturer’s name) … Approved Production Inspection System manual, Revision …, dated ……….., or later CASA approved revision.
2.
The Manufacturer’s Production Inspection System, together with the Manufacturer’s facilities, are subject to CASA audit or investigation. As CASA does not separately approve suppliers, the Manufacturer must advise any suppliers or contractors that their facilities and processes are also subject to CASA audit in assuring the Manufacturer’s system is being properly maintained.
3.
Changes to the Approved Production Inspection System that affect inspection or conformity to the design data are considered major changes. CASA must be advised in writing of the changes within 2 days of implementation. Product or parts produced between the time the change is implemented and CASA evaluation of the change must be quarantined until released by CASA.
4.
Relocation, or expansion of the manufacturing facilities to include new facilities, must be notified to CASA in writing within 10 days of the date the relocation or expansion takes place. Product or parts produced between the dates the relocation or expansion takes place and CASA evaluation of the changes effected in the manufacturing facility, must be quarantined until released by CASA.
5.
Products and parts produced under this approval must be permanently marked with identification in the detail required by CASR Part 21, Subpart Q.
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6.
CASR 21.003 requires the Manufacturer to report to CASA information in the detail and to the timeframe required by CASR 21.003, all defects, failures, and malfunctions in any parts produced, or in processes approved under this approval.
7.
The Manufacturer must make available to CASA, on request, information concerning suppliers who furnish parts or services including; a.
a description of the part/s including part name, and part number,
b.
where and by whom the part or service will be inspected,
c.
any delegation of inspection functions to the supplier,
d.
any delegation of material review functions to the supplier,
e.
name and title of the company contact at the supplier facility,
f.
inspection procedures required to be implemented by the supplier
g.
results of the manufacturer’s internal evaluation, audit and surveillance of suppliers,
h.
related purchase and work orders
i.
feedback relative to service difficulties originating from the manufacturer’s suppliers.
8.
Parts, appliances or services furnished by any suppliers located in a foreign country may not be used in the production of any product under this approval unless: a.
That part or service can and will be completely inspected for conformity at the Manufacturer’s Australian facility; or
b.
CASA has determined that the supplier’s location places no undue burden upon CASA in administering the applicable airworthiness requirements; or
c.
The parts/services furnished by the foreign supplier are produced under the ‘components’ provisions of an Australian Bilateral Airworthiness Agreement or Bilateral Aviation Safety Agreement, and approved for import to Australia in accordance with CASR 21.502.
9.
All technical data required for the parts to be produced under this approval, must be readily available to CASA at the facility at which the parts are being produced. CASR 21.123(1)(b)
10.
CASA must be notified within 10 days if the Manufacturer’s address shown in this approval changes.
Yours faithfully, {Signed} Delegate of CASA
Date issued: ………………..
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Production Approval Procedures Manual 6. Definitions Approved by Executive Manager, Aviation Safety Standards 6.
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Definitions
Term
Definition
AC
Advisory Circular
Act
Civil Aviation Act 1988 as amended
Aeronautical Product
Any part, apparatus, appurtenance, accessory, instrument, mechanism, equipment (including communication equipment), or material that is used, or intended for use, in an aircraft.
APIS
Approved Production Inspection System
APMA
Australian Parts Manufacturer Approval. It is a design and production approval document issued to the applicant by CASA. This would normally be accompanied by an APMA Supplement, which specifies the limit of design and production approval.
Appliance
Any instrument, mechanism, equipment, part, apparatus, appurtenance, or accessary, including communication equipment that is used or intended to be used in operating or controlling an aircraft in flight, is installed in or attached to the aircraft and is not part of an airframe, engine or propeller.
Applicant
Person who applies to engage in an activity for which a Production Approval is required.
ARN
Aviation Reference Number – a unique number issued by CASA to an industry participant.
Article
A part or component manufactured under an ATSOA for use on type certificated products.
Associate Facility
A facility that has been approved as an addition to an original production approval. The address must be listed in the PLR or APMA Appendix.
ATSO
Australian Technical Standard Order: the minimum performance standard for specified articles.
ATSOA
Australian Technical Standard Order Authorisation is a CASA design and production authorisation issued to a specific manufacturer of an article which has been found to meet or exceed a specific Australian Technical Standard Order (ATSO) performance standard. The ATSOA does not confer installation authority. The installation of the article must be separately approved as part of the type design of a type certificated product.
Authorised Person
A person authorised under an Instrument of Authorisation to exercise a power in a specific provision of CASR or CAR where the term ‘authorised person’ appears. The authorisation is specific to the legislative provision.
AWE
Airworthiness Engineer
MI
Manufacturing Inspector
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Term
Definition
BAA
Bilateral Airworthiness Agreement
BASA
Bilateral Aviation Safety Agreement
CAO
Civil Aviation Order
CAR
Civil Aviation Regulations 1988
Certificate Management
The ongoing audit function carried out by CASA following the issue of a production approval.
CASR
Civil Aviation Safety Regulations 1998
CIR
Conformity Inspection Record – Form 882
Critical
A term applicable to parts, appliances, characteristics, processes, maintenance procedures, or inspections which, if they fail, are omitted, or are non-conforming, may cause significantly degraded airworthiness of the product during takeoff, flight, or landing.
Delegate
A person authorised under an Instrument of Delegation to exercise the power of a specific CASR or CAR.
Design Data
Consists of all drawings and specifications, which may be summarised on a master drawing list, that are necessary to show the configuration of the part, and all information on dimensions, tolerances, materials, processes, and procedures necessary to define all characteristics of a part as well as the Airworthiness Limitations Section of the Instructions for Continued Airworthiness. It also includes analysis, technical reports and other related data.
FAA
Federal Aviation Administration of the USA
FAR
Federal Aviation Regulation of the USA
FIS
Fabrication Inspection System
ICAO
International Civil Aviation Organisation
Life Limited Part
Any part which has an established replacement time, inspection interval, or related procedure specified in the Airworthiness Limitations section under CASRs 21.50, 23.1529, 25.1529, 27.1529, 29.1529, 31.82, 33.4, and 35.4 or under an ATSOA or APMA.
Manufacturer
A person producing duplicates of a product, part, appliance or article.
MRB
Material Review Board
NATA
National Association of Testing Authorities
NAA
National Airworthiness Authority
PAH
Production Approval Holder: the holder of a PC, APIS, APMA or an ATSOA who controls the design and quality of a product or part.
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Term
Definition
PC
Production Certificate
PCB
Production Certification Board: a panel of CASA specialists acting under the direction of a chairperson for the purpose of determining the eligibility of the holder of a TC, STC or licence for issue of a complex production approval.
PLR
Production Limitation Record – a schedule attached to, and forming part of a PC, that lists the limits of production approved under the PC.
Production
Manufacture of aircraft, aircraft engines, propellers and parts, including control of materials and processes used in the manufacture.
Project Officer
The CASA officer responsible for the coordination and management of the production approval application. May be Airworthiness Engineer or Airworthiness Inspector depending on the type of production approval application. Airworthiness Engineers will be responsible for APMA and ATSOA applications and Airworthiness Inspectors will be responsible for PC and APIS applications.
QS
Quality System: the total network of administrative and technical data and detailed procedures required to control the product and parts to specified airworthiness standards. It also denotes inspection systems in regard to holders of an APIS or APMA.
Special Process
A process where the results cannot be readily verified by subsequent inspection and testing, and where processing deficiencies may become apparent only after the product is in use. Such processes shall be carried out by qualified operators, and require continuous monitoring and control of process parameters to ensure that the specified design requirements are met.
Standard Part
An item manufactured in complete compliance with an established government or industry-accepted specification that includes design, manufacturing, and uniform identification requirements. The specification must include all information necessary to produce and conform the part. The specification must be published so that any party may manufacture the part. Examples include, but are not limited to, National Aerospace Standards (NAS), Army-Navy Aeronautical Standard (AN), Society of Automotive Engineers (SAE), SAE Aerospace Standard (AS), Military Specification (MS), (RTCA).
Supplier
Any person who furnishes parts or related services (at any tier) to the production approval holder manufacturing a product or part.
STC
Supplemental Type Certificate
TC
Type Certificate
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Production Approval Procedures Manual Revision History Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Revision History
Note: The Revision History shows details of the most recent version first, followed by information about previous versions. Version 2.0
Date
Part/Section
Details
August 2004
All
Complete manual revised. New Form 1248 Request for Conformity Inspection introduced. Form 1143 Australian Parts Manufacturing Approval Supplement (Landscape version) introduced. (Form 1142 remains as Australian Parts Manufacturing Approval Supplement (Portrait version). Form 1148 Name of Part and Technical Standard (Letter) introduced.
1.1
September 2003
2.2.4
Production Certificate (form 737) and Production Limitation Record (form 002) introduced. As a result section 2.2.4 amended, in particular subsection entitled Issuing the PC and Production Limitation Record (PLR): ● Three introductory paragraphs and a new subsection Certificate Numbers added (pages 2-14 to 2-15) ● Sample Production Approval Templates included (pages 2-18 to 2-19)
1.0
May 2000
4.1.5
New section Automatic Production Process inserted and remaining sections renumbered. This necessitated a change in section 4.1.2, list item 7 under ‘Inspector’ to insert the new section 4.1.5.
5.2
APMA Approval Letter revised.
All
New manual
■
RH-1
Production Approval Procedures Manual Revision History Approved by Executive Manager, Aviation Safety Standards
Blank page
RH-2
Version 2.0: August 2004
STATEMENT OF CONFORMITY Section I – Aircraft 1. Manufacturer:
2. Model Designation:
3. Aircraft Serial Number:
4 Place and Year of Manufacture:
5. Registration Mark: VH-
Section II - Engine 1. Manufacturer:
2. Model Designation:
3. Engine Serial No:
Section III - Propeller 1. Manufacturer:
2. Hub Model Designation:
3. Blade Model Designation:
4. Hub Serial No.
5. Blade Serial Numbers:
Section IV – Aeronautical Product 1. Manufacturer:
2. Product:
3. OEM Part Number:
4. Manufacturer’s Part Number.
5. Design Data:
Section V – Certification I hereby certify that: (a)
The requirements of subregulation 21.033(1) of the Civil Aviation Safety Regulations (1998) have been complied with for the product described above.
(b)
The aircraft described above, produced under a type certificate only [CASR Part 21, Subpart F of the Civil Aviation Safety Regulations (1998)], conforms to its type certificate number.
, is in
condition for safe operation, and was flight checked on
/
/
(Date)
(c)
The *engine or *propeller described above, presented herewith for type certification, conforms to the type design.
(d)
The *engine or *propeller described above, produced under type certificate only [CASR Part 21, Subpart F of the Civil Aviation Safety Regulations (1998)], conforms to its type certificate number, is in condition for safe operation and was subjected by the manufacturer to a final operational check on
(e)
/
/
(Date)
The requirements of subregulation 21.303(8) (APMA) or 21.605(2)(a) (ATSOA), as applicable, of the Civil Aviation Safety Regulations (1998) have been complied with for the product/part described above. The final inspection and test were completed on
/
/
(Date)
Tick (!) box/boxes appropriate to certification. * delete item not applicable. Deviations:
Signature of Certifier:
Position in manufacturing organisation:
Printed Name: Manufacturing Organization
Date:
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Form 724 08/2004
Statement of Conformity
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Page 1 of 2
INSTRUCTIONS This form should be submitted to CASA under the following circumstances: • By the applicant for a type certificate or a supplemental type certificate at the time an aircraft or parts is/are presented to CASA for tests. • By the applicant for a type certificate or a supplemental type certificate for each engine or propeller submitted for type certification. • By the type certificate holder or licensee manufacturing products under a type certificate only, upon the initial transfer by him of the ownership of each product or upon application for the original issue of an aircraft airworthiness certificate, or an Authorised Release Certificate Form 917. • By the applicant for an aeronautical product submitted for design, production approval and installation as applicable. This form should be completed as follows: Section I.
Aircraft.
Complete the pertinent part of any of this section when certification covers an aircraft or part thereof.
Section II.
Engine.
Complete this section when certification covers an engine.
Section III. Propeller.
Complete this section when certification covers a propeller.
Section IV. Aeronautical product.
Complete this section when certification covers an aeronautical product or aircraft part.
Section V.
Certification. Item (a).
Check this block when an aircraft or part thereof is presented for flight or ground tests during type certification or supplemental type certification.
Item (b).
Check this block when the holder or licensee of a type certificate only, initially transfers the ownership of an aircraft manufactured under the type certificate, or applies for the original issuance of an airworthiness certificate.
Item (c).
Check this block when an engine or propeller is presented for type certification.
Item (d).
Check this block when an engine or propeller is presented for airworthiness approval and insert the date the product completed a final operational check.
Item (e).
Check this block when an aeronautical product is presented for airworthiness approval and insert the date the product completed final inspection/test.
An authorised person who holds a responsible position in the manufacturing organisation must sign the certification.
Form 724 08/2004
Statement of Conformity
Page 2 of 2
Production Approval – Application Name and Address of Applicant Application Made for: (Attach evidence of certificate of Production under Type incorporation or business name registration) Production Certificate APMA ATSOA Phone: .....................................................
Amendment
Product:
❑ ❑ ❑ ❑ ❑
Aircraft Engine Propeller Other
❑ ❑ ❑ ❑
(Detail)
Fax: ......................................................... Details of Existing Approval or ARN (PC, APMA, ATSOA No.)
Details of Application Design (attach evidence of ownership or licence details)
Type/STC:
Model:
Other:
Location of Production Facilities
Certification I/WE CERTIFY THAT THE ABOVE STATEMENTS IN THIS APPLICATION ARE TRUE AND CORRECT IN EVERY PARTICULAR. (To be signed in respect of an incorporated company by the public officer of the company or executed under the company seal; in respect of an unincorporated organisation, by all members or nominated members of the organisation; in respect of an individual, by the person seeking approval or his/her authorised agent.) Signature of the Applicant(s): ............................................................................................................. For and on behalf of: ..............................................................................
............ / ......... /.........
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form 849 05/2000
Manufacturing - Application - Production Approval Application
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1.
Revision History
Conformity Inspection Record
1. Project Number, TIA/Request Date: _________________
4. Beginning Date: 6. Model: 8. Item No.
2. Sheet ____ of
sheets
5. Ending Date: 7. Inspected By:
9. Nomenclature of Item Inspected
10. Drawing, Document, Specification, etc.
11. Revision and Date
12. No. of Items Determined Satisfactory
13. Comments
Unsatisfactory
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Form 882 05/2002
Production Approval - Record - Conformity Inspection Record
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Page 1 of 2
INSTRUCTIONS 1.
List the CASA assigned project number along with date of TIA or Request for Conformity, as applicable.
2.
List the number of this sheet and the total number of sheets.
3.
List the applicant or the manufacturer, or both. (The manufacturer may be the party producing or responsible for the product.)
4.
List the date the inspection began.
5.
List the date the inspection ended.
6.
If inspecting an aircraft, list the make, model, registration-number, and serial number. For an engine or propeller, list the make, model, and serial number.
7.
Airworthiness safety inspectors must type or print and sign their name, and enter the office identification. Authorised persons must type or print and sign their name, and list their identification number.
8.
Assign consecutive numbers for each item inspected.
9.
List the name or description of the part, appliance, assembly, drawing, document, specification, or name of the process being evaluated.
10. List the technical data that describes the item listed in Block 9—i.e., drawing number, document number, process specification number, etc. 11. List the revision level and date of the technical data described in Block 10. 12. List the number of items that were determined satisfactory or unsatisfactory. Do not record individual characteristics. (NOTE: An item is a single article or unit containing one or more dimensional characteristics or features.) 13. Enter comments in this block that will support any information given in Blocks 8 through 12—i.e., unsatisfactory conditions, corrective actions taken, reference to other item numbers listed, serial numbers, type of inspection accomplished, destination of exported products, buyer furnished equipment, parts processed through manufacturer’s maintenance facility, part new or newly overhauled, condition of part or assembly, etc. 14. To be used for supplementing items 1–13. NOTE: Unsatisfactory conditions are corrected in one of two ways: Method 1: If action is presented to correct an unsatisfactory condition, the action is entered in Block 13 and the number in the UNSAT column of Block 12 is lined through and initialed. The number of items now determined satisfactory is entered in the SAT column next to the corrective action entry. Method 2: If corrective action is not presented, the inspector may continue the inspection by entering the next item inspected. When corrective action to the unsatisfactory condition is eventually presented, assign the item a new number and record the number in Block 8. Complete Blocks 9 and 10, enter a new revision and date if data has changed, and enter the number of items determined satisfactory in Block 12. Record both the corrective action taken and the item number of the unsatisfactory condition in Block 13. Place the item number in parenthesis. Next, line through and initial the number in the UNSAT column located next to Block 13 containing the unsatisfactory condition. Record the corrective action entry item number along with the unsatisfactory condition statement and place the number in parenthesis. 14.
Continuation Block
Form 882 05/2002
Production Approval - Record - Conformity Inspection Record
Page 2 of 2
Production Approval Assessment Control Document MANUFACTURER:
PROJECT OFFICER: ASSOCIATE: AREA OFFICE:
PRINCIPAL FACILITY: Contact:
Telephone:
Fax:
Telephone:
Fax:
OTHER FACILITIES/SUPPLIERS: Contact: PRODUCTION ASSESSMENT BASIS: PC
APIS
APMA
ATSOA
SUPPLIER
❑
❑
❑
❑
❑
PRODUCT/PART/APPLIANCE/ARTICLE DESCRIPTION AND REFERENCE NUMBER
PRELIMINARY ASSESSMENT RESULTS Satisfactory YES
Comments
NO
Quality System Data – STAGE 1
Quality System – STAGE 2
Design Data
form 883 05/2000
Production Approval - Production Approval Assessment Document
Page 1 of 2
DETAIL CORRECTIVE ACTIONS TAKEN BY APPLICANT:
PROJECT OFFICER’S RECOMMENDATION: Issue Approval
Not Issue Approval
❑
❑
Signature:
Date: _______ / _____ / ______
ASSOCIATE’S SIGN OFF
Signature/s:
Date: _______ / _____ / ______ PCB REVIEW (APIS AND PC ONLY) Nonconformance
Corrective Action
PCB RECOMMENDATION: Issue Approval
Not Issue Approval
❑
❑
Signature:
Date: _______ / _____ / ______
Approval Issue Date:__________/ _______ / _____
Approval No.:
Signature:
Printed Name:
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form 883 05/2000
Production Approval - Production Approval Assessment Document
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Page 2 of 2
REQUEST FOR CONFORMITY INSPECTION (Please see next page for instructions on how to complete this form)
To(1): ...................................................................................... ...................................................................................... ...................................................................................... Request for Conformity Inspection
(2)
(3)
Project No. : ............................................................................
! Part Conformity..............................................................................
(4)
Date : .........../............. / ..............
! Installation: .................................................................................... ! Other:............................................................................................. A conformity inspection pertaining to the subject is requested for the following: (5)
Applicant Name : (6)
Company Name : Street: Suburb/Town:
State:
(7)
Postcode:
! Applicant will contact CASA(8)
Time/Date Available : (9)
Type of Installation : (10)
Make/Model
(11)
:
Quantity
Design Data: (with Revision/Date) Special Instructions
(14)
Contact Name
(13)
(16)
:
:
:
CASA Project Manager Remarks
(12)
:
at (Phone number): (15)
:
at (Phone number):
:
! T.I.A Issued(17)
! CASA Form 882 Required(20)
! T.I.R Required(18)
! CASA Form 724 Required(21)
! 917 ARCs Required(19) Note: Please return this request for conformity to the Project Manager together with the CASA conformity document.
The Federal Government TimeSaver initiative aims to assess the time taken to complete Government Forms. Please indicate the approximate time taken to complete this form. Form 1248 08/2004
Request for Conformity
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Page 1 of 2
Instructions on completing this form (refer superscripted numbers against each item on the previous page) Item 1 Item 2
Item 3 Item 4 Item 5 Item 6 Item 7 Item 8 Item 9
Item 10
Item 11
Item 12
Item 13
Item 14
Item 15
Item 16
Item 17 Item 18 Item 19
Item 20 Item 21
To: Enter the CASA inspector or Engineer to whom the conformity inspection is to be delegated. Part Conformity / Installation / Other: Determine the type of inspection to be performed and check the applicable boxes. Part Conformity – this block should be checked when the parts or assemblies are to be conformed. Installation – this block should be checked when conformity inspection of an installation of conformed parts or assemblies are on an aircraft. Other – this block should be checked when test articles, test coupons, test setup, etc. are to be conformed. Also write the word test articles, test coupons, test setup, etc. in the line next to the block. Project No: Enter the CASA Project number. Date: Enter the date the form is initiated (in the form dd/mm/yyyy). Applicant Name: Enter the full name of the applicant seeking Type or Production Certification (eg, The Boeing Company, Western International Aviation). Note: This is not the place to enter the supplier’s name. Company Name: Enter the full name of the company/supplier manufacturing the prototype part/assembly or test article. Enter the address where the actual conformity inspection work is to be preformed. Time/Date Available: Enter the approximate time and date when the inspections are scheduled to take place. However, this time and date does not constitute a commitment by CASA. Applicant will contact CASA: Always put a x in this box. Type of Installation: Enter a brief description of the part, test article, or installation for which the conformity inspection is being requested. (eg, fuselage panel installation, flight management computer installation, test article part etc). Make / Model: Enter the make and model of the aircraft, engine, or propeller for which the conformity inspection is being requested. (eg, McDonnell Douglas DC-9-82, Boeing 747-400, Robinson R44 etc). This make and model should match those referenced on TCDS. Quantity: Enter only the quantity of parts, assemblies or installations necessary to complete the certification program. (eg, 1 shipset, 5 test samples, 4 wing assemblies) If more than one is necessary to complete the test program, then that quantity should be agreed upon in advance with the Project Manager. For test articles the quantities are usually called out in a test plan that is approved in advance by the CASA project manager. In these cases, write “per test plan” in this section. Design Data: (with Revision / Date): Enter a complete description of design data for the parts, installation, or test articles. References to software revisions, if not incorporated in production drawings are required. If there are multiple drawings, the information may be entered on a separate attached sheet with a note in this section that states “See attached sheet(s)”. For installation conformity inspections, an entry of a master drawing list is usually adequate without additional information. This information is very important to an inspector because it defines the relevant design data and revision level. Special Instructions: Enter any special instructions that may aid the inspector conducting the inspection (eg, Test part not intended for use on an aircraft; Perform software conformity in accordance with RTCA DO-178A; Perform review process conformity in accordance with CASA Order 8110.4a etc). Contact: Enter the person’s name and title and phone number at the site identified in Item No 6. This is the person who is responsible for coordinating the inspection with CASA and Designee. This contact usually corresponds with the information in Item 6. CASA Project Manager: Enter the name and phone number of the Manufacturing Inspector or Engineer who initiated the conformity inspection request. This is the person who will answer any technical questions concerning the conformity request. This person will review the deviations listed on the form 724. This is also the person to whom the completed Conformity Inspection Report package is to be returned. Remarks: Enter any applicable information that may help the conformity inspection be conducted in a timely manner. eg, “applicant wishes to use a particular Authorised Person, to conduct conformity inspection” or “Applicant wishes to use a foreign NAA to conduct the conformity inspection” TIA Issued: Check this block when the request is being utilised to supplement a TIA. TIR Required: Check this block to have this conformity request and conformity inspection report placed in the TIR when a TIA has been issued. 917 ARCs required: Check this box when the inspection articles will be moved or shipped from one location to another and evidence of the conformed article is desired. Also check this box when it is desired to have evidence of a conformed article prior to an on-site test. CASA Form 882 Required: Check this box with every request. CASA Form 724 Required: Check this box with every request.
Form 1248 08/2004
Request for Conformity
Page 2 of 2
CASADOC 79
Production Approval Procedures Manual
This is an internal CASA policy manual. It contains guidance material intended to assist CASA officers and delegates in carrying out their regulatory responsibilities and may be made available to the public for information purposes only. Copies of this manual are available from: http://casa.jsmcmillan.com.au/He/cat. Since this is an uncontrolled version of the manual which will not be updated by CASA, it should not be relied upon for any regulatory purpose. The current manual can be viewed at any time via CASA's website at "www.casa.gov.au". You should always refer to the applicable provisions of the Civil Aviation Act, Civil Aviation Regulations and the Civil Aviation Orders, rather than this manual, to ascertain the requirements of, and the obligations imposed by or under, the civil aviation legislation.
Version 2.0: August 2004
Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Table of Contents
1. Introduction to Production Approval Procedures..........................................................1-1 1.1
About this Manual ..................................................................................................1-1 1.1.1 Review of this Manual..................................................................................1-1 1.1.2 Purpose and Scope of the Manual...............................................................1-2
1.2
Regulatory Framework...........................................................................................1-3 1.2.1 Background..................................................................................................1-3 1.2.2 Legislative Basis ..........................................................................................1-4
1.3
Responsibility for Production Approval ...............................................................1-6 1.3.1 Staff Responsibilities....................................................................................1-6
1.4
Production Approval Process ...............................................................................1-7 1.4.1 Production Approval Flowchart ....................................................................1-7
1.5
Processing Inquiries and Applications for Production Approvals ....................1-8 1.5.1 Advice Provided by CASA for General Enquiries.........................................1-8 1.5.2 On Receipt of an Application .......................................................................1-9
1.6
Production Certification Board (PCB) ................................................................1-11 1.6.1 Production Certification Board (PCB) – Description...................................1-11 1.6.2 PCB Membership.......................................................................................1-11 1.6.3 PCB Member Responsibilities ...................................................................1-11 1.6.4 Conduct of the PCB ...................................................................................1-12 1.6.5 PCB Records .............................................................................................1-14 1.6.6 Administration of Production Approvals Granted .......................................1-15
2. Assessment and Issue of Approvals...............................................................................2-1 2.1
Approved Production Inspection System—Production under a TC ..................2-1 2.1.1 Applicability – Approved Production Inspection System ..............................2-1 2.1.2 Responsibility...............................................................................................2-2 2.1.3 Procedure for APIS Issue ............................................................................2-2 2.1.4 APIS Board ..................................................................................................2-4 2.1.5 TC Holder's/TC Licensee's Responsibility under CASR Part 21, Subpart F .....................................................................................................2-5 2.1.6 APIS Holder’s Facility Location....................................................................2-7 2.1.7 Assessment of an Applicant’s Suppliers ......................................................2-7
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Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
2.2
Production Certificate (PC)....................................................................................2-8 2.2.1 Applicability – Production Certificate............................................................2-8 2.2.2 PCs Issued for Fabrication In The Course of Maintenance..........................2-9 2.2.3 Responsibility for PCs..................................................................................2-9 2.2.4 Advising the Applicant................................................................................2-10 2.2.5 Preliminary Assessment Procedures .........................................................2-11 2.2.6 Testing Aircraft, Engines and Propellers....................................................2-19 2.2.7 PC Holder's Location(s) .............................................................................2-19 2.2.8 Responsibility for PC Management............................................................2-20 2.2.9 Assessment of an Applicant’s Suppliers ....................................................2-20 2.2.10 Summary of Distribution of Production Certification Documents................2-21
2.3
Australian Parts Manufacturer Approval ............................................................2-22 2.3.1 Applicability of Australian Parts Manufacturer Approval.............................2-22 2.3.2 Responsibility for Australian Parts Manufacturer Approval ........................2-23 2.3.3 Lodgement of an Application for an APMA ................................................2-23 2.3.4 CASA Engineering Assessment ................................................................2-24 2.3.5 Manufacturing Inspector Assessment ........................................................2-29 2.3.6 APMA Approval .........................................................................................2-30
2.4
Australian Technical Standard Order Authorisation (ATSOA) .........................2-33 2.4.1 Applicability – ATSOA................................................................................2-33 2.4.2 Advising the Applicant................................................................................2-33 2.4.3 Lodgement of an Application .....................................................................2-34 2.4.4 ATSOA Issue Procedure............................................................................2-34 2.4.5 ATSOA Holder's Facility Location ..............................................................2-37 2.4.6 Approval of Materials and Processes.........................................................2-37
3. Assessments .....................................................................................................................3-1
ii
3.1
Assessment of an Applicant's Quality Systems for Manufacture......................3-1 3.1.1 General Principles........................................................................................3-1
3.2
Assessment of an Applicant’s Suppliers .............................................................3-3 3.2.1 Assessment of an Applicant’s Suppliers ......................................................3-3 3.2.2 Assessment .................................................................................................3-4 3.2.3 Stage 1 Quality System Assessment—Desk-top Review ............................3-4 3.2.4 Stage 2 Quality System Assessment – Quality System Evaluation ...........3-23
Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11 3.2.12 3.2.13 3.2.14
Version 2.0: August 2004
Stage 3 Quality System Assessment—Manufacturer's Corrective Action.........................................................................................................3-24 Manufacturer’s Service Documentation .....................................................3-24 Service Difficulty Reports...........................................................................3-24 Reporting of Failures, Malfunctions and Defects During Manufacture .......3-25 Manufacturer’s Maintenance Facility..........................................................3-25 Supplier Quality Control .............................................................................3-25 Engineering Drawings................................................................................3-26 Use of CASA Form 917 Authorised Release Certificate ............................3-26 Use of CASA Form 917 for Unapproved Parts ..........................................3-27 Export Airworthiness Approvals .................................................................3-27
4. Inspections ........................................................................................................................4-1 4.1
Conformity Inspections .........................................................................................4-1 4.1.1 Introduction to Conformity Inspections.........................................................4-1 4.1.2 Conformity Inspections ................................................................................4-1 4.1.3 First Article Inspection..................................................................................4-3 4.1.4 Materials ......................................................................................................4-4 4.1.5 Processes and Processing ..........................................................................4-4 4.1.6 Automatic Production Processes .................................................................4-5 4.1.7 Non-destructive Inspection (NDI) Method Evaluation ..................................4-6 4.1.8 Critical and Major Characteristics ................................................................4-6 4.1.9 Workmanship...............................................................................................4-7 4.1.10 Adequacy of Drawings and Related Change Records .................................4-7 4.1.11 Adequacy of Inspection Records ...................................................................4-7 4.1.12 Material Review Action ..................................................................................4-7 4.1.13 Software ........................................................................................................4-8 4.1.14 Conformity Inspections of Test Articles .........................................................4-8 4.1.11 Structural Test Articles – Aircraft .................................................................4-9 4.1.12 Flight Test Articles—Aircraft ........................................................................4-9 4.1.13 Endurance Test Articles—Engines and Propellers ......................................4-9
4.2
Final Inspection and Flight Test..........................................................................4-11 4.2.1 Applicability — Final Inspection and Production Flight Test.......................4-11 4.2.2 Preliminary Ground Inspection...................................................................4-11 4.2.3 Final Ground Inspection.............................................................................4-11 4.2.4 Flight Inspection.........................................................................................4-12
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Production Approval Procedures Manual Table of Contents Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
5. Sample Letters ..................................................................................................................5-1 5.1
Sample APMA Application Letter..........................................................................5-2
5.2
Sample CASA APMA Approval Letter...................................................................5-3
5.3
Sample CASA APMA Supplement without Licensing Agreement......................5-5 5.3.1 Sample CASA APMA Supplement (Design Approval) Test and Computation ................................................................................................5-5
5.4
Sample CASA APMA Supplement with Licensing Agreement ...........................5-6 5.4.1 Sample CASA APMA Supplement (Design Approval) Identicality ...............5-6
5.5
Sample Australian Parts Manufacturing Approval Supplement.........................5-7
5.6
Sample CASA APMA Design Rejection Letter .....................................................5-8
5.7
Sample ATSO Authorisation Application and Statement of Conformance .......5-9
5.8
Sample ATSO Authorisation................................................................................5-10
5.9
Sample APIS Approval Letter ..............................................................................5-12
6. Definitions .........................................................................................................................6-1 Revision History .................................................................................................................. RH-1 List of Effective Pages ...............................................................................................................v Forms Form 724
Statement of Conformity
Form 849
Production Approval—Application
Form 882
Conformity Inspection Record
Form 883
Production Approval Assessment Control Document
Form 1248 Request for Conformity Inspection (Note: The above forms are only those available to the industry/public via the CASA Website. Forms and templates used internally are available to CASA staff only, via CASAconnect, and are not listed here.)
iv
Production Approval Procedures Manual List of Effective Pages Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
List of Effective Pages
No. of Pages
Version
Date of Issue
Cover and verso
2
2.0
08/2004
Table of Contents List of Effective Pages and Abbreviations
6
2.0
08/2004
1.
Introduction to Production Approval Procedures
16
2.0
08/2004
2.
Assessment and Issue of Approvals
38
2.0
08/2004
3.
Assessments
28
2.0
08/2004
4.
Inspections
14
2.0
08/2004
5.
Sample Letters
12
2.0
08/2004
6.
Definitions
4
2.0
08/2004
2
2.0
08/2004
Part
Revision History
v
Production Approval Procedures Manual List of Abbreviations Approved by Executive Manager, Aviation Safety Standards List of Abbreviations
Abbreviations AC AD APIS APMA ARC ARN ASCD ATSOA AWE CoA ESS FIS FITCOM IPC MI MRB NAA PAH PA PC PCB PLR PO RMU SB SDR STC TC
vi
Advisory Circular Airworthiness Directive Approved Production Inspection System Australian Parts Manufacturer Approval Authorised Release Certificate Aviation Reference Number Aviation Safety Compliance Division Australian Technical Standard Order Authorisation Airworthiness Engineer Certificate of Airworthiness Engineering Support Section Fabrication Inspection System Fabrication in the Course of Maintenance Illustrated Parts Catalogue Manufacturing Inspector Materials Review Board National Airworthiness Authority Production Approval Holder Production Approval Production Certificate Production Certification Board Production Limitation Record Project Officer Record Management Unit Service Bulletin Service Difficulty Report Supplementary Type Certificate Type Certificate
Version 2.0: August 2004
Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.1 About this Manual Approved by Executive Manager, Aviation Safety Standards 1.
Version 2.0: August 2004
Introduction to Production Approval Procedures
1.1
About this Manual
1.1.1
Review of this Manual
Production Approval Manual Review Team This Production Approval Procedures Manual will be reviewed as required and within 12 months of issue or review. The Production Approval Manual Review Team will comprise: ●
Executive Sponsor – Executive Manager, Aviation Safety Standards
●
Technical Sponsor – Head of Airworthiness Standards
●
Chair – Central Office Manufacturing Specialist
●
Two Airworthiness Engineers
●
Three Manufacturing Inspectors
●
Administrative Support.
Recommending Changes to the Manual If any information in this manual needs to be amended or new information added, notify the technical sponsor. Use Form 476 Manual Amendment Request, when making suggestions, including additional sheets if necessary. Definitions See 6. Definitions.
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1-1
Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.1 About this Manual Approved by Executive Manager, Aviation Safety Standards
1.1.2
Version 2.0: August 2004
Purpose and Scope of the Manual
Purpose The purpose of this manual is to provide CASA staff with procedures for assessing applications for Production Approvals (PAs) under CASR Part 21 and for issuing those CASA approvals.
CASR Part 21
Scope CASR Part 21
This manual applies to PAs under Part 21 including but not limited to the following:
CASR Part 21. Subparts F, G, K, O, and Q
●
Production under Type Certificate (TC) (CASR Part 21 Subpart F)
●
Production Certificate (PC) (CASR Part 21 Subpart G)
●
Australian Parts Manufacturer Approval (APMA) (CASR Part 21 Subpart K)
●
CASR Part 21.305 (e)
Australian Technical Standard Order Authorisation (ATSOA) (CASR Part 21 Subpart O)
●
Identification of Aircraft and Aeronautical Products (CASR Part 21 Subpart Q)
●
Other approvals under CASR 21.305(e).
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1-2
Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.2 Regulatory Framework Approved by Executive Manager, Aviation Safety Standards 1.2
Regulatory Framework
1.2.1
Background
Version 2.0: August 2004
An outline of the background to this manual is as follows: CASR Part 21 CAR 30
a. Version 1 of this manual was introduced in May 2000 to address manufacture under CASR Part 21 and for transition from previous approvals issued under regulation 30 of CAR 1988. b. CASR Part 21 provisions were developed with the intent of reflecting the corresponding provisions in US FAR Part 21, but only where these were appropriate to Australian requirements. c. The result has been regulations that harmonise with international best practice while at the same time meeting Australia's obligations as a contracting state to the ICAO Convention.
CASR Part 21
d. Audit of manufacturing approvals is conducted under CASA’s surveillance procedures. e. Amendment 2.0 is introduced to clarify procedures in the light of experience gained since the introduction of CASR Part 21.
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1.2.2
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Legislative Basis
Civil Aviation Act 1988 Section 11 CAA 1988 CAR 1988 CASR 1998 Part 21
Australia, as a contracting state to ICAO, has an obligation to ensure that functions carried out in Australia are performed in accordance with international agreements. The Civil Aviation Act (1988) section 11 refers. CAR1988 and CASR Part 21 are consistent with the provisions of the Act.
Civil Aviation Act 1988 Section 31 and Civil Aviation Safety Regulations 1998 Part 201.4 CAA 31
Section 31 of the Act makes all decisions to refuse to grant, vary, suspend or cancel an approval appealable to the AAT.
CASR 201.4
CASR Part 201.4 makes appealable any condition imposed on an approval, authorisation, authority, certificate or permit.
Civil Aviation Act 1988 Section 97 If a fee is prescribed for the grant of an approval then the approval need not be granted until the fee is paid (section 97 of the Act).
CAA 97
Civil Aviation Safety Regulations Part 1 CASR Part 1
Part 1 describes legislative links to other aviation legislation and practices.
Civil Aviation Safety Regulations Part 21 Subpart A Subpart A defines the applicability of CASR Part 21, including provisions dealing with falsification of applications, suspension and cancellation actions and reporting of failures by production approval holders.
CASR Part 21
Civil Aviation Safety Regulations Part 21 Subpart F CASR Part 21 Subpart F
Subpart F prescribes the requirements for approval of production under a TC only. It contains the requirements for establishing a production inspection system and a Materials Review Board (MRB). This approval does not provide the same degree of flexibility as a Production Certificate.
Civil Aviation Safety Regulations Part 21 Subpart G CASR Part 21 Subpart G
Subpart G prescribes the requirements for issue of a Production Certificate and the rules governing the production of aircraft, aircraft engines and propellers and certain parts.
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Civil Aviation Safety Regulations Part 21 Subpart K CASR Part 21. Subpart K,
Subpart K prescribes the requirements for issue of an Australian Parts Manufacturer Approval. This approval requires the establishment of a Fabrication Inspection System (FIS) in addition to design approval.
Civil Aviation Safety Regulations Part 21 Subpart O CASR Part 21. Subpart O.
Subpart O prescribes the requirements for issue of an Australian Technical Standard Order Authorisation. This approval is both a design and production approval.
Civil Aviation Safety Regulations Part 21 Subpart Q CASR Part 21. Subpart Q
Subpart Q prescribes the requirements for part identification and marking.
Civil Aviation Safety Regulations 21.305 (e) CASR Part 21.305 (e)
Section 21.305(e) authorises approval of items not otherwise covered by other approval mechanisms.
Civil Aviation Safety Regulations Part 201 CASR Part 201
Part 201 prescribes the appointment of authorised persons.
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.3 Responsibility for Production Approval Approved by Executive Manager, Aviation Safety Standards 1.3
Responsibility for Production Approval
1.3.1
Staff Responsibilities
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Executive Sponsor The Executive Sponsor has responsibility for the overall control of this manual. Technical Sponsor The Technical Sponsor assumes technical responsibility for this manual and manages its development through to completion, or its amendment as and when required, in accordance with the Manual of Controlled Documents. Managers Managers ensure that CASA staff correctly implement the procedures in this manual. CASA Officers CASA officers are to: ●
●
Adhere to the procedures in this manual Bring to the notice of the Sponsor the need for amendments to the manual, in accordance with the instructions for Recommending Changes to the Manual.
CASA Project Officer The Head of the Engineering Support Section (ESS) appoints a Project Officer (PO) for a particular production approval, who ensures that the production approval application is assessed effectively and that all aspects of the approval are complete and in accordance with this manual. When satisfied, the Project Officer recommends the issue of the approval. The PO for PC and APIS applications will be a Manufacturing Inspector (MI). The PO who evaluates the APMA and ATSOA applications will be an Airworthiness Engineer (AWE).
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Production Approval Procedures Manual 1. Introduction to Production Approval Procedures 1.4 Production Approval Process Approved by Executive Manager, Aviation Safety Standards 1.4
Production Approval Process
1.4.1
Production Approval Flowchart
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Initial advice to applicant
Receive application Conduct onsite evaluation/ audit of QC system Set up project files
Does applicant follow approved procedures?
Acknowledge application
ESS assigns a Project Officer
Is this the facility's first approval?
No
Notify applicant to take corrective action
Yes
Is PC board involved?
No
No
Yes Convene PC board
Yes Establish PC board if the application is for a PC
Yes
Is there a major change in the facility's procedures?
No
Has applicant met all requirements?
No
Notify applicant to take corrective action
Yes
Review data for compliance
Issue the approval
Do procedures comply? Yes
No
Notify applicant to revise procedures
Complete files and enter approval details on CASA Internet database
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Processing Inquiries and Applications for Production Approvals
1.5.1
Advice Provided by CASA for General Enquiries
AC 21.14, 21.16, 21.20, 21.27, 21.601
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When people make inquiries about production approvals, provide them with relevant advice and request that they read the appropriate Advisory Circular (AC) for the particular approval, including: ●
AC 21.14
Production Certificates
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AC 21.16
Australian Parts Manufacturer Approval
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AC 21.20
Production Under TC
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AC 21.27
Manufacturing Approval — Overview.
●
AC 21.601
ATSOA (Yet to be issued)
Should the person wish to proceed, advise that a formal written application to CASA is required before the application can be processed. Enquirers must be advised that cost recovery procedures are applicable. Regardless of which production approval is sought, it should be stressed to the applicant that it is the applicant’s responsibility to demonstrate conforming products and parts. It is a CASA responsibility to find that conforming parts have been demonstrated as a basis for issue of the approval sought. A non-conformed proof-of-concept product is not a basis for CASA assessment and subsequent approval. The CASA officer should advise the applicant of the advantages of obtaining a PC. The advantages of being a PC holder, compared to production under a TC only, include the following: ●
●
●
CASR 21.325
●
No requirement to submit a Statement of Conformity to CASA, for each conformed product Reduced CASA involvement, relative to conformity inspections An Authorised Person within the Approved Production Inspection System (APIS) will be able to issue airworthiness certificates and approvals for completed products without reliance on CASA inspections The issue of export approvals for small aircraft without assembly or flight test (CASR 21.325).
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On Receipt of an Application
Administrative Procedures 1. All correspondence is to be recorded and controlled in accordance with Record Management Unit (RMU) guidelines. 2. All actions to be properly documented and filed as appropriate. 3. All other administrative processes to be in accordance with local ESS internal procedures. Cost Recovery Procedures The cost recovery procedures for production approvals are similar to those described in the Type Certification Procedures Manual. Engineering Manager The Engineering Manager or Team Leader is to monitor the progress of the application. If it becomes evident that the application will not be processed within the normal timeframe, ensure that the applicant is notified accordingly. Project Officer 1. Raise Form 883 Production Approval Assessment Control Document and place it on the appropriate file. 2. Check that Form 849 Production Approval Application and covering letter are complete and on file. 3. Check the LARP database for any current enforcement actions pending or proceeding in relation to the applicant or whether any exclusion periods have been imposed. Refer any of these to the Office of Legal Counsel for advice. 4. Prepare a cost-recovery estimate within 7 days. 5. Forward the file with the attached cost-recovery details to Administration. 6. Liaise with Central Office personnel, as applicable, to advise them of the application and, if the application is for an APIS or PC, to arrange the establishment of a Production Certification Board (PCB). Refer to 1.6.1 Production Certification Board. The ESS and Central Office managers will allocate resources.
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7. Send the applicant a letter of acknowledgment when notified that the applicant has accepted the estimate for service and/or the prescribed fee has been paid. If a PCB is required, pre-PCB (CASA) and pre-PCB (applicant) meetings may now be convened (refer to 1.6.1 Production Certification Board), to prepare both CASA officers involved in the assessment and the applicant for the requirements of the assessment. A PCB is required for Class 1 items, and may be required for other items, at the discretion of the Head of ESS, depending upon the complexity and investigations required. 8. If the application does not require the establishment of a PCB, proceed as for the preliminary assessment only. Administration Officer 1. Complete the cost recovery documentation in accordance with the Financial Procedures Manual. 2. Return the file to the Project Officer.
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Production Certification Board (PCB)
1.6.1
Production Certification Board – Description
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A Production Certification Board (PCB) is a CASA panel established for the purpose of facilitating the assessment of a production approval PCBs should be convened for initial production approvals covered by production under TC or Production Certificate, or when entire facilities have been relocated or are to be added to the production approval. PCBs should not be convened for the addition of new models to the production approval or for relocation of a portion of a facility, unless significant changes in production technology or processes apply. In these instances, follow the procedures in Chapter 2.
■ 1.6.2
PCB Membership The PCB will include a Chairperson nominated by the ESS manager, the Project Officer and any other nominated specialists. These members will assist in evaluating the applicant's production, engineering, flight test procedures, and other related functions. The Project Officer may be, or act as, the Chairperson of the PCB and will coordinate activity through the Head of ESS.
■ 1.6.3
PCB Member Responsibilities
PCB Chairperson The PCB chairperson is responsible for: ●
●
●
●
●
●
Assigning board members, as deemed appropriate for the particular product, and notifying members of the pending PCB schedule in sufficient time to permit adequate planning and preparation Notifying the applicant of the PCB schedule Selecting a representative number of the applicant's supplier facilities for evaluation to determine whether or not the applicant's quality system provides for satisfactory supplier control Conducting pre/post-PCB meetings with CASA officers and/or the applicant Reviewing and analysing the PCB findings and ensuring that appropriate corrective actions have been or will be taken by the applicant Completing, signing, and distributing the PCB minutes.
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Project Officer The Project Officer is responsible, using administrative assistance as appropriate, for: ●
Establishing schedules
●
Making arrangements for meeting rooms
●
Obtaining sufficient copies of quality system data
●
Making all other arrangements necessary for convening and conducting the PCB in the most expeditious manner
●
Ensuring that all agreed-upon corrective actions have been taken by the applicant
●
Preparing the minutes of the PCB.
Certification Specialists The Certification Specialists are responsible for: CASR 21.127, 21.128, 21.129, 21.143 (1)(c)
●
●
●
Evaluating and approving the applicant's production engine/propeller test procedures, as required by CASR 21.143(1)(c), 21.127, 21.128 or 21.129 Evaluating and approving the applicant's flight test procedures and check-off lists as required by CASR 21.143(1)(c) Reporting and making recommendations to the Project Officer (rather than making direct communication with the applicant).
■ 1.6.4
Conduct of the PCB A PCB is generally conducted as follows: ●
Initial CASA personnel meeting
●
Pre-PCB meeting
●
PCB meetings
●
Review of the PCB process and conduct.
Initial CASA Planning Meeting A meeting of CASA personnel is held to plan the preliminary assessment, ESS Office recommendations, and related correspondence between CASA and the applicant. This meeting is also used to plan the PCB schedule for subsequent meetings; and establish agenda items for the pre-PCB meetings.
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Pre PCB Meeting A Pre-PCB meeting may be held with the applicant's representatives upon receipt of the production approval application. This meeting should include the Chairperson and any other specialist as necessary. The purpose of this meeting is to advise the applicant of the purpose of the CASA PCB and of CASA's evaluation plans. CASR 21.125, 21.135, 21.137
Inform the applicant that the PCB is a fact-finding body convened to determine whether or not the applicant is in compliance with CASR 21.125 or 21.135 and, that in making this determination, the PCB will thoroughly evaluate the applicant’s quality system, data, organisation and production facilities. It is at this point that the Chairperson determines whether or not the location of the applicant’s facilities poses an undue burden on CASA, as specified in CASR 21.137. PCB Assessment of Applications Following the pre-PCB meeting with the applicant, the PCB evaluates the applicant's quality system data and performs an on-site evaluation of the applicant's quality system, organisation production facility and suppliers, as appropriate. PCB Meetings PCB meetings attended by all board participants are conducted as needed to discuss and evaluate each unsatisfactory condition and related recommendation submitted by each member. All unsatisfactory conditions are recorded as findings on Form 883 Production Approval Assessment Control Document. A final meeting, attended by all PCB members and representatives of the applicant, is held to advise the applicant of the PCB findings. Each unsatisfactory condition and recommendation should be presented and briefly discussed. Corrective Action In those instances where a product is being produced under a TC, the PCB must request that the applicant commence immediate corrective action on those items that directly involve the product and related quality practices. A reasonable time may be allowed for correcting deficiencies in the quality system data. However, the applicant must be advised that the PCB cannot recommend that an approval be issued until all applicable regulations are complied with and the ESS Office has evaluated all corrective actions and found them to be satisfactory. Formal Confirmation The applicant must also be advised that the applicant will receive an official letter confirming the verbal presentation of the list of unsatisfactory conditions and recommendations. This formal notification should be prepared and signed by the PCB Chairperson, within ten working days of the final meeting with the manufacturer.
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Violations CASR Part 21 Subpart F
If the applicant is manufacturing a product under a TC, and any of the unsatisfactory conditions are determined to be violations of CASR Part 21, Subpart F, appropriate enforcement actions should be initiated by the ESS Office.
Final Phase of the PCB The final phase of a PCB is the evaluation by the ESS Office of the corrective action taken by the applicant. The results of any re-inspection should be reported to the Chairperson of the PCB and, if satisfied, the Chairperson will make a recommendation to the ESS Manager and sign off on Form 883 Production Approval Assessment Control Document. PCB Conclusion CASR 21.123, 21.135
The ESS Office will formally advise the applicant in writing, as soon as practicable, that based on a demonstrated compliance with CASR 21.123 or 21.135, an approval will be issued. Conversely, if compliance has not been demonstrated, the applicant will be formally advised that an approval will not be issued, and a statement of reasons must be advised to the applicant.
■ 1.6.5
PCB Records The Project Officer shall prepare the PCB minutes for the signature of the Chairperson. The minutes should contain a concise record of the entire PCB proceedings, including the names and titles of all participants. All correspondence and forms relating to the PCB, including letters to the applicant, the applicant’s replies, etc, are considered to be part of the minutes and should be attached as appendices. Once accepted by the Chairman, the PCB minutes should be distributed as follows: ●
Original to the applicant’s file
●
One copy to Certification Support Services Section
●
Copies to the members of the PCB.
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1.6.6
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Administration of Production Approvals Granted
Approval Numbers All PA numbers incorporate the Aviation Reference Number (ARN) of the organisation. PC Numbers A PC’s number consists of the letters PC- followed by the ARN of the applicant—for example, PC-123456. It is unlikely that there would be more than one PC issued to an organisation because the PLR can list multiple activities. For PCs issued for Fabrication in the Course of Maintenance (FITCOM), -1 is added after the ARN, for example PC-123456-1. APIS Numbers An APIS number consists of the letters APIS- followed by the ARN of the applicant—for example, APIS-123456. The specific products are specified on the Type Certificate. APMA Numbers Only one APMA is likely to be issued to an organisation. An APMA number consists of the letters APMA- followed by the ARN of the applicant—for example, APMA-123456. The specific products and parts are listed on the supplement, which is re-issued to add or delete products and parts. The first and any additional supplements are numbered consecutively from 001. ATSOA Identification CASR 21.865, 21.870
An ATSOA is expected to be a discrete issue, and an organisation is likely to have multiple ATSOA approvals. The Letter of Approval identifies the specific item(s). The applicant’s ARN will be quoted in the letter. The articles must be marked in accordance with CASR 21.865 or 21.870. ESS PA Database After each PA is issued, the ESS administration staff are to enter the details of the specific approvals given into the MS Excel spreadsheet of PAs. Either weekly or as required, a copy of the complete database is to be forwarded to the CASA website controller in Canberra. The website controller will update the CASA external website and the intranet.
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Production Approval Procedures Manual 2. Assessment and Issue of Approvals 2.1 Approved Production Inspection System—Production under a TC Approved by Executive Manager, Aviation Safety Standards 2.
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Assessment and Issue of Approvals
2.1
Approved Production Inspection System—Production under a TC
2.1.1
Applicability – Approved Production Inspection System
CASR Part 21, Subpart F
This section provides guidance on the assessment and issue of an Approved Production Inspection System (APIS), under CASR Part 21, Subpart F. It applies to a holder or licensee of a TC who wants to manufacture complete aircraft, aircraft engines or propellers and parts thereof under an APIS prior to obtaining a Production Certificate (PC).
AC 21.20, 21.27
Additional guidance is contained in AC 21.20 and AC 21.27. Applicants should be aware that CASA considers an APIS an interim production stage, and they should be encouraged to achieve a PC for their activities. This is because, from the date of issue of the Type Certificate (TC) and prior to the issue of an APIS, CASA provides the resources to determine whether the product, and parts manufactured by the applicant, conform to the type design and are in a condition for safe operation. Because there is a six-month deadline from date of issue of a TC to the time when an applicant must have an APIS in place, the applicant should signal his or her intention to produce duplicates at the start of the type certification process. The regulations require the APIS holder to have process specifications, materials review records, test procedures and flight check forms that are acceptable to CASA, and the applicant should have started developing these data concurrently with other data relevant to type certification requirements.
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2.1.2
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Responsibility Subsequent to the date of issue of the TC and prior to the issue of an APIS (or PC), CASA has full responsibility for determining whether the product and parts thereof conform to the type design and are in a condition for safe operation. The ESS is responsible for managing all aspects of progression to an APIS or PC and for the relevant surveillance activities once an APIS or PC has been issued. The Project Officer performs detailed inspections of all incoming materials (at the source, if necessary), installations, operations, processes, detail parts, sub-assemblies and completed products. These inspections must be documented as prescribed in section 4.1 Conformity Inspections, so that there is a complete inspection record for each product/part. The ESS Office maintains the complete inspection record of each product/part thereof.
■ 2.1.3
Procedure for APIS Issue
Preliminary Assessment Procedures CASR 21.123
An applicant for an APIS must show compliance with CASR 21.123. This preliminary assessment consists of an evaluation of the applicant’s: ●
●
Production inspection system data Facilities, equipment, processes, personnel, control of suppliers, stores, etc, to ensure that they are adequate for the purpose.
The assessment of the data will require a number of visits to the applicant’s facilities and suppliers, as necessary; to evaluate and confirm that the procedures provide control for the conformity of detail parts, sub-assemblies and completed products. In other words, the Project Officer must evaluate the adequacy of the quality system by personally observing the control of each stage of production, and all supporting functions such as document control. In the preliminary assessment, use the appropriate sections of this manual to assess: ●
Suppliers
●
Supplier control
●
All quality systems.
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Project Officer 1. Make arrangements to conduct the preliminary assessment only after the applicant has accepted the CASA estimate of costs and has the capability to comply with the regulatory requirements. 2. Assess the applicant's quality system assisted by specialists, as required. 3. Carry out the assessment concurrently with conformity inspections of first articles prior to the issue of an APIS. That is, assess the applicant’s inspection system for adequacy on a progressive basis. 4. As parts of the system are found to meet the regulatory requirements: ❍ Maintain a record of those portions of the system considered satisfactory on Form 883 Production Approval Assessment Control Document ❍ Reduce conformity inspections to spot-checks for articles covered by those parts of the system found satisfactory ❍ Place increasing emphasis on securing corrective actions on the parts of the system where procedural discrepancies or nonconformities are found, or where the system is found to be inadequate, as recorded on Form 883 Production Approval Assessment Control Document. Assessing the Applicant's Progress Project Officer 1. Periodically assess the applicant's progress in obtaining approval of the APIS. CASR 21.123(1)(c)
2. If it appears that the applicant may not be eligible for the APIS by the deadline date (six-month period specified in CASR 21.123(1)(c)), advise the applicant in writing of all known deficiencies. Also, caution the applicant that after the deadline date, CASA will not issue any airworthiness certificates or any other approvals unless an extension of the time period is authorised by the delegate. Keep the delegate informed if such a situation becomes inevitable. 3. Extension of six-month period: An application for extension of the six-month period must take into consideration the impact the extension would have on CASA staff, resources and safety.
CASR 21.123(3)
CASR 21.123(3) allows CASA to grant an extension when there are unusual or extenuating circumstances which would preclude the establishment of an APIS within the six-month limitation. 4. Forward requests for extension, together with a detailed summary of the ESS Office inspections and assessment results during the six-month period to the delegate.
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Failure to Establish APIS: When an applicant fails to establish an APIS by the end of the six-month period (except as otherwise extended as above), CASA will no longer make conformity determinations. Discontinue all inspections. Do not issue airworthiness certifications and approvals. Provided that manpower resources allow, CASA may continue to counsel and advise the applicant to the extent necessary to assist in obtaining an APIS as soon as practicable. Notifying the Applicant Project Officer 1. On completion of the preliminary audit, formally notify the applicant of any corrective actions needed. Further advise the applicant that these items only represent CASA’s preliminary findings and that additional requests for corrective actions can be anticipated as a result of subsequent findings by the APIS Board, future routine audits and surveillance activities.
■ 2.1.4
APIS Board
Conduct of the APIS Board and Records of Its Findings The APIS Board is conducted in a manner similar to a PCB, including the use of a Chairperson. The PCB procedures in 1.6.1 Production Certification Board (PCB) should be followed, as appropriate, by the Project Officer. Also, the APIS Board findings should be documented in the same manner as the findings of a PCB, as applicable to the particular situation. Preparation and Delivery of the APIS Approval Letter Project Officer CASR Part 21
When the APIS Board has determined and documented that the manufacturer's complete production inspection system complies with CASR Part 21, prepare a letter of approval for the signature of the delegate. (A sample letter is provided in section 5.9.) Note: When an APIS is based on a licensing agreement for a specific period of time, the same period of time must be indicated on the APIS approval letter as a limitation to the approval. ESS Administration Officer 1. Forward the APIS approval letter to the applicant and retain a copy in the ESS file.
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Revision of an APIS Approval Letter If, subsequent to the issue of the original letter, the manufacturer applies to add another type-certificated product or a new model to the manufacturer's APIS, the ESS Manager or team leader must appoint a Project Officer to evaluate any required changes to the APIS resulting from new technology change to the facilities and staff. Project Officer 1. If the change is considered to be significant, you may re-convene the APIS Board to make the determination, and process the application in accordance with this section. 2. If an APIS Board is not required, a Project Officer may carry out an assessment, issue the revised APIS approval letter and request the manufacturer to return the original approval letter to the ESS Office ESS Admin Officer 1. Mark the returned APIS approval letter "superseded" and retain it in the ESS Office files.
■ 2.1.5
TC Holder's/TC Licensee's Responsibility under CASR Part 21, Subpart F
CASR Part 21, Subpart F, 21.130.
Manufacturers producing aircraft, aircraft engines or propellers under a Type Certificate Only (CASR Part 21, Subpart F) are required to submit to CASA a Statement of Conformity (Form 724) for each completed aircraft, aircraft engine or propeller. The Statement of Conformity is required before aircraft produced only under a Type Certificate can be issued with a Certificate of Airworthiness or, in the case of engines and propellers, before an Authorised Release Certificate can be issued. The Statement of Conformity submitted by the manufacturer is a certification that the product conforms to its type design and is in a condition for safe operation. See form 724, the Statement of Conformity required by CASR 21.130.
CASR 21.125
Subsequent to the issue of an APIS, the TC holder/licensee is additionally responsible for maintaining the APIS in accordance with CASR 21.125 to ensure that each product conforms to the type design and is in a condition for safe operation. The manufacturer must also comply with any terms or conditions as prescribed in the APIS approval letter.
CASR 21.003
A TC holder/licensee is responsible for reporting any failures, malfunctions, and defects as required by CASR 21.003.
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Note: The manufacturer must report to CASA for serious occurrences as listed in CASR 21.003 (4) that have occurred.
CASR 21.003
The manufacturer does not need to report to CASA for things as listed in CASR 21.003 (4) that might occur unless the product is outside the manufacturer’s control. Normal manufacturing problems can be fixed and not reported to CASA if the product has not left the manufacturer’s control or can be readily retrieved. The manufacturer does not have to report to CASA on an occurrence that is of a kind listed in CASR 21.003 (5) (21.10 refers) ie, improper maintenance or usage, or has already been reported.
CASR Part 21, Subparts F and Q.
Products manufactured under the provisions of CASR Part 21, Subpart F, must be marked in accordance with the requirements of CASR Part 21 Subpart Q.
Testing (aircraft, engines, propellers). CASR Part 21, Subpart F, 21.127, 21.128, 21.129
Each person who produces a completed product (except rocket engines) under CASR Part 21, Subpart F, must flight test and/or functional test that product. ●
●
Aircraft: Each aircraft produced under CASR Part 21, Subpart F, both prior to and subsequent to the issue of an APIS, must be flight-tested by a CASA approved flight test pilot in accordance with an approved production flight test procedure and flight checklist as required by CASR 21.127. Engines and Propellers: Each engine or propeller produced under CASR Part 21, Subpart F, both prior to and subsequent to the issue of an APIS, must be subjected to an acceptable test run or functional test in accordance with the requirements of regulations 21.128 or 21.129, as appropriate.
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2.1.6
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APIS Holder’s Facility Location An APIS holder's manufacturing complex may consist of a principal facility and associate facilities using the same quality system approved by CASA for the particular type certificated product(s). The APIS is issued to the principal manufacturing facility that controls the quality of the product(s) for which the approval was granted. The principal facility and associate facility addresses are listed on the APIS. A post office box address is not acceptable for a facility because the actual location must be identified. However, post office boxes may be used as postal addresses for correspondence. When CASA surveillance is required at an associate facility located outside the geographical area of the ESS Office controlling the APIS, the ESS Manager may arrange for surveillance in accordance with the procedures contained in the Surveillance Procedures Manual. When an APIS holder moves the principal manufacturing facility to a new location the APIS is no longer effective. When the APIS holder moves an associate facility or adds a new plant, the ESS Office must be notified of the changes. Before the new plant or moved facility is approved for production it must be subjected to a satisfactory audit or be assessed by an APIS Board if the change is significant. The APIS must be amended to reflect this change.
■ 2.1.7
Assessment of an Applicant’s Suppliers See 3.2 Assessment of an Applicant’s Suppliers for supplier evaluation procedures.
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Production Approval Procedures Manual 2. Assessment and Issue of Approvals 2.2 Production Certificate (PC) Approved by Executive Manager, Aviation Safety Standards 2.2
Production Certificate (PC)
2.2.1
Applicability – Production Certificate
Version 2.0: August 2004
CASR Part 21, Subpart G
This section provides guidance on the assessment and issue of a Production Certificate (PC) when an applicant complies with CASR Part 21 Subpart G.
AC 21.14
Additional guidance is contained in AC 21.14.
CASR 21.135,
The following persons may be issued with a PC when CASA finds, after examination of supporting data, inspection of the organisation and production facilities, that the applicant has complied with CASR 21.135:
21.021 21.029
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The holder/licensee of a CASR 21.021/21.029 TC
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The holder/licensee of a Supplementary Type Certificate (STC)
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The holder of a PC who wishes to apply for an STC, may include the production approval for the STC on the PLR. Note: STC holders who only desire to produce the modification parts/kit should apply for an Australian Parts Manufacturer Approval (APMA).
CASR 21.025, 21.031 CASR 21.133 (2B)
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The holder/licensee of a CASR 21.025 TC, when the TC issue was based on submission by the TC applicant and CASA approval of the type design data required by CASR 21.031 The holder of a PC issued for the fabrication of components specific to a particular aircraft undergoing maintenance in accordance with CASR 21.133 (2B).
A PC may not be issued to: CASR 21.027, Part 21, Subpart C
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The holder of a TC issued under CASR 21.027, or CASR Part 21, Subpart C (provisional TC) An organisation whose manufacturing facilities are located outside Australian territory, unless it has been determined that such location(s) would place no undue burden on CASA.
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Production Approval Procedures Manual 2. Assessment and Issue of Approvals 2.2 Production Certificate (PC) Approved by Executive Manager, Aviation Safety Standards
2.2.2
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PCs Issued for Fabrication In The Course of Maintenance
CASR 21.133
This procedure has been introduced to assist industry in obtaining aeronautical products, required as part of the maintenance of an aircraft, from other organisations qualified to fabricate those products. Thus, Fabrication in the Course of Maintenance (FITCOM) is facilitated by utilising the facilities and expertise of suitably approved manufacturing organisations. A PC for this purpose may be issued under CASR 21.133(2B). The approval is limited to the fabrication of components for supply to a maintenance organisation, the owner of an aircraft or the operator of an aircraft for the installation in or on an aircraft, engine or propeller in the course of maintenance activities.
CASR 21.133
A PC issued under CASR 21.133 (2B) can be issued in accordance with the procedures in this manual, with the following limitation entered on the PLR in the Limitations section: “Limited to the fabrication and supply of parts to be consumed in the course of maintenance for the supply to: ❍
A maintenance organisation
❍
An owner/operator of the aircraft or component”
The requirements on the fabricator are the same as those requirements for any PC, other than an MRB process is not permitted. All parts fabricated must conform to the approved data and be in a condition for safe operation. CASR 21.151
The PLR may include generic instructions eg for cables and hoses, by material specification, length and fittings. The PAH is expected to receive an application to fabricate each part, identifying the aircraft in which the part will be installed. Note that CASR 21.151 (c) requires the PLR to have a description of each product to be fabricated. However, note that specific replacement parts for general sale (including cables & hoses) are required to be manufactured under an APMA or ATSOA. Note: The use of CASA Form 917 Authorised Release Certificate for a one-off PC is given in 3.2.12. (Form 917 is available at http://casa.gov.au/manuals/regulate/misc/form917.pdf and can also be purchased from J.S McMillan at http://casa.jsmcmillan.com.au/He/cat.
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Responsibility for PCs ●
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The Project Officer, supported by an AWE, is responsible for managing all aspects of an application for a PC The Head of ESS is responsible for ongoing certificate management.
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2.2.4
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Advising the Applicant As part of the assessment, CASA must ensure that the PC applicant understands that the holder of a PC is responsible for: ●
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CASR 21.147
CASR 21 Subpart Q CASR 21.003
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Maintaining the quality system in accordance with the regulations, data and procedures approved for the PC Ensuring conformity with the Type Design or Product Design, as applicable, and condition for safe operation of each completed product or part Notifying CASA of any changes to the quality system in writing to the responsible CASA ESS Office that may affect the inspection, conformity, or airworthiness of the product or part—CASR 21.147 requires the holder of a PC to notify CASA immediately. These changes include: ❍ Relocation of a part of a facility or addition to existing facilities ❍ Discontinuing production for an extended period of time for other than normal reasons such as scheduled holidays ❍ Resumption of production after discontinuance ❍ Significant curtailment/resumption of production operations ❍ Significant reduction/reassignment of quality system personnel ❍ Changes or revisions to quality system data and related procedures Marking products in accordance with the requirements of the regulations (CASR 21 Subpart Q) and approved design data Reporting all failures, malfunctions, and defects as required by CASR 21.003.
Project Officer 1. Advise the applicant that: AC 21.14 CASR Part 21, Subpart G
a. AC 21.14 provides an acceptable means of compliance with CASR Part 21, Subpart G. Where an applicant proposes to use a different means of compliance to that published in the AC, the delegate will assess this and the applicant advised accordingly.
AC 21.27,
b.
The data required to be submitted is described in appendix 1 of AC 21.27.
2. A title must be provided for the quality system manual for positive identification. In addition, a revision page or similar control is required to ensure that the original approval date and the date of each revision is recorded. A number or letter, and date of the revision must identify each revision. CASR 21.143
3. Where an applicant has existing quality control procedures for other purposes, the applicant must identify those parts that comprise the quality system that show compliance with CASR 21.143.
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2.2.5 AC 21.14
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Preliminary Assessment Procedures The application Form 849 Production Approval - Application is recorded at the ESS office is accordance with local procedures. ESS Administration Officer 1. On receipt of the application, issue a letter of acknowledgment. 2. Provide an estimate of costs for assessment of the application in accordance with CASA cost-recovery procedures, advising the applicant that CASA cannot proceed with the assessment until his or her payment/acceptance, in writing, of the estimate of costs.
Preliminary Assessment Project Officer 1. Plan for the establishment of the PCB and a pre-PCB meeting with the applicant so that the meetings can proceed on payment/acceptance of the estimate of costs. 2. Before the preliminary assessment, convene a pre-PCB meeting, if necessary. 3. After acceptance of the estimate of costs make arrangements to commence the preliminary assessment. This assessment consists of an evaluation of the applicant's: ❍ Quality system data ❍ Facilities, equipment, processes, personnel, control of suppliers, stores, etc, to ensure that they are adequate for the purpose. The assessment of the quality system data may require a number of visits to the applicant’s facilities and suppliers as necessary, to evaluate and confirm that the procedures are in fact adequate to control the conformity of detail parts, subassemblies and completed products. The MI must evaluate the adequacy of the quality system by personally observing the control of each stage of production and all supporting functions. Establishing the PCB and Holding Meetings of the PCB Project Officer Establish the PCB and meet, as appropriate, in accordance with the procedures in 1.6.1 Production Certification Board (PCB) – Description.
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Notifying the Applicant On completion of the preliminary assessment, formally notify the applicant of any corrective actions needed. Further advise the applicant that these items only represent CASA’s preliminary findings and that additional requests for corrective actions can be anticipated as a result of subsequent findings of the PCB, future routine audits and surveillance activities. Issuing the PC and Production Limitation Record (PLR) The PC and PLR certificates are prepared using the CASA templates for the Production Certificate (Form 737) and the Production Limitation Record (PLR) (Form 002). (The templates are available on CASA's Intranet). PCs and PLRs are printed on the official CASA certificate quality paper No 401 CERTIFICATE PAGE 1 – LOGO & BORDER (refer to the McMillan catalogue on the CASA Intranet for supply). See sample Production Approval Templates on page 2-15 (Production Certificate) and page 2-16 (Production Limitation Record). When issued, the original PC and PLR are given to the applicant. Copies of the PC and PLR are kept on the project file and on the master folders of PCs and PLRs issued or amended. The details of the PC and PLR are entered on the PC and PLR Register held as a shared drive in the Certification Support Services (CSS) Section. Electronic copies are also held on the shared drive. ESS Office CASR Part 21
1. When the PCB has determined and documented that the manufacturer's quality system and procedures comply with CASR Part 21, prepare the PC and PLR, together with a draft letter of approval for the signature of the appropriate delegate. When preparing the PLR, list: ❍ The TC number or Design Data Reference of each product authorised for production ❍ The model numbers and the date on which production was authorised ❍ Any limitations (eg limitation to parts only). Note: When a PC is issued and based on a licensing agreement for a specific period of time, the PC must terminate on the same date. The approval letter to the applicant must refer to this date.
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Additions to the PLR If a PC holder wants to add a new TC, or a new model or new parts, the holder must apply in the same manner as for the original issue. ESS Office 1. Normally it is not necessary to establish a PCB. However, in place of the PCB, conduct an audit to the extent necessary to determine whether the quality control system is adequate or has been appropriately changed to ensure positive control of the product/parts to be added to the PLR. However, if changes to the quality control system are substantial, establish and convene a PCB to make the determination. 2. If the revisions to the PLR are to include new products/models, prepare and issue the revised PLR, together with a draft approval letter for the delegate’s signature. 3. After the PLR has been approved and signed by the delegate, forward the revised PLR to the applicant with a request to return the superseded PLR to the ESS Office. Deletions to the PLR Responsible ESS Office 1. Where production of a type-certificated product has been discontinued, and more than one TC is listed on the PLR, the following applies: a. If neither the complete product nor spare parts are being produced, delete the discontinued product or model from the PLR. b. If production of the complete product has ceased, but spare parts are still being produced, revise the PLR to reflect this: CASR 21.147
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❍
CASR Part 21, Subpart G
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Ensure that the manufacturer remains in compliance with CASR 21.147 and continue to advise CASA of any changes in the organisation, systems, procedures or processes Continue surveillance, in accordance with established procedures, of those facilities that are still active, paying particular attention to determine whether: The quality control data adequately covers the remaining procedures and processes involved The PC holder continues to comply with the requirements of CASR Part 21, Subpart G.
2. The revised PLR supersedes all previous issues of the PLR and is now the current approval for production.
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STC Modifications Incorporated by the PC Holder There are two means available: ●
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The TC holder may apply to CASA to have the STC entered on the TC. The PC holder as either the TC holder or licensee of the TC may then incorporate the STC during production; or The PC holder may apply to CASA to have the STC entered on the PLR.
The production inspection system must be revised to address the incorporation of the STC during production.
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Production Approval Procedures Manual 2. Assessment and Issue of Approvals 2.2 Production Certificate (PC) Approved by Executive Manager, Aviation Safety Standards
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Sample Production Approval Templates Sample Production Certificate
CIVIL AVIATION SAFETY REGULATIONS 1998
Production Certificate Number PC-123456 In accordance with regulation 21.134 of the Civil Aviation Safety Regulations 1998, this certificate including the associated production limitation record(s) authorises: Planemaker Aircraft Pty Ltd ABN 91 123 456 789
to manufacture Class 1 Products
at the following manufacturing facilities: 2A Industrial Place Werribee, Victoria 3030
This certificate terminates on: 15/06/2004 This certificate is subject to the condition that the holder must notify CASA in writing of any change to the business address of the holder. (signed) A. G. Citizen Date Issued:
15/06/2003
Original Issue:
22/05/2002
Delegate of CASA
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Sample Production Limitation Record
Production Limitation Record The holder of Production Certificate No. PC-123456 may produce: Aircraft and Parts
manufactured in accordance with the following design data. Design Data
Model or Parts
VA999 ASR028SY
Airhawk 132B ACME R12
Date Production Authorised 1 December 2003 12 December 2003
Conditions and Limitations: None.
(Signed) 12/12/2003
A. G. Citizen
Date Issued: (dd/mm/yyyy)
Delegate of CASA
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Sample Production Certificate for Fabrication in the Course of Maintenance
CIVIL AVIATION SAFETY REGULATIONS 1998
Production Certificate Number PC-123456-1 In accordance with regulation 21.134 of the Civil Aviation Safety Regulations 1998, this certificate including the associated production limitation record(s) authorises: Planemaker Aircraft Pty Ltd ABN 91 123 456 789
to fabricate Class III Products
at the following manufacturing facilities: 2A Industrial Place Werribee, Victoria 3030
This certificate terminates on: 15/06/2004 This certificate is subject to the condition that the holder must notify CASA in writing of any change to the business address of the holder. (signed) A. G. Citizen Date Issued:
15/06/2003
Original Issue:
22/05/2002
Delegate of CASA
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Sample Production Certificate for Fabrication in the Course of Maintenance
Production Limitation Record The holder of Production Certificate No. PC-123456-1 may produce: Class III Products
manufactured in accordance with the following design data. Design Data Design data approved by CASA or a CASR 201.001 Authorised Person, specific to an individual aircraft
Module or Parts Sheet metal parts as defined by the design data
Date Production Authorised 1 December 2003 12 December 2003
Conditions and Limitations: Limited to the fabrication and supply of parts to be consumed in the course of maintenance (FITCOM), for the supply to: • a maintenance organisation • an owner/operator of the aircraft.
(Signed) 12/12/2003
A. G. Citizen
Date Issued: (dd/mm/yyyy)
Delegate of CASA
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2.2.6
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Testing Aircraft, Engines and Propellers
Aircraft. CASR 21.197(1)(c)
All aircraft produced under a PC must pass an approved production flight test as part of the inspection procedure required for issue of an airworthiness certificate. A Special Flight Permit is issued to authorise production flight-testing under CASR 21.197 (1)(c).
CASR 21.325
Small aeroplanes and gliders manufactured under a PC and being exported without assembly or flight test under the provisions of CASR 21.325 are exceptions. However, in these instances the manufacturer, as a condition of the PC, must provide CASAapproved assembly and flight test procedures.
Engines and Propellers CASR 21.143(1)(c)
Engines and propellers produced under a PC must pass a production test approved as part of the quality system data required by CASR 21.143(1)(c).
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PC Holder's Location(s) A PC holder's manufacturing complex may consist of a principal facility and associate facilities using the same quality control system approved by CASA, for the particular type certificated product(s). The PC is issued to the manufacturing facility that controls the final assembly, testing and airworthiness release. The principal facility, and all associate facility addresses are listed on the PC. A post office box address is not acceptable for a facility because the actual location must be identified. However, post office boxes may be used as postal addresses for correspondence.
CASR 21.155, 21.159
A PC is not transferable—CASR 21.155. If the PC holder relocates any part of the manufacturing complex, the PC holder is required to apply for a new PC, as per CASR 21.159. A new PC under the same number will be issued to reflect the change.
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2.2.8
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Responsibility for PC Management On receipt of an application for a PC, the ESB Manager assigns responsibility for coordinating progress of the application to a Manufacturing Inspector (MI). The assigned MI is responsible for: ●
Coordinating any PCB activities and chairing the PCB meetings during the evaluation phases of the application
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Carrying out the preliminary assessment of the quality system data and facilities
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Assessing the inspection/quality system for manufacturing and special processes
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Assessing the applicant’s quality system for compliance with regulatory provisions
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Approval of quality system data and review of all changes to the quality system that may affect the inspection, conformity or airworthiness of the product Conducting conformity inspections on prototype and production products and parts, as necessary Providing guidance and assistance to the PC holder as necessary. Investigating non-conformities, rejected products and Materials Review Board (MRB) activities Ensuring that appropriate corrective actions are taken for all unsatisfactory conditions reported, such as non-conformance notices issued during the company’s internal audits Monitoring the PC holder's supplier facilities, and conducting audits at those facilities as necessary to ensure conformity of the TC product Issuing airworthiness and export approvals as necessary Advising the assigned AWE whenever technical data is found to be inadequate for producing duplicates—eg, material/process specifications not listed or inadequate; drawings and drawing lists not approved etc.
■ 2.2.9
Assessment of an Applicant’s Suppliers See 3.2 Assessment of an Applicant’s Suppliers for supplier evaluation procedures.
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2.2.10 Summary of Distribution of Production Certification Documents The Project Officer is to distribute the PC documents as indicated below. Application for PC, CASA Form 849 ●
Original retained by the ESS Office, together with: ❍ Copies of the applicant’s legal identity ❍ Licensing agreement(s) ❍ Documented quality control system when approved.
Prepared PC, PLR and Draft Letter of Approval ●
The ESS Office prepares these documents after the satisfactory completion of the assessment, completion and acceptance of the PCB findings, and approval of the quality system data. The Project Officer forwards the documents to the delegate.
Approved PC, PLR and Draft Letter of Approval The delegate when satisfied signs and forwards: ●
The originals to the applicant
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Copies to the Project Officer for filing.
Request for Amendment to the Production Certificate CASR 21.153
The applicant is to submit the Production Approval Application form (Form 849). An ESS Project Officer will assess the application for amendment in accordance with these procedures for revised PC and for its compliance with CASR 21.153. The PC and PLR will be re-issued to reflect the amendment.
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Production Approval Procedures Manual 2. Assessment and Issue of Approvals 2.3 Australian Parts Manufacturer Approval Approved by Executive Manager, Aviation Safety Standards 2.3
Australian Parts Manufacturer Approval
2.3.1
Applicability of Australian Parts Manufacturer Approval
CASR Part 21, Subpart K, 21.303
Version 2.0: August 2004
This section covers the assessment and issue of an Australian Parts Manufacturer Approval (APMA) for replacement and modification parts for installation on a type certificated product, in accordance with CASR Part 21, Subpart K, regulation 21.303. Note: AN APMA is not issued for production of parts for installation on non-type certificated aircraft or products. The section provides guidance for CASA to be satisfied that the applicant has shown compliance with airworthiness requirements on the basis of tests and computations, or in certain cases, on the basis of identicality.
CASR 21.303
CASR 21.303 requires that any person producing replacement or modification parts for sale for installation on a type-certificated product must obtain an APMA. An APMA must be obtained for replacement or modification parts for an STC if they are not being produced under a PC. CASA does not approve manufacturing inspection procedures, materials or special processes such as heat treatment, plating, shot peening etc. If such processes are required in the manufacture of parts, the APMA approved data will specify the requirement. Note: The part or parts for a STC, which carry or carries a one-time only limitation, may be manufactured under maintenance approval for the one aircraft involved.
CASR 21.303(2)(e)
Note:
Standard parts conforming to an established industry or Australian specification—eg, AN bolts and nuts are not eligible for an APMA (CASR 21.303(2)(e)).
Imported Products CASR 21.502, 21.502A
If, in producing a part under an APMA, imported parts are to be used, they must be imported parts in accordance with CASR 21.502 and 21.502A.
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2.3.2
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Responsibility for Australian Parts Manufacturer Approval
Applicant The applicant must show that the design meets the applicable airworthiness standards. The applicant shows compliance in two ways: ●
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The applicant demonstrates that the design of the part is identical to the design of a part covered under a TC or STC; or The applicant demonstrates through tests and/or computations that the design of the part meets the airworthiness requirements applicable to the product on which the part is installed. The applicant must assure that no interference with mating or adjacent hardware occurs and that the part performs its intended function.
Applicants intending to demonstrate that the design is identical must produce evidence of any licensing agreement held with original equipment manufacturer or STC holder. The applicant must establish and maintain a Fabrication Inspection System (FIS) that meets the requirements of CASR 21.303(11).
CASR 21.303(11),
Assigned Engineer and Manufacturing Inspector CASR 21.303 (3)
The assigned AWE assesses the design data, any test reports and computations for compliance with the applicable airworthiness requirements – CASR 21.303 (3).
CASR 21.303
The MI assesses the APMA applicant’s facilities, process, documentation and fabrication inspection system for compliance with the airworthiness requirements – CASR 21.303.
■ 2.3.3
Lodgement of an Application for an APMA Applicants should be advised to submit an application for an APMA in a letter complete with Form 849 Production Approval – Application to the Manager, ESS.
CASR 21.303
The suggested format of the application and a list of required attachments are shown in 5.1 Sample APMA Application Letter in Chapter 5 Sample Letters. The applicant must comply with CASR 21.303. Note: The applicant must have produced conforming parts in support of the application. A non-conformed proof-of-concept part is not a basis for CASA assessment and subsequent approval.
Initial Assessment The AWE and MI should jointly assess the application. If the application or Form 849 does not contain all the relevant information the ESS Office will advise the applicant.
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2.3.4
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CASA Engineering Assessment
Design Assessment 1. Ensure that the applicant’s engineering design data package meets the applicable airworthiness design standards and complies with the relevant certification regulations. This may require the AWE to refer aspects of the design package to other engineering specialists. CASR 21.303(c) 21.303 4)
2. Design data as defined in CASR 21.303(c) that has been approved by an Authorised Person for CASR 21.303(4) is to be reviewed at the discretion of the AWE, commensurate with the knowledge and experience that /casa has of the Authorised Person. 3. Determine whether the application for the APMA establishes that the part meets the relevant airworthiness requirements applicable to the type certificated product on which the part is to be installed. Also verify the eligibility for installation of the part on the type-certificated product. 4. If the applicant's design does not meet all the above design considerations, advise the applicant accordingly. Do not process application any further. A revised application may be required to resolve outstanding issues. Note: The Issue Paper process as described in the Type Certification Procedures Manual may be used for documenting items requiring further discussion.
Compliance Considerations Applicant The applicant must submit: AC 21.16
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A Compliance Statement listing the applicable regulatory requirement (refer AC 21.16)
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The means or documents showing compliance
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A 'yes' or 'no' compliance statement.
Assigned Engineer 1. Irrespective of the method by which an applicant chooses to show compliance as listed on the Compliance Statement, prior to issuing APMA approval, carefully review the application, in coordination with the MI, as appropriate, to determine whether the applicant can ensure: a. Compliance with the applicable airworthiness requirements. b. That materials conform to the specifications in the design. c. That the part conforms to the drawings in the design.
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d. That the applicant has demonstrated that the fabrication processes, construction and assembly conform to those specified in the applicant's design (CASR 21.303 (8)(d) refers).
CASR 21.303 (8)(d) CASR 21.865
e. That part marking requirements are satisfactory and in accordance with CASR 21.865.
CASR 21.003
f.
Continued airworthiness under the applicable airworthiness requirements, including reporting requirements under CASR 21.003, for the manufactured part and the product upon which the part is installed.
Verification of Installation Eligibility Project Officer The applicant’s claim of installation eligibility must be verified. This may be one or more of the following: ●
Licensing agreement with TC or STC holder
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TC Data Sheet
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Training notes
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Maintenance manuals
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Service Bulletins
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Technical Publications
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Flight Manuals
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Airworthiness Directives
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Illustrated Parts Catalogues (IPCs).
While some of these sources may not be NAA approved, they may be used carefully in conjunction with other data to provide verification. Service History Considerations Project Officer 1. Consider the service history of the part in question and verify that it is not the subject of an Airworthiness Directive (AD), other continued airworthiness problems, or subject to an incident/accident investigation.
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2. If the part is subject to one of the above, and the design is identical to the original part and produced under a licensing agreement, use the following guidelines: a. If there is an AD that removes the original part from service, immediately or in the future, the APMA application should be rejected unless the application includes design changes that satisfactorily address the AD problem. b. Consult with the Section Head, Airframes or Systems Section to ascertain whether CASA is currently developing or considering development of an AD to remove the original part from service. CASR 21.303(4)(a)
c. If CASA and/or ATSB are investigating an incident/accident where the original part may be causal, CASA may delay or suspend the processing of the APMA application until the part is cleared. (Refer CASR 21.303(4)(a).) d. If an AD calls for repetitive inspections but prescribes no terminating corrective action—eg, no modification or replacement of the part provided—and if the repetitive inspections are intended to catch failures that may occur before the part reaches the published service life, CASA should reject the application for an identical part APMA. CASA should always strive for terminating corrective action; an APMA to produce and distribute identical parts only complicates and prolongs the problem. If the part is subject to Service Difficulty Reports and CASA is pursuing corrective action with the TC holder, the application for APMA should be rejected. In these cases an improved replacement part should be sought. e. The fact that the TC holder issues an Alert Service Bulletin (ASB) to remove a part from service does not, in itself, exclude issue of an APMA.
Life-limited Parts Irrespective of the method under which an applicant seeks an APMA, the applicant must establish the life limit of that part. The required substantiating data must include tests on components produced by the applicant. Special Considerations – Identicality Engineering design data can be accepted for approval when the applicant shows, and CASA finds, that the design of the part for which the APMA is requested is identical in dimension, tolerances, materials, processes, and specifications to the design of the part covered under a TC or STC. Some part designs may contain features that may have nothing to do with form, fit, or function or being airworthy. Some of these features may include tooling holes, colour, tighter tolerances, location/type of part marking, etc. It may not be necessary that these features be identical, however these will require engineering assessment and acceptance.
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Engineering Review of Data Package Review the data package as necessary with Engineering specialists in conjunction with CASA type certification personnel to determine whether manufacturing processes specified in the design data are appropriate and acceptable. For critical parts, coordination with CASA technical specialists is required. Reverse Engineering The process of reverse engineering is one way to develop the design of a part. However, reverse engineering will not produce a design that is identical to a type certificated part. While an applicant could establish the use of identical materials and dimensions, it is most unlikely that a showing could be made that the tolerances, processes, and manufacturing specifications are identical. The Test and Computation method is the only practical means of demonstrating compliance with the applicable regulations. Rejecting an Application CASR 21.002B
CASR 21.002B refers. Project Officer CASA in general does not have access to the commercial in confidence original certified data in order to make a determination of identicality. Therefore, in practice, identicality can only be established for parts manufactured to design data supplied under licensing agreement with a TC or STC holder. 1. When the design data submitted is based on showing identicality (including the manufacturing processes) and the data does not show that the part is identical to a part covered under a TC, return the application to the applicant with a notification that it does not show the applicant's part to be identical. See 5.6 Sample CASA APMA Design Rejection Letter.
CASR 21.303(8)
Note: An APMA may be granted if the applicant resubmits and shows, on the basis of Test and Computations, that the part meets all applicable airworthiness requirements in accordance with CASR 21.303(8).
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2. You may also require that the applicant submit inspection and test reports to substantiate that the design and manufacturing data will produce a part that meets the airworthiness requirements and is safe for installation on applicable type-certificated products. If you determine that the airworthiness of a part cannot be assured solely by the showing of equivalence to the design covered under a TC or the design cannot be shown to comply with the original TC design standard, also send the applicant a letter of design rejection. See 5.6 Sample CASA APMA Design Rejection Letter. Tests and Computations Considerations for the Project Officer 1. Review and evaluate the test schedule submitted prior to any CASA test to determine if it is appropriate for the part. 2. Ensure the part conforms to the design data and/or the test proposal before testing. 3. For critical parts, coordination with technical specialists may be required. Evaluate the Data Package 1. Evaluate each applicant's capabilities to reproduce a part on a case-by-case basis. 2. Coordinate with the appropriate MI to assure that the manufacturing process produces replacement and modification parts according to the approved design. All applications should include: ❍ Detailed design criteria, including drawings, technical data necessary to establish structural strength, part marking information, and process specifications necessary to define the configuration. CAR 35, 36
❍
❍
For engineering design modifications approved under CAR 35, the depth of assessment may be varied at the discretion of the engineer. Other data necessary to establish the pertinent characteristics of the part. The applicants must identify detail drawings as their own unless evidence of a licensing agreement is submitted. In evaluating any data package, consider the following: ❍ Manufacturing and Process Specifications: Manufacturing procedures and process specifications may affect the airworthiness of the part. If the applicant's detail drawings reference the TC holder's process specifications, those specifications must be submitted. As the data package is reviewed, coordination with the CASA type certification personnel may be necessary to determine what effect these specifications may have on the airworthiness of the design or to a finding of identicality (see Special Considerations – Identicality). For critical parts, coordination with the relevant specialist is required.
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Master Control Drawings: Master control drawings or their equivalent must be carefully evaluated to determine whether the applicant has appropriate control over the configuration and manufacture of the part. The applicant must submit all applicable detail drawings and specifications for acceptable evaluation of the sources listed on master control drawings. The applicant must have satisfactory and verifiable control procedures included in the Fabrication Inspection System (FIS) for vendor supplied items prior to the issue of the APMA. Drawing Notes: The Project Officer, with particular reference to any drawing notes or process specifications identified on the drawing, should check the applicant’s ability to produce conforming parts before issuing APMA approval.
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Manufacturing Inspector Assessment The following procedures are performed when the MI receives a copy of the APMA application letter and the relevant FIS data from the Project Officer. See 5.1 Sample APMA Application Letter.
Fabrication Inspection System MI CASR 21.303(11) AC 21.27
1. Ensure that the APMA applicant has advised CASA that the Fabrication Inspection System required by CASR 21.303(11) has been established and is ready for assessment. If part production is under a license agreement, CASA is to receive a copy of the licensing agreement and to sight the original. The data from the design/production holder should be nominated and confirmed as controlled data. 2. Carry out an assessment of the FIS in accordance with 3.1 Assessment of Quality Systems for Manufacture and 3.2 Assessment of an Applicant's Suppliers. 3. When these data have been found to be acceptable, notify the Project Officer in writing.
CASR 21 Subpart Q
4. Ensure the FIS includes procedures for the marking of parts in accordance with CASR 21 Subpart Q requirements.
Facilities Inspection MI 1. Conduct an evaluation of the applicant's facility, including any supplier's facilities as appropriate, to determine whether the facilities are suitable for manufacturing the nominated parts and that the applicant's FIS is operating effectively. CASR 21.303(5)
This evaluation, in accordance with CASR 21.303(5), should be coordinated with the Project Officer.
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Validation of the Applicant’s Conformity Inspection MI CASR 21.303(8)
1. Conduct validation conformity checks, as necessary, to ensure conformity of the parts to the approved design drawings and data as undertaken in accordance with the applicant's FIS in compliance with CASR 21.303(8). Validation conformity checks include incoming materials and processes used in producing the conformed part. Parts inspected for conformity are to be recorded on the Conformity Inspection Record (Form 882), together with comments regarding identified non-conformities. 2. An agreement must be reached with the applicant as to how the identified nonconformities will be addressed and, if necessary, the FIS re-presented to CASA
Manufacturing Procedures MI CASR 21.303(8) 21.303(11)
When satisfied that the manufacturing facilities, procedures and processes and inspection system comply with CASR 21.303(8) and (11), complete the relevant section of Form 883 Production Approval Assessment Control Document.
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APMA Approval
Design Acceptance/Approval Project Officer 1. Confirm design compliance. 2. Confirm with the MI that satisfactory manufacturing processes, material control and FIS have been assessed and are acceptable. 3. Ensure that a master drawing list or similar has been prepared and dated at the revision level. 4. Ensure that all drawings and data required are listed. Make sure that a copy of the submitted data package is retained on the project files.
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Final APMA Approval Project Officer CASR 21.303
1. Draft an APMA approval letter (pursuant to CASR 21.303) together with an APMA Supplement for approval for the appropriate delegate’s signature. Ensure that both the letter of approval and Supplement document are identified with the same APMA approval number. See: ❍ 5.2 Sample CASA APMA Approval Letter ❍ 5.3 Sample CASA APMA Supplement without Licensing Agreement ❍ 5.4 Sample CASA APMA Supplement with Licensing Agreement. Note: Form 1142 is used for portrait APMA Supplement and Form 1143 is used for landscape APMA Supplement. (Forms available to CASA staff only.) 2. Finalise costing charges by CASA in accordance with CASA’s cost-recovery procedures. 3. Forward all relevant documents to the delegate 4. Forward the original documents to the applicant and retain copies on file. 5. Advise the ESS Administration Officer of the approval details for entry onto the database of production approvals, and for inclusion in the ESS audit program.
Assessment of Data An assigned Airworthiness Engineer (Project Officer) will carry out the assessment of the application, together with an MI if necessary, in a similar manner to the APMA procedures for parts approval. Approval Processing and final approval of an application for a material or process will be similar to the procedure for APMA approval described in this section. A letter of approval shall be issued in a similar manner to that of an APMA. Design Changes CASR 21.303 (3)(c)
CASR 21.303 (3)(c) refers.
AC 21.16 7.1(a)
Design changes to the part for an APMA granted on the basis of identicality and under a licensing agreement with the TC or STC holder may be carried out as minor modifications to the part under the APMA, provided that TC or STC holder agreement has been obtained. Refer AC 21.16 7.1(a).
CASR 21.303 (4)
For an APMA based on test and computation, all the design changes must be submitted to CASA or an Authorised Person for CASR 21.303 (4) for assessment.
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Changes to an Existing APMA The MI should conduct or arrange for an evaluation, as appropriate, when additional parts are approved to an original APMA approval or when the manufacturer makes changes to the FIS or relocates a facility. Advice to CASA of Changes to a FIS or Location CASR 21.303 (4)
A Production Approval Holder (PAH) is required to notify CASA within 10 days of any change to the manufacturing facility (CASR 21.303 (13)), and within 2 days of any change to the FIS (CASR 21.303(13A)), however, the MI response to that advice may differ in each situation.
CASR 21.303(12)
On advice that a facility has been expanded or relocated, the MI is to determine the likely airworthiness impact. If the same procedures are still applied, and a satisfactory first article conformity inspection is conducted and documented, then it may be sufficient to file the notification and use the advice to focus the next audit to the changed areas. If the PAH does not conduct a satisfactory first article conformity inspection after the facility is expanded or relocated, the MI is to advise the PAH that the APMA is no longer in force (ie, suspended) (CASR 21.303(12)) until this is achieved or the facility is re-evaluated by the MI with the intent of re-issuing the APMA or authorising continued production. If the PAH has changed the FIS without prior advice to CASA, the inspection process may not ensure conformity, and the MI needs to evaluate the APMA. When issuing an APMA the applicant should be encouraged to include suitable procedures in the procedures manual for having changes to the FIS approved by CASA before implementation so the approved system can be maintained. If conformity is affected, the APMA holder is required to quarantine production until the change is approved.
APMA Data Package AC 21.16
The recommended content of an applicant’s data package is given in AC 21.16. Provision of this information will assist assessment of the application.
Statement of Conformity The use of CASA Form 724 Statement of Conformity by the applicant is recommended for first article Statement of Conformity. Use of the form prompts for the information required to process the application. APMA Letter of Approval A template for the APMA Letter of Approval is provided (Form 1202, accessible by CASA staff via CASAconnect).
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Production Approval Procedures Manual 2. Assessment and Issue of Approvals 2.4 Australian Technical Standard Order Authorisation (ATSOA) Approved by Executive Manager, Aviation Safety Standards 2.4
Australian Technical Standard Order Authorisation (ATSOA)
2.4.1
Applicability – ATSOA
Version 2.0: August 2004
An ATSOA is a CASA design and production authorisation, issued to a specific manufacturer of an article which has been found to meet or exceed a specific Australian Technical Standard Order (ATSO) performance standard, or other performance standard accepted by CASA. CASR Part 21 Subpart O
An ATSOA must be obtained by persons who want to manufacture ATSO articles under CASR Part 21, Subpart O, Australian Technical Standard Order System. An ATSOA holder is a manufacturer who controls the design and quality of an article produced under the ATSO system, including all related parts, processes or services obtained from an outside source. The ATSOA system does not apply to parts produced under an APMA, TC only, or a PC. A letter of ATSO design approval for an appliance may be issued to foreign manufacturers located in countries with which Australia has an agreement which provides for the acceptance of appliances, provided that: ●
●
The NAA of the country in which the appliance will be manufactured certifies to CASA that the design of the particular appliance meets the pertinent design requirements of the specific ATSO The NAA is advised that each appliance that is produced under the provisions of the ATSO design approval and exported to Australia must be accompanied by an airworthiness approval issued by the NAA of the foreign country certifying that the article conforms with the appropriate ATSO and is in a condition for safe operation.
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Advising the Applicant
Project Officer 1. Advise the applicant that: AC 21.27
a. AC 21.27 contains guidance on what is an acceptable quality system. b. An ATSOA consists of the design and production approval. c. An ATSOA can only be obtained for the current ATSO for the particular article.
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Lodgement of an Application The applicant (or the applicant’s authorised agent) must submit an application for an ATSOA to the Manager, Engineering Support Branch. See 5.7 Sample ATSO Authorisation Application and Statement of Conformance.
CASR 21.605
The application must be accompanied by those documents required by CASR 21.605, and any documents required by the performance standard.
CASR 21.617
Foreign manufacturers who want to obtain a letter of ATSO design approval, (as provided for in CASR 21.617) must submit their application through their NAA to the Head of Airworthiness Standards, Civil Aviation Safety Authority, GPO Box 2005, Canberra, ACT 2601, Australia.
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ATSOA Issue Procedure
Design Approval Administration Officer 1. On receipt of the application, forward it to the ESS Team Leader at the appropriate geographical location. Project Officer CASR 21.605
1. On receipt of the application, check all incoming material to determine that documents and all data conform to the requirements of CASR 21.605. 2. If the data are incomplete, advise the applicant by letter that no further work will be done until the missing data are supplied.
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Assessment of Design Data Project Officer CAR 35
The design and production approval must be carried out by CASA. Data submitted with a CAR 35 Authorised Person’s approval still needs to be assessed by the CASA Project Officer. 1. Examine the technical data to ascertain that the technical requirements of the ATSO are met. The examination should include: ❍ A check of the adequacy and validity of technical data and test results
CASR Part 21.605
❍
Drawings and prescribed equipment installation information, and specified limitations should be checked for completeness and adequacy since such data are important to evaluation of aircraft type designs as well as for determination of the ability of the applicant to produce duplicate articles per CASR 21.605(4).
2. Notify the applicant in writing of any omissions. 3. Visit the applicant’s facility for the purpose of appraising the applicant’s competence to certify conformance with the ATSO. This visit should be in company with the assigned MI responsible for production approval compliance who should determine that compliance tests, as prescribed, are being realistically conducted. 4. When the authorisation is granted, add ATSOA holders to the engineering Surveillance Procedures Manual (SPM) audit pan to verify holders continue to comply with the performance standards of the ATSO. Quality System Data Compliance CASR 21.143, 21.144
The applicant for an ATSOA must submit, along with the application, a written description of the quality system in the detail specified in CASR 21.143 and 21.144. The quality system data compliance is determined in the following manner: Project Officer 1. Request an ESS MI to carry out a thorough evaluation of the quality system data submitted by the applicant. 2. If the MI advises of any quality system deficiencies, ensure all unsatisfactory conditions are addressed.
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MI CASR 21.143 AC 21-27(0)
AC 21-27
CASR 21.605
1. Carry out the procedures detailed in 3.1 Assessment of an Applicant’s Quality Systems for Manufacture, to determine compliance with CASR 21.143 and 21.144. The quality system data must include an acceptable test procedure meeting the ATSO requirement to which each production article will be tested. Guidance on an acceptable quality system is in AC 21-27 Manufacturing Approval Overview. 2. Advise the Project Officer as to whether or not these data comply with CASR 21.605. 3. In those instances when the quality system is found to be unsatisfactory, note the deficiencies on the Form 883 Production Approval Assessment Control Document and advise the applicant.
CASR 21.605
4. When satisfied that the data is in compliance with CASR 21.605, notify the Project Officer.
Issue of the ATSOA Project Officer 1. When satisfied that both the design approval aspects and quality control data aspects are compliant, forward a recommendation for the issue of an ATSOA to the Head of Certification Support Services Section through the ESS Manager. 2. Advise the ESS Administration Officer of the approval details for entry onto the database of production approvals, and for inclusion in the ESS audit program 3. Normally a separate letter of ATSOA approval will be issued for each article complying with the performance standard. Post-issue Compliance CASR 21.143 CASR 21.144
Subsequent revisions to the quality system must be submitted by the ATSOA holder to the responsible ESS Office to determine compliance with CASR 21.143 and 21.144.
CASR 21.143 CASR 21.144
The assigned MI is to advise the ATSOA holder as to whether or not the revisions comply with CASR 21.143 and 21.144.
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ATSOA Holder's Facility Location An ATSOA holder's manufacturing complex may consist of a principal facility and associate facilities using the same quality control system approved by CASA. The ATSOA is issued to the principal manufacturing facility which controls the design and quality of the product(s) for which the approval was granted. The principal facility, and all associate facility addresses are listed on the ATSOA. A post office box address is not acceptable for a facility because the actual location must be identified. However, post office boxes may be used as postal addresses for correspondence. If an ATSOA holder moves a manufacturing facility to a new location, CASA must conduct an assessment at the new location to ensure that the ATSOA holder continues to comply with CASR 21.605 and 21.607.
CASR 21.605, 21.607
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Approval of Materials and Processes
Introduction CASR Subpart K
CASR 1998, Subpart K also provides for approval of the use of materials and processes.
CASR 21.305
Under the provisions of CASR 21.305, the use of a particular material or process may be approved:
CASR 21.502 CASR 21.305
●
If it is included as part of an APMA or ATSOA
●
In conjunction with type certification for an aircraft engine or propeller
●
If it meets the requirements of CASR 21.502 (1) (a) and (b) for imported materials
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In any other manner approved by CASA.
Application CASR 21.305
Applicants seeking CASA specific approval of the use of a material or process under CASR 21.305 (e), should be advised to lodge their application by letter to the Manager, ESS. This letter of application should include details regarding: ●
●
●
The identity of the type certificated product or part on which the material or process will be utilised The name and address of the material manufacturing or process application facility Material or process specification details, including test reports showing the material’s physical and chemical properties
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Reports and computations necessary to show that the use of the material or process is compatible with, and does not in any way compromise, the design of the type certificated product or part on which it is utilised
The applicant may be required: ●
●
To carry out any other tests considered necessary to verify material or process specifications To carry out appropriate tests to show the effect of the material or process in service.
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Production Approval Procedures Manual 3. Assessment of an Applicant's Quality Systems for Manufacture 3.1 General Principles Approved by Executive Manager, Aviation Safety Standards Version 2.0: August 2004 3.
Assessment of an Applicant's Quality Systems for Manufacture
3.1
General Principles
3.1.1
General Principles
CASR Part 21, Subparts F, G, K or O
The purpose of this part is to assist in assessing quality systems of applicants seeking production approvals under CASR Part 21, Subparts F, G, K or O (APIS, PC, APMA, ATSOA). Not all the functions/elements specified in this part are necessarily applicable to every applicant's system, and the assessing MI/AWE before undertaking this assessment should, therefore, ensure a good understanding of the applicant's organisation and the extent of the manufacturing work to be undertaken. All aspects of the intended manufacturing activity must be clearly and adequately specified in the applicant's quality system.
Assessment Stages Assessment of any quality system is normally a three-stage process. Stage 1 Quality System Assessment—Desk-top Review Conduct a "desk top" review of the applicant's system to ensure that all the required procedures are included and adequately address the regulatory requirements. Stage 2 Quality System Assessment—Quality System Evaluation Evaluate the system at the manufacturing facility or facilities to ensure that the procedures have been documented, implemented and effectively control the work. Stage 3 Quality System Assessment—Manufacturer's Corrective Action The manufacturer rectifies any noted deficiencies and discrepancies by amending documented procedures or correcting discrepancies at the manufacturing facility or facilities. Quality Systems Documentation All production approval applicants are required to establish and maintain a quality system. It follows that the documented system must contain adequate procedures for the maintenance of the approved system. The documented system should identify the person who is responsible for CASA liaison, and will approve and implement quality system changes within the entity. For APMA and APIS formal CASA approval of a proposed quality system change is necessary before the change is implemented.
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Quality systems for PC and ATSOA applicants are required to comply with CASR 21.143 and 21.144. The quality system must be documented in a manual, and must include procedures for the following functions.
CASR 21.143, 21.144
1. Organisation Structure, Authority and Responsibility of Appointed Persons. 2. Technical Data Control. 3. Manufacturing Processes. 4. Special Processes. 5. Non-destructive Inspection. 6. Tool and Gauge Control. 7. Receiving Inspection/Supplier Control. 8. Inspection and Testing. 9. Material Review Procedure (Except for a CASR Part 21.133(2B) PC). 10. Stores Control. 11. Certification and Release. 12. Service Difficulty Reporting and Control. CAR 1998 21.123(1), 21.303(11)
The requirements for an APIS and APMA quality (fabrication inspection) system must also address items (1) to (12) above. The regulations covering APIS and APMA do not contain a specific requirement for the applicant's organisational structure to be included. However, CAR 1998 21.123 (1)(c) and 21.303 (11) require the applicant to establish and maintain a system which ensures that each completed product or part conforms to its design and is safe for operation or installation. To satisfy this requirement the applicant's organisational structure must also be included in such quality systems.
Establishment of Evaluation Teams The Project Officer shall coordinate with the appropriate ESS Team Leader to conduct an evaluation of an applicant's quality system. When the application is for manufacture of aircraft, the flight test personnel from Airworthiness Standards Branch are required to evaluate the relevant sections of the data and approve the production flight test schedule.
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Assessment of an Applicant’s Suppliers
3.2.1
Assessment of an Applicant’s Suppliers
Preliminary and Ongoing Audits of the Supplier’s Facilities CASR Part 21
This section provides guidelines for CASA’s assessment of an applicant’s supplier production facility to ensure that the supplier control system implemented by the Production Approval Holder (PAH) meets the intent of CASR Part 21. The PAH has initial and on-going responsibility for control of suppliers. CASA may undertake audit of the facilities.
CASR Part 21, Subparts F, G, K, and O
CASR Part 21, Subparts F, G, K, and O, require the establishment of a quality system as a prerequisite to the issue of CASA a production approval. A critical part of such a system is to establish and maintain procedures for ensuring that components and materials produced by suppliers conform to the approved design data and are in a condition for safe operation. It is the PAH's responsibility to ensure that each completed product, part or appliance, including supplied components and materials, conforms to the approved design data and is in condition for safe operation. When suppliers are located outside of Australian territory CASA may request assistance from the NAA of the foreign country to act on its behalf, to perform assessment (and audit) activities. Such assistance may come under the terms of formal state agreements, memorandums of agreement between the authorities, or requests for assistance on a case-by-case basis. A PAH may utilise any supplier as long as the PAH’s quality control system provides assurance that all parts or services, including engineering services, furnished by a supplier are in compliance with its production approval. The PAH should place special emphasis on controlling those suppliers that it authorises to deliver parts/materials directly to a user/operator of the PAH’s completed product. Each PAH must make available to CASA a list of its direct ship suppliers. The PAH should have objective evidence that the suppliers have been notified that their facilities are subject to CASA audit. Emphasis is placed on the PAH's control of its suppliers, since the PAH is totally responsible for all of its supplier-furnished parts and services. CASA may evaluate the PAH's quality system implementation at selected suppliers.
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Assessment The same procedures and criteria used to accomplish and record assessment of the PAH quality system and facilities are to be used for evaluating suppliers, even though not all elements may be applicable to individual suppliers. MIs are to exercise their judgment and experience in performing supplier assessments. These procedures and criteria are detailed in 3.3 Quality System Assessment. Note: When a supplier to multiple PAHs is evaluated, it is of the utmost importance to ensure that the quality control requirements for the applicant being currently evaluated are met by the supplier.
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Quality System Assessment
3.3.1
Stage 1 Quality System Assessment—Desk-top Review
System Data Evaluation This stage is a thorough evaluation of a manufacturer's data (including any referenced procedures, policies, standards, instructions, processes), which describes the quality system required for a particular production approval. Note: All applications to CASA for production approval, conformity inspection, certificates of airworthiness or special flight permits must be signed by a legally empowered company principal or a letter of agency must accompany each application. Data Evaluation Method 1. It is of the utmost importance that the Project Officer critically evaluates the submitted data to ensure that: a. The described quality system will adequately provide for the consistent acceptance of only those products/parts that conform with the approved design data. b. The manufactured products/parts are in a condition for safe operation. 2. The prime objective of all quality system data is to ensure that it describes the procedures that meet the intent of the pertinent regulations, and can be realistically implemented. Applicants must understand that penalties can apply to non-compliance with the approved system, therefore the system described must reflect ‘local’ operations rather than ‘generic’ procedures. 3. All data must be positively identified by title, revision, and date; and must be approved for use by an authorised management representative (often the Quality Manager). 4. The initial evaluation of a manufacturer's quality system data must be thorough and comprehensive. However, any subsequent evaluation of a particular manufacturer's data may consist of: a. A cursory review of previously submitted data to determine whether or not it has remained adequate. b. A thorough review of any data that has been revised since the last evaluation. c. A thorough review of any new data that has been developed and implemented since the last analysis—for example, review of the quality assurance provisions of a new bonding process introduced subsequent to the last analysis.
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5. When evaluating the data, inspectors should flag: a. Any ambiguous data that may be subject to misinterpretation. b. Any overly complex or cumbersome inspection procedures that may be difficult to implement, be disregarded or even circumvented. Consistency of Compliance Standards CASR Part 21
Although the CASR Part 21 production approvals require different types of production control systems, this does not mean that less stringent standards are acceptable for manufacturers of like products or parts. Notwithstanding the type of production approval held, the product or part must, when completed, conform to its approved design and be in a condition for safe operation. For example, there is no need for an APMA holder who is authorised to produce a replacement part, to have the sophisticated quality management system required of a PC holder. However, the APMA holder must have the same manufacturing and quality control procedures in place, appropriate to the production of the part in question that would be required of a PC holder producing the same part. Some variance in requirements is balanced by the extent of CASA oversight. For example, an APIS holder is normally subjected to a greater degree of CASA involvement than a PC holder since the production inspection system does not provide for the same assurance of control as that provided under a PC.
Quality System Elements The system elements detailed below are common to all production approvals, although the level of detail required to ensure control of any particular element may vary between the different types of approvals. Evaluating inspectors must be satisfied that the applicant has adequately addressed each necessary requirement and the procedures are satisfactory to ensure the product or part conforms to the approved design. The following tables include the essential elements and evaluation criteria. Note 1: In describing the quality system, references to other documents or data maintained by the applicant may be used, provided that a brief description is included in the quality system. All referenced documents must be submitted for evaluation. Note 2: In the tables the ‘Esential Elements’ define the breadth of requirements under each sub-title. The ‘Evaluation Criteria’ column briefly outlines criterion that satisfy the requirements The Essential Elements and Evaluation Criteria in the following tables are not meant to directly correlate across the table.
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1. Organisation Structure, Authority and Responsibility of Appointed Persons Essential Elements
Evaluation Criteria
1. Management has responsibility for the quality system.
1. A concise statement that describes the assigned responsibilities and delegated authority of senior management for the quality system including maintenance of the system.
2. Clearly described responsibilities for control of production and quality functions, including internal audit responsibilities.
2. (i) An organisation chart that shows the functional relationship of the QC organisation to management and to the other organisational components. 2. (ii) A concise statement that describes the authority and responsibilities of each Appointed Person, including CASA Authorised Persons, within the production and quality functions.
3. Management responsibility for training of personnel.
3. A description of the chain of authority and responsibilities within the organisation for task-specific training and maintenance of operator approvals.
4. Personnel performing critical operations, inspections, special processes etc, or certifying for inspections and/or stages of work are adequately trained and approved.
4. Procedures for incorporating changes to the quality system and outlining the authority of those authorised to make such changes.
5. Ensure that each tag, form or other document used under the approved system is described by sample in the approved manual and has instructions for correct use.
5. (i) Procedures to ensure that any change to the quality system that may affect inspection, conformity, or airworthiness of the product are forwarded immediately to CASA in writing. 5. (ii) Procedures to ensure that any change to the production location results in a first article inspection following start-up production at the new location, and advice to CASA within 10 days of the re-location.
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Essential Elements
Evaluation Criteria
6. Ensure procedures exist for keeping 6. Procedures for establishing and a technical master file and record of maintaining all controlled documents all current and superseded identified in the quality system. approved design and production system documentation to ensure the complete production history of product and parts is available. 7. Management has and applies procedures for inspection record retention compliant with the applicable regulatory provision. Record retention includes back-up and security provisions.
7. Procedures that provide for an adequate method of self-audit by the manufacturer of the entire QC system, including supplier facilities. (The prime objective of the self-audit is for the manufacturer to determine compliance with their own procedures and to ensure that management is aware of any existing system deficiencies.)
8. Ensure inspection stamps are controlled and procedures exist to cover stamp loss or absence of the stamp holder. 2. Technical Data Control Essential Elements
Evaluation Criteria
1. Technical data (drawings, specifications, software and changes thereto) must be approved only by authorised personnel.
1. Procedures for drawing, engineering and software change control including drawing and specification lists necessary to define the configuration of the CASA approved design.
2. Technical data must be approved prior 2. Procedures for informing company to release, and should contain the date inspectors of approved changes in of effectivity and the signature and engineering data, specifications and the position of the person authorised to quality system. release the data. 3. Distribution of technical data is controlled to ensure that current data is readily available to production and inspection personnel.
3. Procedures that require all process changes to be submitted to CASA for evaluation and incorporation into the approval. Process specification changes are deemed to be major changes.
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Essential Elements
Evaluation Criteria
4. Inapplicable, inappropriate, or obsolete technical data must be removed from use.
4. Procedures to ensure that major changes to the design and data are approved by CASA prior to being incorporated in the product or part.
5. Current approved technical data must be used for inspection acceptance.
5. Procedures to ensure that design changes generated as a result of Airworthiness Directives (ADs) are immediately incorporated in the design data to ensure that the design change is incorporated on production products.
6. Drawings and specifications bearing unauthorised changes or unauthorised notations must not be used for inspection acceptance purposes. 7. Ensure procedures have been properly implemented to adequately provide for immediate incorporation of design changes resulting from ADs. 8. Where appropriate, ensure procedures are applied to incorporate production changes back into the applicable Instructions for Continued Airworthiness and Flight Manual. 9. Ensure a determination of major or minor change is made and recorded for each design change. CASR Part 21 21.093 21.132A(2) 21.303 (3)(c) 21.611
Part 21.093 applies to APIS and TC designs only. Part 21.132A(2) defines Class ll and III product designs, 21.303(3)(c) defines APMA designs and 21.611 applies to ATSOA designs. Ensure procedures acceptable to CASA are applied to approve minor design changes.
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3. Manufacturing Processes Essential Elements
Evaluation Criteria
1. Production facilities should be arranged to preclude contamination of products and parts—for example, isolation of grinding, painting, or sanding areas from a critical assembly area.
1. Procedures for generating, validating and approving manufacturing and inspection function recording sheets. These should list the approved data to be used, together with methods of inspection by tooling, characteristics, and sampling quantities, and also identify the persons performing the manufacturing work, and those conducting the inspection and certification.
2. Products and parts must be properly handled and stored to prevent corrosion, damage or contamination.
2. Procedures for suitable identification and inspection marking of products and parts throughout the manufacturing cycle—that is, part number, serial number, acceptance, rejection, NDT, process and material identification.
3. Shop travellers, checklists, or similar media should be used to ensure the proper movement, handling, and storage of products and parts from one station to another through all phases of the manufacturing process.
3. A description of actions required, or a flow chart, for processing all products and parts through the manufacturing cycle.
4. Inspection records must be maintained and used as required.
4. Procedures that will provide for the selection of appropriate inspection methods and plans for each product and part to ensure that all parts will be inspected as required to eliminate discrepancies and to ensure that the end item will be in conformity to the design.
5. The degree of protection afforded by any sampling plan used should be known and the associated conditions for its satisfactory use enforced by the manufacturer.
5. Procedures for establishing and maintaining the qualifications of personnel appropriate to the various processes, tests, and inspection functions.
6. Technical data must be appropriately authorised and must reflect the proper revision for the particular manufacturing process.
6. Procedures to control material lot splitting to ensure complete accountability—that is, action to be taken when a lot or batch contains more or less pieces than recorded on the shop traveller or routing sheet.
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Evaluation Criteria
7. Inspection stations must be located at points in the manufacturing process where accurate quality determinations can be made.
7. Procedures to control the movement of products and parts throughout the manufacturing process showing production and inspection status at all times.
8. Inspection equipment being used must be adequately controlled for accuracy. 9. The facilities and equipment must be adequate for the manufacture and inspection of the products and parts. 10. Planning methods must ensure the complete inspection of the in-process product or part up to its completion. 11. Inspection sequences must be established and inspections accomplished at intervals where accurate quality determinations can be made. 12. Nonconforming products or parts thereof must be segregated and identified to preclude incorporation into the end product or part. 13. An operator verification program (production personnel performing inprocess checks) if used, should have adequate controls so that final acceptance responsibility remains with the quality control organisation. 14. The degree and timeliness of training that production personnel receive should be commensurate to the skill level necessary to perform the assigned duties. 15. The conditions in environmentally controlled areas must be established and maintained through appropriate procedures and calibrated controls.
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4. Special Processes Essential Elements
Evaluation Criteria
1. All special processes being performed should be covered by appropriate and approved specifications.
1. Procedures for the control of special process characteristics that affect safety.
2. Special process specifications should 2. Procedures that require all special contain inspection/quality assurance process changes to be submitted to criteria that will ensure that all products CASA for evaluation and approval. and parts that are processed and accepted, conform to the particular specification. 3. Current special process specifications should be readily available and be used by operator and inspection personnel.
3. Procedures for special processes to address necessary controls related to personnel qualifications, equipment, and testing methods.
4. Equipment such as tools, gauges, instruments, timers, ammeters, voltmeters, should be readily available and continuously maintained for accuracy.
4. Procedures for the inspection and quality assurance provisions of the special process specification should be approved as part of the quality system data, when applicable.
5. Processes, equipment, and operators should be qualified and approved by the manufacturer in accordance with the specification/manufacturer's procedures.
5. Procedure for the qualification of special processes and the re-testing should changes be implemented.
6. Products and parts should be properly handled throughout the area to prevent damage, contamination, rust, etc. 7. Records should be maintained to accurately reflect compliance with the special process specification requirements. 8. The degree and timeliness of training production personnel received is commensurate to the skill level necessary to perform the assigned duties.
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5. Non-destructive Inspection Essential Elements
Evaluation Criteria
1. Operators should be qualified, and approved by CASA, or by the manufacturer when authorised by CASA.
1. Procedure for training, qualification and periodic re-qualification of personnel.
2. Operators' qualifications must be kept current.
2. Procedure for periodic calibration of test equipment, and validation of processes and materials.
3. The operator must always work to the current, applicable process specifications.
3. Procedure for performance of each NDT method utilised, including use of approved data, and certification of completed NDT inspection together with a record of inspection results.
4. Equipment must be inspected and calibrated periodically to ensure accuracy. 5. Realistic acceptance criteria must be established. 6. Inspection acceptance/rejection criteria must be established to conform with the current design data. 7. Records must be maintained to accurately reflect compliance with the specification requirements.
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6. Tool and Gauge Control Essential Elements
Evaluation Criteria
1. All equipment used for inspection purposes must have the degree of accuracy necessary to determine conformity of the characteristic being inspected.
1. Procedures to ensure that calibrations are traceable to national standards recognised by NATA.
2. Tool and gauge controls should include procedures for protecting, maintaining, and updating this equipment as required, to ensure product conformity to approved design data.
2. Procedures that provide adequate instructions for the operation, inspection, and testing of all equipment and tooling used for the acceptance of dimensional characteristics.
3. The quality system should require identification, inspection acceptance and periodic reinspection of all inspection equipment.
3. Procedures that ensure adequate control of tools and gauges including initial approval and periodic inspections. The procedures should define acceptable methods of tool and gauge rework and reinspection.
4.
4. Procedures to ensure quarantine until re-calibration of tools or gauges identified as out of tolerance or of unknown calibration status.
Control of inaccurate inspection tools, gauges, instruments, and jigs, must ensure their identification and removal from use until repair, rework, or recalibration has been accomplished.
5. Calibration records must be maintained of all equipment used for inspection purposes. These records should contain the nomenclature, serial number, location, details of all repair or rework accomplished and date next inspection is due.
5. Procedures to ensure compensation factors are applied to calibrated tooling to account for environmental conditions that may affect accuracy in use.
6. Calibration intervals may be adjusted where analysis of reliable data indicates no adverse effect on safety.
6. Procedures must be established to uniquely identify and account for calibration of personally owned tools and gauges used for product acceptance.
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7. Receiving Inspection/Supplier Control Essential Elements
Evaluation Criteria
1. Any holder of a production approval 1. Procedures relative to the who has delegated inspection duties or manufacturer's periodic evaluation, relies on suppliers for controlling surveillance, and control of supplier conformity should ensure by evaluation produced raw materials, purchased and/or surveillance that those suppliers items, parts and assemblies. Purchase are continuously in compliance with his Order documents must be reviewed for approved QC system. accuracy and completeness by an appointed person. 2. Each manufacturer must make information available to CASA regarding all delegation of authority to suppliers to make major inspection of any products/parts thereof.
2. A description of any delegation of authority to suppliers to make inspections or conduct tests of products or parts on behalf of the manufacturer.
3. The manufacturer must advise CASA, in writing, of any authority granted the supplier to ship directly to the user.
3. Procedures for advising CASA of any suppliers performing inspections of products or parts that cannot or will not be completely inspected by the manufacturer.
4. The supplier control function should ensure that all material review actions and design changes taken on supplierfurnished parts and services are approved by the manufacturer, prior to use.
4. Procedures outlining inspection acceptance of raw materials, purchased items, parts and assemblies, including independent verification of material specification.
5. The manufacturer's receiving 5. Procedures to ensure that suppliers inspection function must ensure that all submit all design changes for approval supplier furnished parts/services and are provided with the latest conform to the approved design. applicable revisions to the design data.
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Essential Elements
Evaluation Criteria
6. Procedures to ensure that all incoming 6. The manufacturer's receiving inspection function must ensure that all material is supplied with appropriate documentation or details of verification incoming raw material is properly testing to be carried out. identified by batch, specification and verification test results for the batch to Shelf-life limited materials and products the specification. must have life verified to specification. Parts received under cover of an First article inspection is required on Authorised Release Certificate (ARC) parts from a new supplier. (Form 917) and marked ‘Conformity only’, a Statement of Conformity, or equivalent document from a recognised authority would be acceptable in lieu of providing verification test results. If verification test results, an ARC from a CASA approved distribution house or a ‘Statement of Conformity’ from a supplier are not provided the manufacturer must undertake verification testing to the material specifications. 7. The manufacturer's purchase order or equivalent must reflect the current design data, and the pertinent quality system requirements.
7. Procedures for ensuring inspection acceptance, identification, proper segregation, protection and issuance of product and parts in storage areas, including controls for incorporation of applicable design changes in stored items.
8. Parts that are damaged in transit or parts that are waiting certification must be properly segregated until dispositioned. 9. Supplier quality system data, procedures, certificates, reports required for CASA review must be translated to English. 10. Receiving inspection records must be generated and maintained to establish final conformity of products and parts.
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8. Inspection and Testing Essential Elements
Evaluation Criteria
1. The manufacturer must establish and comply with test procedures applicable to products or part design data.
1. Procedures to ensure that the inspection of products or parts will be performed and properly recorded at points in production where accurate quality determinations can be made.
2. For aircraft, the manufacturer must establish and ensure compliance with the approved flight test procedures and flight test check-off form.
2. Procedures to properly perform, control, record, and identify all inspection processes.
3. Test equipment must be controlled and 3. Procedures to ensure that the use of calibrated to ensure accuracy. any statistical sampling inspection plan will not result in an unsafe condition in a product or part. 4. Products and parts subjected to adjustment or rework after inspection must be retested to approved test procedures.
4. Procedures that provide adequate instructions for recording information in inspection records.
5. Where sampling inspection tests are 5. Procedures for the control, issuance, used, other inspections and tests and use of all inspection stamps, and should be implemented, as required, to other in-process marking equipment. ensure the acceptance of only those products or parts that conform to the design data and are safe for operation. 6. Records of all tests conducted must be maintained in accordance with the manufacturer's approved procedures.
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9. Material Review Procedure (Except for a 21.133(2B) PC). Note 1: The material review process is only permitted to disposition minor changes to the CASA approved design. A major change to design must be approved by CASA before formal disposition of parts through the MRB. CASR 21.133
Note 2: A 21.133 (2B) PC holder is ineligible to apply MRB processes. A disposition of ‘Scrap’ is the only available response to non-conformities unless the design data is changed and re-approved to extinguish the non-conformity. Note 3: Parts from assemblies dispositioned as ‘Scrap’ may be recovered only if the MRB determines those parts do not contain the identified non-conformances.
Essential Elements
Evaluation Criteria
1. Except for APMA and a 21.133(2B) PC 1. Procedures that require corrective a Material Review Board (MRB) must action (in-plant, at suppliers, and inbe established and must include service) where processes or procedures representatives from the Inspection result in a nonconforming product/part and Engineering departments. thereof. 2. The MRB procedures must outline the complete MRB system including requirements for obtaining CASA engineering approval on any nonconformities to the product/part thereof which constitute a major change to the approved design data, prior to final acceptance of the product or part.
2. A description of the Material Review Board System (MRB) including the procedure for recording MRB decisions and disposing of nonconforming products or parts—that is, use as is, rework, scrap, return to supplier.
3. The MRB procedures must provide controls for identification, segregation, and disposition of nonconforming products or parts.
3. Procedures for the identification and segregation of products or parts set aside for MRB review.
4. As part of the decision recording requirements the manufacturer should list the MRB members present.
4. MRB delegation procedures to a similar standard as the manufacturer when the manufacturer relies upon or delegates MRB duties to supplier facilities.
Note: ‘Use as is,’ is not an option unless the design data is changed.
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Evaluation Criteria
5. Nonconforming products/parts thereof must not be released by MRB until they have been properly dispositioned and suitable reinspection and retest procedures determined.
5. Procedures for the review of inspection and service records for evaluation and corrective action on repetitive discrepancies.
6. MRB withheld products or parts must be quarantined to prevent their unauthorised removal. 7. The MRB records must as a minimum include part number, quantity, date, adequate description of nonconformance including a determination of major or minor, disposition, and authorised MRB signatures. 8. The MRB procedures must provide a system for obtaining effective corrective action in-plant, at suppliers or in-service to prevent recurrence. The procedures must provide for monitoring corrective action response, implementation and effectiveness.
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10. Stores Control Essential Elements
Evaluation Criteria
1. The system must ensure that only conforming, accepted and identified products or parts are placed in production storage. Non-conforming items must be suitably identified and quarantined.
1. Procedures for each of the essential element items 1 to 5.
2. The system must ensure that products and parts that are subject to deterioration from prolonged storage are periodically reinspected and dispositioned and controlled.
2. Procedure for the traceability of incoming material, parts and standard parts, including their matching records and certification or specification documents.
3. The system should assure the protection from damage and deterioration of products and parts that are in process or in transit or stored.
3. Procedures to quarantine and identify non-conforming parts, parts awaiting conformity inspection or materials, including those shelf life expired, awaiting MRB disposition.
4. The system must ensure that required design changes are incorporated on products or parts in storage prior to their release. 5. The system must ensure that only those products or parts, identified as having passed company conformity inspection are issued from stores.
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11. Certification and Release Essential Elements
Evaluation Criteria
1. All engineering data used for the acceptance of the product or part must be CASA approved.
1. Procedures to identify completed products and parts.
2. The product or part must conform to the approved engineering data.
2. Procedures to ensure that all required inspections and tests are satisfactorily accomplished prior to final acceptance of the completed products or parts.
3. All required inspections and tests necessary to ensure that the end product or part conforms to the approved design data and is in a condition for safe operation must be accomplished before the product or part can be certificated as airworthy.
3. Procedures that ensure products or parts are in conformity with approved design data and are in a condition for safe operation.
4. The aircraft, engine, or propeller logbooks and records should have inspections and operating time properly recorded, signed and dated.
4. Procedures to ensure that certifications for completed work are only made by appointed or authorised personnel.
5. Each product or part must be properly identified.
5. Procedure to ensure that the final certification for completion of the manufacture of the product or part is made pursuant to the applicable CASR.
6.
A Statement of Conformity under APIS 6. Procedures to ensure that the must be properly documented, signed, Authorised Release Certificate, (ARC dated, and submitted to CASA. Form 917), or other approved document is properly completed, signed and issued by appointed personnel, and that this document provides traceability for the applicable part.
7. Applications for conformity inspection, Certificate of Airworthiness (CoA) or Special Flight Permit (SFP) issue should be properly executed, signed, and submitted to CASA, or where appropriate, an authorised person.
7. Procedures to ensure that completed aircraft, engines and propellers are released with appropriate Log Books, Instructions for Continued Airworthiness and for aircraft, a Flight Manual.
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Essential Elements
Evaluation Criteria
8. Personnel making final certifications are appointed in the quality system.
8. Procedures to ensure that all pre-CoA issue work on type certificated products is properly certified. For an aircraft, CoA issue or acceptance by CASA of a Statement of Conformity under APIS marks the end of the production cycle.
9. The system must ensure that before final release, all required ADs are incorporated or accounted for (for aircraft) that all post flight test adjustment has been certified, and the approved flight test completed.
9. Procedures for airworthiness certification of products or parts to be exported, includes appointment of personnel authorised to make such certifications.
10. Persons approving export of products or parts are identified in the quality system and are appropriately authorised. For export approval of aircraft a CASA instrument of authorisation must be held. 12. Service Difficulty Reporting and Control
CASR 21.003
Essential Elements
Evaluation Criteria
1. The system should ensure that service problems are investigated and the manufacturer takes corrective actions.
1. Procedures that define the manufacturer's responsibilities and corrective actions relative to service difficulties involving products or parts inplant, or in-service, including spares in storage or shipped to a user.
2. The system should have a means for keeping users of the product or part informed of service difficulties and resultant CASA-approved changes to the type design.
2. Procedure to ensure reporting of failures, defects and malfunctions to CASA as required by CASR 21.003.
3. The system should provide for receiving feedback on service problems from users of the product or part.
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3.3.2 CASR 21.123(1), 21.135, 21.303(5), 21.605(4)
Stage 2 Quality System Assessment – Quality System Evaluation This stage of the assessment consists of an evaluation of the quality system at the production facilities to determine that the applicant has satisfactorily implemented and is capable of maintaining the required quality system. During this stage inspect parts applicable to the application in order to assess the applicant's ability to produce conforming parts or products. CASR 21.123(1), 21.135, 21.303(5) and 21.605(4) refer.
System Assessment An adequately described system is useless if not properly implemented and maintained. The project officer must therefore ensure that the manufacturer practices rigid system discipline. CASA does not dictate to a manufacturer the specific manner in which a product will be produced. However, once a manufacturer commits to a specific system that is approved by CASA, the manufacturer is obligated to adhere to every facet of the system without deviation. Whenever a change to the system is necessary, the manufacturer must make the change in accordance with the provisions of his approved system prior to implementation. The following guidelines should be utilised during the course of evaluating a manufacturer's quality system functions: 1. Use the standards described under the Essential Elements columns in the preceding tables—as applicable—as the basis for conducting the evaluation. 2. Use the information detailed under the Evaluation Criteria columns in the preceding tables as an aid in conducting the evaluations of the applicable quality system elements. 3. Be alert to any inadequacies in the system, such as a lack of necessary instructions or procedures, or, more commonly, repetition of regulatory requirements instead of proper procedures. It is virtually impossible during the desk-top review of Section 3.2.2 to determine whether the submitted system complies with all regulatory requirements and provides the necessary safety assurances. Findings When a non-conformance to the design or design data is noted, the inspector(s) must continue with the evaluation to determine whether the condition is a symptom of a quality system deficiency or breakdown. When a quality system deficiency or breakdown is indicated, the inspector must evaluate the system to determine the cause. Necessary corrective action must be taken by the applicant to ensure the quality system remains compliant and effective. Stage 3 Quality System Assessment—Manufacturer's Corrective Action refers (see next section below).
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3.3.3
Stage 3 Quality System Assessment—Manufacturer's Corrective Action Before CASA can approve the application, the manufacturer must complete corrective action to address all deficiencies or discrepancies arising from assessment of an initial application or change to an existing system. This stage is completed when the inspector finds that the manufacturer's corrective actions and quality system amendments comply with all pertinent Part 21 requirements and conforming products or parts have been produced following the final form of the quality system submitted for approval.
■ 3.3.4
Manufacturer’s Service Documentation The PAH may need to issue Service Bulletins (SBs), Service Letters or other continuing airworthiness information. CASA only approves the relevant technical content of a Service Bulletin if a SB is required to address an Airworthiness Directive. The PAH is to submit such a proposed SB to the ESS for engineering assessment and approval of the technical content in the form of a letter to the PAH authorizing the issue of the SB by the PAH.
AC 21.095
The PAH is permitted to issue any other SBs or Service Letters etc without reference to CASA. However, changes to a design must be approved in accordance with the PAH’s Procedures Manual. For further information refer to AC 21.095 section 10.
■ 3.3.5
Service Difficulty Reports In-service Service Difficulty Reports (SDRs) received by CASA relating to production item issues will be processed in accordance with CASA’s SDR procedures, and referred to the ESS as well as technical specialists.
CAR 50
The Manufacturing Inspector is to be involved in any follow-up actions (CAR 50).
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3.3.6
Reporting of Failures, Malfunctions and Defects During Manufacture
CASR 21.003(4)
The holder does not have to report to CASA all failures, defects or malfunctions that might cause an occurrence (as listed in CASR 21.003 (4)) unless the defective part has left the holder’s control by the time the defect is discovered.
CASR 21.003(4) CASR 21.003(10)
The holder must report to CASA all failures, defects or malfunctions that have resulted in an occurrence [as listed in CASR 21.003(4)]. However, failures, malfunctions and defects caused by improper maintenance or improper usage, or which have been reported to CASA by another person, may not have to be reported to CASA by the holder. See Subregulation 21.003(10). Manufacturing errors and irregularities can be rectified. Parts found to be defective by the holder’s quality system can be repaired, scrapped or quarantined. These defects do not have to be reported to CASA if the parts have not left the holder’s control, or can be reliably retrieved.
■ 3.3.7
Manufacturer’s Maintenance Facility Which Division of CASA issues the maintenance approval is an administrative matter. If the maintenance approval is limited to maintenance of the company’s own products then provided the MI has the delegation and training, the MI may issue the approval and conduct surveillance on this restricted MMF. This would be subject to ESS resource limitations, on occasions the task would need to be delegated to Aviation Safety Compliance Division (ASCD). If the organisation intends to conduct general maintenance on other than its own products, then this is the province of the Aviation Safety Compliance Division
■ 3.3.8
Supplier Quality Control The last production quality system is that for suppliers. Suppliers may not have a CASA production approval, however, suppliers make up the bulk of the manufacturing effort in producing aircraft, aircraft engines, and propellers. Suppliers are controlled by the PAH that they work for, ie, PC, APIS, APMA and ATSOA. Suppliers are not required to have a quality manual, and have no regulatory privileges or responsibilities. However, they may not sell production parts on the open market without their own production approval.
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3.3.9
Engineering Drawings Drawings reviewed by CASA ESS engineering and used by MIs in the conduct of conformity inspections must meet a level commensurate with the minimum standards of the CASRs, which assures safety. CASA regulations require that an applicant submit sufficient drawings, special process documents, specifications and test reports to identify and substantiate the product for which CASA approval is sought. CASA ESS reviews this data for minimum compliance with the airworthiness standards. That data is then used for inspecting the product. The CASA MI utilizes the data to witness a conformity inspection of the product at the applicant’s facility, or at an agreed upon location, and reports the results of that conformity inspection to ESS engineering. Provided all of the drawing requirements have been met, the product is then tested. If the test is acceptable, the product is approved, and the applicant proceeds to manufacture the part/assembly. Once a CASA approval is issued, the drawings used to inspect the original product are considered to be the approved CASA baseline. That baseline never changes unless there is a modification to the drawings after the approval is issued. Any deviations from the drawings for a part or assembly must be documented, dispositioned, and approved in the same manner as the original drawings were. CASA will accept drawings that meet some recognised drawing standard that can produce a quality part within a minimum tolerance range when the manufactured part has been inspected and tested and has shown to meet the minimum CASR requirements.
■ 3.3.10 Use of CASA Form 917 Authorised Release Certificate CAR 42 CAAP 42W2(3)
CAR (1988) 42 WA sets out the requirement for Form 917, and CAAP 42W2(3) provides guidance as to the use of the form. Manufacturers holding a PA may sign a Form 917 to accompany a finished part. However, suppliers to the PAH can only issue some form of conformity statement with clear delivery documents. They are not entitled to issue a Form 917.
CASR 21.133(B)
For use by the holder of a PC issued for the support of a FITCOM activity in block 13 ‘Remarks,’ add the words “This ARC is issued under the provisions of CASR 21.133(B).” Additionally, a statement qualifying Block 14 is to be entered in Block 13, “This part is manufactured for certificate of Approval Holder number xxx (or owner/operator by name, as appropriate) per order number yyy.
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3.3.11 Use of CASA Form 917 for Unapproved Parts These are parts produced (and to be conformed) to certain controlled design data that has not yet been approved to be part of the Type Design, Usually, these parts are for use in a ground or flight test development or certification program, ie usually a prototype. Neither the manufacturer nor CASA can sign a release for fitment to a certificated aircraft for such a part. However, the manufacturer or CASA (if requested by a foreign NAA) can do the administrative function of signing a Form 917 limited to conformity only and referring to the particular controlled data against which the product is conformed. This fulfils the function of communication between NAAs in a standardised form.
■ 3.3.12 Export Airworthiness Approvals A person must be included in the class of persons of the appropriate CASA Instrument of Appointment, to issue a Form 917 as an Export Airworthiness Approval.
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Inspections
4.1
Conformity Inspections
4.1.1
Introduction to Conformity Inspections This Chapter provides procedures and methods to be followed by the inspector when conducting inspections to determine that parts, appliances and products (aircraft, aircraft engines, propellers or parts) conform to the approved design drawings and specifications. Conformity inspections are carried out during the certification phase in obtaining a Type Certificate (TC) or during initial production to verify that parts and products conform to design data.
■ 4.1.2
Conformity Inspections The depth of conformity inspections may vary depending on the particular manufacturer. In the case of a manufacturer with well-established policies, quality system procedures, experience, inspection personnel, equipment and facilities and who has previously demonstrated first article acceptability, the inspector may choose to reduce the depth of conformity inspection by a form of sampling inspection of the manufacturer’s product and procedures. In the case of a manufacturer whose ability is unknown—eg, during the initial production period by a manufacturer producing under a TC only—it will be necessary to conduct in-depth conformity inspections until the inspector is confident that reducing the degree of assessment will not compromise safety. The Project Officer is recommended to use CASA Form 1248 Request for Conformity Inspection as a positive means of documenting those particular inspections required.
Inspector 1. Regardless of the manufacturer’s ability, the initial parts or products inspected for conformity for issue of a production approval need to be inspected to a level which conforms all detail parts and processes specified by the design data. 2. When the degree of conformity inspection required has been determined, develop an appropriate conformity verification plan. The plan should focus on: ❍ Verifying the conformity of the critical and major characteristics of materials, parts and assemblies. ❍ Evaluating process controls to assure production of consistent and uniform products. For other than initial conformity statistical quality control methods may be utilised for process evaluation. Complete descriptions of such statistical methods should be documented. ❍ Observing tests of important functional parameters of systems, modules, components and completed products.
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3. Regardless of the manufacturer’s experience, CASA is responsible for determining that the manufacturer has carried out a complete article conformity inspection and that the results of that inspection are properly recorded, before carrying out the conformity inspection (Refer to 4.1.3). In the case of a manufacturer producing under a TC only prior to the issue of an APIS, CASA holds full responsibility for the conformity inspection 4. Record all conformity inspections conducted or tests witnessed on Form 882 CASA Conformity Inspection Record and include all discrepancies, non-conformities and corrective actions. 5. Retain these records on the applicable CASA file at the ESS Office. 6. Where design non-conformities or discrepancies are found, forward a copy of the applicable documents to the Head of ESS. 7. Address the following issues when undertaking a conformity inspection as described in sections 4.1.4 through 4.1.16 as follows: ❍ 4.1.4 Materials ❍ 4.1.5 Processes and Processing ❍ 4.1.6 Automatic Production Processes ❍ 4.1.7 Non-destructive Inspection (NDI) Method Evaluation ❍ 4.1.8 Critical and Major Characteristics ❍ 4.1.9 Workmanship ❍ 4.1.10 Adequacy of Drawings and Related Change Records ❍ 4.1.11 Adequacy of Inspection Records ❍ 4.1.12 Material Review Action ❍ 4.1.13 Software ❍ 4.1.14 Conformity Inspections of Test Articles ❍ 4.1.15 Structural Test Articles—Aircraft ❍ 4.1.16 Flight Test Articles—Aircraft ❍ 4.1.17 Endurance Test Articles—Engines and Propellers. Should discrepancies be found, you may require the manufacturer to carry out a requalification of the part/product. 8. Following any re-qualification of the manufacturer, carry out a further conformity inspection, considering the previous results as appropriate.
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First Article Inspection (Reference Standard SAE AS 9102.) The purpose of First Article Inspection (FAI) is a physical and functional inspection process commonly used to provide objective evidence that all engineering design and specification requirements are properly understood, accounted for, verified and documented. The first conforming article is intended to be a ‘standard’ that verifies conformance and one that provides a yardstick for corrective actions and problem resolution. FAI shall be performed for a new part representative of the first production run including all detail parts and sub assemblies that constitute the end item ordered. The FAI record is not complete until all non-conformities are resolved. Note: Prototype parts or parts made using different methods or processes cannot be considered part of the first production run. The FAI requirement applies even after initial production compliance and CASA approval. Depending on the degree to which characteristics are affected partial or complete accomplishment of the FAI is required for the following events: 1. A change of design affecting form, fit or function of the part. 2. A change in manufacturing source(s), processes, inspection method(s), location, tooling or materials with the potential of affecting the form, fit or function of the part. 3. When required as part of a corrective action for a part with repetitive rejection history. (Typically with three repeat rejections). 4. A change in the numerical control program or translation to another media. 5. A natural or man-made occurrence that may adversely affect the process. 6. A lapse in production of two years. All documented FAI reports are considered a quality record under the CASR record keeping requirements. Inaccessible characteristics shall be evaluated as early in the process as possible provided they are not affected by subsequent operations. Naturally, tooling used to verify a design characteristic must be qualified by FAI verification back to national standards. Where feasible, FAI measurement equipment and/or personnel shall be independent of the equipment or personnel utilized for the final product acceptance inspection. It should be noted that where FAI results are near limits of tolerances, additional parts should be inspected to verify hardware conformance.
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The FAI process for a given part initially includes identification of the original source documents and their respective revision status. Purchase orders or equivalent documents must be examined to determine the basic requirements and the validity of the data called up by the customer. Relevant drawings and specifications must be subject to source substantiation to ensure that the current complete data is available for the inspection.
4.1.4
Materials ●
●
●
●
Were raw materials used in the fabrication process in conformity with the design data? Is evidence available to assure that chemical and/or physical properties were identified and checked as appropriate? Is there documented evidence to show traceability from the raw material to the completed part? Are there any parts or process deviations recorded against the submitted design data (including material review dispositions)?
■ 4.1.5
Processes and Processing Production approval regulations require fabrication methods that consistently produce conforming parts and all methods requiring close control to attain this objective must be covered by approved process specifications. In evaluating processes, the MI is primarily concerned with performance and conformity. Process performance should be capable of consistently producing articles that meet the specified requirements. Process conformity is determined by checking the articles being processed to determine that they are being processed in accordance with the process specification and that the materials, tools, and equipment called for are being utilised. Since the end results depend on strict adherence to the process instructions, any deviation or discrepancy should be corrected on the initial runs. Product conformity is determined by inspecting the processed articles. The manufacturer should make a determination that the process operations are capable of consistently producing articles in conformity with the design requirements. The method used in determining this fact should be measurable, as required by the process specification, and recorded.
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Automatic Production Processes
Background Modern production methods involve many automatic machines such as: ●
Milling machines
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Lathes
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Work Centres
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Riveters
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Routers
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Fabric cutters
●
Lay-up placers
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Electronic component placers, etc.
Traditionally, conformity inspection has been against clearly defined Type Design (TD) data, in the form of drawings and specifications. With numeric- or computer numeric-controlled (NC or CNC) machines, traditional conformity inspections may be difficult due to the non-existence of traditional TD data. Nevertheless, conformity must be achieved. TD data that may now be in the form of Computer Aided Design (CAD) models or other computer instructions must achieve and demonstrate conformity. That is the regulatory requirement and nothing less is acceptable. Conformity is evidence that the automatic machine software is performing correctly. Conformity Inspection Requirements The CASA inspector must be satisfied that the applicant has the systems and ability to produce conforming parts. The CASA inspector should ensure that the applicant has a system in place that ensures that: ●
The approved TD data is permanently stored and available for conformity inspections. The TD may be in the form of drawings and specifications or computer generated models or instructions
●
Any software used is identifiable as to the package and the version
●
Computer programs such as CAD programs used are of proven validity
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Operators of CAD programs have demonstrated competencies in the use of the particular CAD package Computer Aided Manufacturing (CAM) programs used are of proven validity Operators of CAM programs have demonstrated competencies in the use of the particular CAM program Operators of NC or CNC machines have demonstrated competencies in the use of the machine(s) Manually-inserted CNC machine instructions are related to approved drawings Conformity is performed against the approved TD data, which may be held electronically. The conformity inspection may be in any form acceptable to CASA that achieves the result, eg; a. Comparison against drawings printed out from the relevant CAD package, or from other approved drawings or sketches. b. Use of calibrated “go” and “no go” gauges developed from the TD data, for specified dimensions. c. Use of a Computer Coordinate Measuring Machine (CCMM) for comparison with the computer-held model.
■ 4.1.7
Non-destructive Inspection (NDI) Method Evaluation The procedure for evaluating an NDI method must provide for the manufacturer to demonstrate to the MI’s satisfaction that the NDI method used has the capability to detect the allowable defect size and location specified by the engineering data, that the inspection results are repeatable, and that instruments required to perform the inspection meet the procedural acceptability requirements.
■ 4.1.8
Critical and Major Characteristics ●
●
●
●
Has the manufacturer identified and inspected all the critical and major characteristics? Does the manufacturer have a record of these inspections? Does witnessing the re-inspection and surveillance indicate that the above inspections were accurate and adequate? Are there any deviations recorded against the approved design data (including material review disposition)?
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Workmanship ●
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Does workmanship contribute to the safety of the product? Have criteria been established to identify acceptable production techniques and practices?
■ 4.1.10 Adequacy of Drawings and Related Change Records ●
●
●
●
●
●
Can the part be produced and inspected using the information on the drawing? Are drawing tolerances practicable and attainable under production conditions? What evidence supports this? Have all of the changes been correctly made to drawings submitted for CASA approval or MRB approval in the case of minor changes? What procedure is used to ensure the incorporation of an engineering change in the production part, on the relevant drawing/s and on completed parts in store? Does the drawing include all the characteristics necessary to inspect the part, the material to be used, the treatment of the material such as hardness, finish and special process specifications? Does the drawing (or associated engineering data) include applicable test specifications?
■ 4.1.11 Adequacy of Inspection Records ●
Do the inspection records show all inspections that are conducted?
●
Do they show who conducted the inspection?
●
●
Do they indicate the results of the inspection and disposition of unsatisfactory conditions? Are procedures adequate to ensure re-inspection of any parts that are reworked?
■ 4.1.12 Material Review Action ●
●
Is the material review procedure documented and adequate to ensure disposition of non-conformities? Is there adequate corrective action for observed non-conformities to prevent recurrence?
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4.1.13 Software ●
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●
●
●
●
●
Are all software products (version description document, source code, object code, documentation, test procedures, loaded hardware/firmware etc) properly identified, including revision levels, when compared to the hardware and software engineering drawings? Have all software problem reports been properly actioned? Do the records indicate that all software products, including support software and procedures, have been placed under configuration control? Have the verification and acceptance tests been successfully executed to approved test procedures and results recorded? Are there records that indicate that the object code was compiled from released source code by approved procedures? Do records indicate technical acceptance of the software prior to loading into the system or product? Are there any indications of non-compliance with the software manufacturer’s procedures?
■ 4.1.14 Conformity Inspections of Test Articles ●
●
●
Prior to initiating conformity inspection activity for test articles, it is essential that the manufacturer and the MI establish and document the parameters of the test article configuration and test equipment configuration. The conformity of the test article and test set-up such as for static, endurance, operational, pressure, environmental etc tests, should be established by an MI or AWE as appropriate to determine conformity. In all cases, the approved engineering data should include: ❍ Appropriate instructions ❍ Reference to the manufacturer’s agreed test plan. When witnessing tests, the MI should determine that the instructions and test schedule described in the agreed test plan are followed.
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4.1.15 Structural Test Articles – Aircraft CASR 21.033
CASR 21.033 requires the manufacturer to allow CASA to perform or witness conformity inspections. This includes structural tests during fabrication and assembly. The final design submitted for CASA inspection must reflect all changes that have been found necessary as a result of previous tests. CASA must ensure that such changes are incorporated into the production drawings. Only then can CASA be certain that subsequent production articles conform to the tested articles. It is strongly recommended, due to the different effects of non-conformities on structural test articles versus flight articles, that parts and assemblies destined for structural testing should be clearly identified. This should be necessary only in those cases where structural test articles are being fabricated concurrently with prototype flight articles. Once parts and assemblies have been subjected to structural testing beyond limit load they must be clearly and permanently identified to prevent their use in production.
■ 4.1.16 Flight Test Articles—Aircraft Determining conformity of flight test articles, including system checks, should begin during fabrication. It is important that flight test articles conform to the data specified in the design data on which the manufacturer’s statement of conformity is based.
4.1.17 Endurance Test Articles—Engines and Propellers In addition to conformity of production, endurance test conformity will also be required. These tests will be part of the CASA approved specifications, and the inspector should coordinate with the CASA engineers before undertaking conformity of endurance tests. CASR Part 33 Part 35 CASR 201.001
At the conclusion of the endurance test, during the teardown inspection, the MI should spot-check conformity of major and critical parts by witnessing the manufacturer’s inspections, paying particular attention to critical characteristics. Teardown inspection of test articles after endurance testing is a specific requirement of CASR Part 33 and Part 35. These activities should be witnessed by the MI, a CASA engineer or a CASR 201.001 appropriately authorised person. The manufacturer should not clean or disassemble the test article until the independent inspector is present, at which time the manufacturer’s inspection should be conducted as follows.
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Inspector 1. Verify that the manufacturer carefully notes the appearance of subassemblies during the teardown and before complete disassembly. The manufacturer should specifically note any abnormal leakage in valves, seals, fittings, etc; indication of excessive or lack of lubrication; excessive coking; metal or foreign particles in the oil screens or passages; sticking or breakage of parts; lack of freedom of moving parts; breakaway torques; and any other condition which may not be noticeable after complete disassembly and cleaning. 2. Verify that all parts are thoroughly cleaned and visually inspected for indications of galling, metal pickup, corrosion, distortion, interference between moving parts, and cracks. Highly finished surfaces should be checked for condition and any discolouration due to excessive heat and lack of lubrication. Special attention should be given to bearings, gears, and seals. Engine pistons, cylinder heads, and turbine assemblies should be carefully inspected for indications of cracking, burning or local collapse. 3. Verify that both ferrous and nonferrous stressed parts are inspected for incipient failures by suitable non-destructive testing methods such as magnetic particle inspection, x-ray, penetrant, ultrasonics, etc, in accordance with the test plan. 4. Verify that all parts subject to wear of distortion are dimensionally inspected to determine the extent of change during the test. This may be done by pre-test and post-test dimensional comparisons. The manufacturer should record the results in a suitable manner. 5. On completion of the above steps for certification of an engine or propeller, the manufacturer’s inspection report, verified by the independent inspector, is submitted to the Section Head, Certification Support Services Section. This report should contain the results of the inspection, giving a comprehensive description of all defects, failures, wear or other unsatisfactory conditions including photographs as required. Since the report is used for evaluation, its importance cannot be overemphasised. 6. Ensure that non-conforming parts are identified and retained by the manufacturer in safe storage for review by CASA.
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Final Inspection and Flight Test
4.2.1
Applicability — Final Inspection and Production Flight Test
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The basic purpose of the ground inspection is to physically determine that the aircraft readied for flight test: ●
Conforms with the technical data
●
Is safe for the flight tests intended.
The results should be recorded for the project file, together with any other data requested by CASA engineering and flight test personnel. The ground inspection is normally a progressive inspection of parts and assemblies culminating in the aircraft being finally readied for its initial test flight.
■ 4.2.2
Preliminary Ground Inspection Preliminary ground inspection includes all inspections of the first production unit that can be performed satisfactorily in the course of construction.
Manufacturing Inspector 1. Require the manufacturer to notify the MI whenever changes are made to components, systems, or installations previously cleared. 2. Witness such re-inspection as necessary.
■ 4.2.3
Final Ground Inspection The final ground inspection is the final inspection of the complete aircraft and should be performed just prior to first production flight test. Detailed procedures for conducting inspections and test for the assembled product should be included in the approved production procedures. They should also be coordinated by the manufacturer to preclude unnecessary delays and duplication of effort and to assure that all required inspections and tests are properly accomplished before flight.
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Inspector Notify CASA flight test personnel when the initial flight test phase is to commence. Make sure that flight test personnel have sufficient time to prepare for the flight test program. The manufacturer should provide all necessary assistance, equipment, and data essential for the flight test. Flight Test and Manufacturing Inspector 1. Carry out the inspection: ❍ Witness the operation of all ground operable systems by the manufacturer’s personnel. ❍ Witness the weighing of the aircraft and verify scale accuracy. ❍ Verify equipment installed, including test equipment, during each flight test to determine flight loadings. ❍ Verify the weight and balance report, showing the actual empty weight centre of gravity together with the list of equipment installed. Retain a copy of these records and make sure flight test personnel have a copy. ❍ If necessary during this phase, verify weights and moment arms of equipment items. 2. Determine what other inspections remain, such as instrument markings, placards, unusable fuel, etc. These inspections must be completed prior to issue of the Statement of Conformity by the manufacturer.
■ 4.2.4
Flight Inspection
Manufacturing Inspector 1. Establish with the Flight Test Pilot a mutually agreeable system for informing the Manager, Engineering Support Section of changes to the aircraft and any problems encountered during flight test. Cooperation with the Flight Test Pilot is crucial to the safe and professional completion of the flight-testing. 2. Prior to the flight test, determine that the manufacturer carries out the various loading conditions specified by the flight test specialist. This includes a determination that the ballast used is accurately weighed, located, and safely secured.
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3. Throughout the flight test program, determine that the manufacturer has a plan to ensure that the aircraft is adequately inspected to reveal any unsafe conditions that may develop and to require their correction prior to further flight tests. The frequency and extent of such checks should be coordinated with CASA. Participate in the checks whenever practicable to determine compliance. The MI and the flight test specialist should have a system of informing each other of changes made to the aircraft and problems encountered during any flight test. Flight Test Pilot The Flight Test Pilot is not to fly a test aircraft without coordinating with the Project Officer or Head of Engineering Support Section to be assured that the aircraft is released for flight. The final acceptance of the test aircraft as it relates to the operation of the aircraft and the integrity of the test is the responsibility of the CASA Flight Test Pilot. Instruments, gauges, recording devices, etc., which are used in the official flight test for flight, should be in current calibration by a qualified agency and calibration reports furnished. The Flight Test Pilot is to be given copies of the reports prior to flight.
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Production Approval Procedures Manual 5. Sample Letters 5.1 Sample APMA Application Letter Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Contents of this Chapter This chapter includes the following sample letters: 5.1
Sample APMA Application Letter
5.2
Sample CASA APMA Approval Letter
5.3
Sample CASA APMA Supplement without Licensing Agreement 5.3.1
5.4
Sample CASA APMA Supplement (Design Approval) Test and Computation
Sample CASA APMA Supplement with Licensing Agreement 5.4.1
Sample CASA APMA Supplement (Design Approval) Identicality
5.5
Sample Australian Parts Manufacturing Approval Supplement
5.6
Sample CASA APMA Design Rejection Letter
5.7
Sample ATSO Authorisation Application and Statement of Conformance
5.8
Sample ATSO Authorisation
5.9
Sample APIS Approval Letter.
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Production Approval Procedures Manual 5. Sample Letters 5.1 Sample APMA Application Letter Approved by Executive Manager, Aviation Safety Standards 5. 5.1
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Sample Letters Sample APMA Application Letter
Senior Manufacturing Inspector Engineering Support Section CASA (See Address of nearest CASA Manufacturing Office below) Dear Sir, Request for Australian Parts Manufacturer Approval Applicant:
THOMAS MANUFACTURING P/L 12 Aviation Street, TULLAMARINE, VIC 3043
Manufacturing Facility Address: As Above Contact Person: John Thomas, Managing Director Telephone (03) 1234 1234 Part for which APMA is requested: Part Description: Spring Part P/N: THOMAS 7654321 For Installation on: General Aircraft Models T210, 315, 327 and Jonkers 234 Replacement for Original Part P/N: Bendix BS 89 Design Data: Drawing No 7654321 Licence Agreement: Nil (See enclosed documentation for application design data and manufacturing procedures.) The following are enclosed: ❍ Two copies of the spring drawing No 7654321 ❍ One copy of the procurement Bill of Material ❍ One copy of heat treatment process specifications ❍ One copy of technical justification supporting a finding of test and computation and other supporting documentation. ❍ A compliance statement for design and manufacturing against the regulatory requirements. ❍ A statement that Thomas Manufacturing P/L has established the Fabrication Inspection System in compliance with CASR 21.303(11). ❍ CASA form 849 Application for a Production Approval and CASA form 724 Statement of Conformity ❍ One conforming ‘first article’ spring. It is our understanding that if the APMA is granted, one copy of the drawing (stamped approved) will be returned to Thomas Manufacturing P/L and that this approved drawing is to be kept on file at the Thomas Manufacturing P/L manufacturing facility. I look forward to a positive CASA response to this application. Yours faithfully,
John Thomas 5 August 1999 CASA Manufacturing Office Postal Addresses Melbourne Sydney Brisbane
PO Box 558 Collins St. West, Vic. 8007 PO Box CP57 Condell Park, NSW 2200 39 Navigator Place, HENDRA QLD. 4011
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Sample CASA APMA Approval Letter
File Ref:04/9999-1 ARN: 123456 CIVIL AVIATION SAFETY AUTHORITY AUSTRALIAN PARTS MANUFACTURING APPROVAL APMA No: APMA-123456 Mr John Thomas Managing Director Thomas Manufacturing P/L 12 Aviation Street TULLAMARINE VIC. 3043 Dear Mr Thomas, I refer to your APMA application to CASA dated 5 August 1999. In accordance with the provisions of CASR 21.303, CASA has found the drawings, specifications and processes submitted as design data by Thomas Manufacturing P/L (the Manufacturer) on 5 August 1999 meet the airworthiness requirements of the Civil Aviation Safety Regulations (1998) applicable to the products on which the part(s) is to be installed. That design data is hereby approved. CASA has determined that the Manufacturer has established the documented Fabrication Inspection System required by CASR 21.303(11). The documented system is identified as Revision 2, dated 30 July 1999 of the Thomas Manufacturing P/L Quality System Manual. The Manufacturer must maintain the documented system in continuous compliance with the requirements of CASR 21.303(11). The attached Supplement defines the extent of approval given under this APMA and is to be read in conjunction with this approval. Manufacture in accordance with the established Fabrication Inspection System, and the attached Supplement, is approved at the following locations: 12 Aviation Street TULLAMARINE VIC 3043. In accordance with CASR 21.303(9), this APMA is granted to the Manufacturer to produce the part(s) listed in the attached Supplement in conformity with the CASA approved design. This APMA is not transferable and, unless suspended, continues in force until cancelled. Subject to due process, CASA may suspend or cancel this APMA by written notice if the holder ceases to comply with the relevant parts of CASR Part 21. This APMA is issued subject to the following conditions: 1. The Manufacturer must produce all parts in accordance with the documented (Manufacturer’s name) … quality system manual, Revision …, dated ……….., the approved system, or later CASA approved revision. 2. The Manufacturer’s Fabrication Inspection System, methods, and procedures documented in the approved quality system manual, together with the Manufacturer’s facilities, are subject to CASA audit or investigation. As CASA does not separately approve suppliers, the Manufacturer must advise any suppliers or contractors that their facilities and processes are also subject to CASA audit in assuring the Manufacturer’s system is being properly maintained. 3. The design and process data listed on the attached Supplement is approved data. This data is not to be altered unless permitted and approved by CASA.
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4. Changes to the Fabrication Inspection System that may affect inspection or conformity to the design data or airworthiness of the part are considered major changes to the APMA. CASA must be advised in writing of the changes within 2 days of implementation. 5. Relocation, or expansion of the manufacturing facilities to include new facilities, must be notified to CASA in writing within 10 days of the date the relocation or expansion takes place. 6. Parts produced under this approval must be permanently marked with APMA identification in the detail required by CASR 21.865. If an APMA is granted for an assembly, detail parts of the assembly sold separately must also be marked in accordance with the requirements of CASR 21 Subpart Q. 7. CASR 21.003 requires the Manufacturer to report to CASA information in the detail and to the timeframe required by CASR 21.003, all defects, failures, and malfunctions in any parts produced, or in processes approved under this APMA. 8. In addition to Item 7 above, the Manufacturer must report to CASA in a timely manner, all information concerning service difficulties on any part produced under this approval. 9. The Manufacturer must make available to CASA, on request, information concerning suppliers who furnish parts or services including; a) a description of the part/s including part name, and part number, b) where and by whom the part or service will be inspected, c) any delegation of inspection functions to the supplier, d) any delegation of material review functions to the supplier, e) name and title of the company contact at the supplier facility, f) inspection procedures required to be implemented by the supplier g) results of the manufacturers internal evaluation, audit and surveillance of suppliers, h) related purchase and work orders i) feedback relative to service difficulties originating from the manufacturer’s suppliers. 10. Parts, appliances or services furnished by any suppliers located in a foreign country may not be used in the production of any part listed in the enclosed APMA Supplement unless: a) That part or service can and will be completely inspected for conformity at the Manufacturer’s Australian facility; or b) CASA has determined that the supplier’s location places no undue burden upon CASA in administering the applicable airworthiness requirements; or c) The parts/services furnished by the foreign supplier are produced under the ‘components’ provisions of an Australian Bilateral Airworthiness Agreement or Bilateral Aviation Safety Agreement, and approved for import to Australia in accordance with CASR 21.502. 11. All technical data required by CASR 21.303(3)(c) for the parts to be produced under this approval, must be readily available to CASA at the facility at which the parts are being produced. 12. CASA must be notified within 10 days if the Manufacturer’s address shown in this approval changes. Yours sincerely, {Signed} Delegate of CASA
Date of original issue: 30 September 1999
Attachment: APMA Supplement
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5.3
Sample CASA APMA Supplement without Licensing Agreement
5.3.1
Sample CASA APMA Supplement (Design Approval) Test and Computation
Australian Parts Manufacturing Approval Supplement No. 001 Australian Parts Manufacturing Approval No. APMA-123456 Dated: 30 September 1999 To:
Thomas Manufacturing P/L 12 Aviation Street, TULLAMARINE, VICTORIA 3043
APMA Replacement Part: Part Name: For Installation on: Part P/N: Replacement for Part P/N: Design Data: Approval Means: Licence Agreement:
Spring General Aircraft Models THOMAS 7654321 Bendix BS 89 Drawing No 7654321 Rev 1 Test and Computation Nil
APMA Supplement Revision: 0
Yours faithfully, {Signed} Delegate of the Civil Aviation Safety Authority.
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5.4
Sample CASA APMA Supplement with Licensing Agreement
5.4.1
Sample CASA APMA Supplement (Design Approval) Identicality
APMA Production Approval Supplement No. 001 Australian Parts Manufacturing Approval No. APMA-654321 Dated: 14 December 1998 To:
Thomas Aircraft Interiors, Inc., 12 Aviation Street, TULLAMARINE, VICTORIA 3043
APMA Replacement Part: Part Name: For Installation on: Eligibility: Part P/N: Replacement for original P/N: Design Data: Design Approved: Approval Means: Licensing Agreement:
Galley ACE Aircraft Model 700 ACE Aircraft Model 700, S/N 123 and up S101001-101 S101001-301 101001-101 101001-301 Interior Inc STC, drawings per licensing agreement Interior Inc. FAA STC No xxxx Identicality License agreement between Thomas Aircraft Interiors and Interiors Inc. Refer Thomas File No 04/8888 FAA STC No. NN12345 Holder : Interiors Inc. 12 Main Street, Los Angeles Airport, CA 900012, USA
APMA Supplement Rev 1 Yours faithfully, {Signed} Delegate of the Civil Aviation Safety Authority.
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Sample Australian Parts Manufacturing Approval Supplement
AUSTRALIAN PARTS MANUFACTURING APPROVAL SUPPLEMENT Manufacturer Thomas Manufacturing Pty Ltd 12 Aviation St Tullamarine Victoria 3045 Approved Location(s) 747 Mackay Ave. Bowenmango QLD. 4108
Part Name
Approved Replacement Part Number for Part Number(s)
Battery Kit 1
A123
Battery Kit 2
A125
Spacer Block
A126-1
Battery Tray
A126-2
L/H Support Bracket
A126-3
See STC NN555
APMA No:
APMA-599999
Supplement No:
001
ARN:
599999
Date:
30 September 2004
Approval Basis Approved Design/Process Data
Make Eligibility
Model Eligibility
Identicality per STC NN555
Anstrom
Unitsia 204 Series
A126-4
End of Listing
(Signed) Delegate of the Civil Aviation Safety Authority.
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Production Approval Procedures Manual 5. Sample Letters 5.6 Sample CASA APMA Design Rejection Letter Approved by Executive Manager, Aviation Safety Standards 5.6
Version 2.0: August 2004
Sample CASA APMA Design Rejection Letter
To:
Thomas Aircraft Interiors, Inc., 12 Aviation Street, TULLAMARINE, VICTORIA 3043
14 December 1998 I refer to your APMA application dated 01 November 1998 CASA has reviewed the data you submitted. CASA does not find that compliance with the regulatory requirements for APMA has been demonstrated. Non-compliance in relation to CASR 21.303(3) was found in the following areas: The design data was not found to be compliant with the corresponding end product Type Certificate design standard. or for ‘Identicality’, The design data was not found to be identical with the corresponding replacement part data. The data you submitted is enclosed. Yours faithfully, {Signed} Delegate of the Civil Aviation Safety Authority.
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5-8
Production Approval Procedures Manual 5. Sample Letters 5.7 Sample ATSO Authorisation Application and Statement of Conformance Approved by Executive Manager, Aviation Safety Standards 5.7
Version 2.0: August 2004
Sample ATSO Authorisation Application and Statement of Conformance
{Date} Head of CASA Engineering Support Section
Dear Sir, Subject: ATSO {title of ASTO} for
{model or part number}-( ) Series I am applying for issue of an Australian Technical Standard Order Authorisation (ATSOA). I certify that the article(s) listed below by model, type and part number {use applicable designation} has (have) been tested and meet(s) the performance standards of {ATSO number}. In addition, the applicable provisions of CASR Part 21 have been met. {Model, type or part number} Example:
Model ________-( ) Series.
The technical data required by the ATSO are enclosed. The quality control data required by CASR 21.605(2)(c) are enclosed. CASA form 724 Statement of Conformity is enclosed.
Yours faithfully,
{Signed}
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Production Approval Procedures Manual 5. Sample Letters 5.8 Sample ATSO Authorisation Approved by Executive Manager, Aviation Safety Standards 5.8
Version 2.0: August 2004
Sample ATSO Authorisation
Ref: 04/12345 Avia Belts Pty. Ltd. PO Box 578910 Numpytown Qld 4896 For Attention: Mr D Samuelson Subject: Avia Belt Restraint Harness Technical Standard Order C114 Dear Sir, This Letter of Approval refers to your application, dated 01 May, 2003, requesting an Australian Technical Standards Order Authorisation (ATSOA) for your restraint harness Part Number ABPL 5-A1. Based on the data presented and your statement certifying that the article meets in full the minimum performance standards of TSO C114 as applicable, and the requirements of Civil Aviation Safety Regulations Part 21, Subpart O, authorisation is granted. Effective from the date of this authorisation you are authorised to manufacture the restraint harness P/N ABPL 5-A1 and mark the articles with the identification marks required in CASR 21.607(c) and, if applicable, any additional marking requirement. All ATSO articles must be manufactured at the authorised location in accordance with the Avia Belts Pty. Ltd. ATSOA Quality Assurance and Procedures Manual, Initial Issue dated 27 July, 2003 or later CASA-approved revision. Revisions must be passed to CASA for review before implementation. Your production authorisation methods, and procedures documented in the approved quality system manual, together with the manufacturing facilities, are subject to CASA audit or investigation. As CASA does not separately approve suppliers, you should advise any suppliers or contractors that their facilities and processes are also subject to CASA audit in assuring CASA your system is being properly maintained. The authorised design data may be changed, however the requirements of CASR 21.611 apply. Minor design changes must be forwarded to CASA at intervals not exceeding six months. Major design changes require a new ATSOA application to CASA. You are required to report to CASA information in the detail and to the timeframe required by CASR 21.003, all defects, failures and malfunctions in any parts produced, or in processes authorised under this ATSOA. Reports are to be forwarded to your CASA controlling office. The production location is identified as: 9 Markus Street, Numptytown QLD 4896
! 5-10
Production Approval Procedures Manual 5. Sample Letters 5.8 Sample ATSO Authorisation Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
This authorisation is not transferable to another location or person and continues in force until it is surrendered, suspended or cancelled. Subject to due process, CASA may suspend or cancel this ATSOA by written notice if the holder ceases to comply with the relevant parts of CASR Part 21. Parts, appliances or services furnished by any suppliers located in a foreign country may not be used in the production of any ATSOA article unless: a)
That part or service can and will be completely inspected for conformity at the authorised manufacturer’s Australian facility; or
b)
CASA has determined that the supplier’s location places no undue burden upon CASA in administering the applicable airworthiness requirements; or
c)
The parts/services furnished by the foreign supplier are produced under the provisions of an Australian Bilateral Airworthiness Agreement or Bilateral Aviation Safety Agreement, and approved for import to Australia in accordance with CASR 21.502.
Should you cease to manufacture the subject ATSO article, you are required to send to CASA copies of the complete and current technical data file for the article including design drawings and specifications in accordance with CASR 21.613(1)(a). This ATSOA is a design and manufacturing authorisation, not an installation approval. Therefore, to address end user/installer responsibilities and in accordance with the applicable TSO requirements, the following text must be supplied with each article: “The conditions and tests required for ATSO approval of this article are minimum performance standards. It is the responsibility of each person intending to install the article on or within an aircraft to determine that the conditions in which the article will be installed are not more onerous than those specified in the ATSO. The article may only be installed in accordance with installation data approved by CASA or an appropriately authorised person.” Yours faithfully,
Delegate of the
Date issued: ………………..
Civil Aviation Safety Authority
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Production Approval Procedures Manual 5. Sample Letters 5.9 Sample APIS Approval Letter Approved by Executive Manager, Aviation Safety Standards 5.9
Version 2.0: August 2004
Sample APIS Approval Letter
Ref: 04/12345 Avia Belts Pty. Ltd. PO Box 578910 Numpytown Qld 4896 Dear , Production Inspection System Approval Your production inspection system established and maintained at {facility address} has been evaluated and found to be in compliance with CASR 21.125. You are now authorised to produce the following Aircraft/Engines/Propellers and their associated parts in compliance with the requirements contained in CASR Part 21, Subpart F, and in conformity with the type design data forming the basis for the following type certificate(s): Type Certificate
Make
Model
Subject to due process, CASA may cancel this approval by written notice if the holder ceases to comply with the relevant parts of CASR Part 21. 1.
The Manufacturer must manufacture all products and parts in accordance with the documented …(Manufacturer’s name) … Approved Production Inspection System manual, Revision …, dated ……….., or later CASA approved revision.
2.
The Manufacturer’s Production Inspection System, together with the Manufacturer’s facilities, are subject to CASA audit or investigation. As CASA does not separately approve suppliers, the Manufacturer must advise any suppliers or contractors that their facilities and processes are also subject to CASA audit in assuring the Manufacturer’s system is being properly maintained.
3.
Changes to the Approved Production Inspection System that affect inspection or conformity to the design data are considered major changes. CASA must be advised in writing of the changes within 2 days of implementation. Product or parts produced between the time the change is implemented and CASA evaluation of the change must be quarantined until released by CASA.
4.
Relocation, or expansion of the manufacturing facilities to include new facilities, must be notified to CASA in writing within 10 days of the date the relocation or expansion takes place. Product or parts produced between the dates the relocation or expansion takes place and CASA evaluation of the changes effected in the manufacturing facility, must be quarantined until released by CASA.
5.
Products and parts produced under this approval must be permanently marked with identification in the detail required by CASR Part 21, Subpart Q.
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Production Approval Procedures Manual 5. Sample Letters 5.9 Sample APIS Approval Letter Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
6.
CASR 21.003 requires the Manufacturer to report to CASA information in the detail and to the timeframe required by CASR 21.003, all defects, failures, and malfunctions in any parts produced, or in processes approved under this approval.
7.
The Manufacturer must make available to CASA, on request, information concerning suppliers who furnish parts or services including; a.
a description of the part/s including part name, and part number,
b.
where and by whom the part or service will be inspected,
c.
any delegation of inspection functions to the supplier,
d.
any delegation of material review functions to the supplier,
e.
name and title of the company contact at the supplier facility,
f.
inspection procedures required to be implemented by the supplier
g.
results of the manufacturer’s internal evaluation, audit and surveillance of suppliers,
h.
related purchase and work orders
i.
feedback relative to service difficulties originating from the manufacturer’s suppliers.
8.
Parts, appliances or services furnished by any suppliers located in a foreign country may not be used in the production of any product under this approval unless: a.
That part or service can and will be completely inspected for conformity at the Manufacturer’s Australian facility; or
b.
CASA has determined that the supplier’s location places no undue burden upon CASA in administering the applicable airworthiness requirements; or
c.
The parts/services furnished by the foreign supplier are produced under the ‘components’ provisions of an Australian Bilateral Airworthiness Agreement or Bilateral Aviation Safety Agreement, and approved for import to Australia in accordance with CASR 21.502.
9.
All technical data required for the parts to be produced under this approval, must be readily available to CASA at the facility at which the parts are being produced. CASR 21.123(1)(b)
10.
CASA must be notified within 10 days if the Manufacturer’s address shown in this approval changes.
Yours faithfully, {Signed} Delegate of CASA
Date issued: ………………..
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Production Approval Procedures Manual 5. Sample Letters 5.9 Sample APIS Approval Letter Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Blank page
5-14
Production Approval Procedures Manual 6. Definitions Approved by Executive Manager, Aviation Safety Standards 6.
Version 2.0: August 2004
Definitions
Term
Definition
AC
Advisory Circular
Act
Civil Aviation Act 1988 as amended
Aeronautical Product
Any part, apparatus, appurtenance, accessory, instrument, mechanism, equipment (including communication equipment), or material that is used, or intended for use, in an aircraft.
APIS
Approved Production Inspection System
APMA
Australian Parts Manufacturer Approval. It is a design and production approval document issued to the applicant by CASA. This would normally be accompanied by an APMA Supplement, which specifies the limit of design and production approval.
Appliance
Any instrument, mechanism, equipment, part, apparatus, appurtenance, or accessary, including communication equipment that is used or intended to be used in operating or controlling an aircraft in flight, is installed in or attached to the aircraft and is not part of an airframe, engine or propeller.
Applicant
Person who applies to engage in an activity for which a Production Approval is required.
ARN
Aviation Reference Number – a unique number issued by CASA to an industry participant.
Article
A part or component manufactured under an ATSOA for use on type certificated products.
Associate Facility
A facility that has been approved as an addition to an original production approval. The address must be listed in the PLR or APMA Appendix.
ATSO
Australian Technical Standard Order: the minimum performance standard for specified articles.
ATSOA
Australian Technical Standard Order Authorisation is a CASA design and production authorisation issued to a specific manufacturer of an article which has been found to meet or exceed a specific Australian Technical Standard Order (ATSO) performance standard. The ATSOA does not confer installation authority. The installation of the article must be separately approved as part of the type design of a type certificated product.
Authorised Person
A person authorised under an Instrument of Authorisation to exercise a power in a specific provision of CASR or CAR where the term ‘authorised person’ appears. The authorisation is specific to the legislative provision.
AWE
Airworthiness Engineer
MI
Manufacturing Inspector
! 6-1
Production Approval Procedures Manual 6. Definitions Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Term
Definition
BAA
Bilateral Airworthiness Agreement
BASA
Bilateral Aviation Safety Agreement
CAO
Civil Aviation Order
CAR
Civil Aviation Regulations 1988
Certificate Management
The ongoing audit function carried out by CASA following the issue of a production approval.
CASR
Civil Aviation Safety Regulations 1998
CIR
Conformity Inspection Record – Form 882
Critical
A term applicable to parts, appliances, characteristics, processes, maintenance procedures, or inspections which, if they fail, are omitted, or are non-conforming, may cause significantly degraded airworthiness of the product during takeoff, flight, or landing.
Delegate
A person authorised under an Instrument of Delegation to exercise the power of a specific CASR or CAR.
Design Data
Consists of all drawings and specifications, which may be summarised on a master drawing list, that are necessary to show the configuration of the part, and all information on dimensions, tolerances, materials, processes, and procedures necessary to define all characteristics of a part as well as the Airworthiness Limitations Section of the Instructions for Continued Airworthiness. It also includes analysis, technical reports and other related data.
FAA
Federal Aviation Administration of the USA
FAR
Federal Aviation Regulation of the USA
FIS
Fabrication Inspection System
ICAO
International Civil Aviation Organisation
Life Limited Part
Any part which has an established replacement time, inspection interval, or related procedure specified in the Airworthiness Limitations section under CASRs 21.50, 23.1529, 25.1529, 27.1529, 29.1529, 31.82, 33.4, and 35.4 or under an ATSOA or APMA.
Manufacturer
A person producing duplicates of a product, part, appliance or article.
MRB
Material Review Board
NATA
National Association of Testing Authorities
NAA
National Airworthiness Authority
PAH
Production Approval Holder: the holder of a PC, APIS, APMA or an ATSOA who controls the design and quality of a product or part.
! 6-2
Production Approval Procedures Manual 6. Definitions Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Term
Definition
PC
Production Certificate
PCB
Production Certification Board: a panel of CASA specialists acting under the direction of a chairperson for the purpose of determining the eligibility of the holder of a TC, STC or licence for issue of a complex production approval.
PLR
Production Limitation Record – a schedule attached to, and forming part of a PC, that lists the limits of production approved under the PC.
Production
Manufacture of aircraft, aircraft engines, propellers and parts, including control of materials and processes used in the manufacture.
Project Officer
The CASA officer responsible for the coordination and management of the production approval application. May be Airworthiness Engineer or Airworthiness Inspector depending on the type of production approval application. Airworthiness Engineers will be responsible for APMA and ATSOA applications and Airworthiness Inspectors will be responsible for PC and APIS applications.
QS
Quality System: the total network of administrative and technical data and detailed procedures required to control the product and parts to specified airworthiness standards. It also denotes inspection systems in regard to holders of an APIS or APMA.
Special Process
A process where the results cannot be readily verified by subsequent inspection and testing, and where processing deficiencies may become apparent only after the product is in use. Such processes shall be carried out by qualified operators, and require continuous monitoring and control of process parameters to ensure that the specified design requirements are met.
Standard Part
An item manufactured in complete compliance with an established government or industry-accepted specification that includes design, manufacturing, and uniform identification requirements. The specification must include all information necessary to produce and conform the part. The specification must be published so that any party may manufacture the part. Examples include, but are not limited to, National Aerospace Standards (NAS), Army-Navy Aeronautical Standard (AN), Society of Automotive Engineers (SAE), SAE Aerospace Standard (AS), Military Specification (MS), (RTCA).
Supplier
Any person who furnishes parts or related services (at any tier) to the production approval holder manufacturing a product or part.
STC
Supplemental Type Certificate
TC
Type Certificate
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Production Approval Procedures Manual 6. Definitions Approved by Executive Manager, Aviation Safety Standards
Blank page
6-4
Version 2.0: August 2004
Production Approval Procedures Manual Revision History Approved by Executive Manager, Aviation Safety Standards
Version 2.0: August 2004
Revision History
Note: The Revision History shows details of the most recent version first, followed by information about previous versions. Version 2.0
Date
Part/Section
Details
August 2004
All
Complete manual revised. New Form 1248 Request for Conformity Inspection introduced. Form 1143 Australian Parts Manufacturing Approval Supplement (Landscape version) introduced. (Form 1142 remains as Australian Parts Manufacturing Approval Supplement (Portrait version). Form 1148 Name of Part and Technical Standard (Letter) introduced.
1.1
September 2003
2.2.4
Production Certificate (form 737) and Production Limitation Record (form 002) introduced. As a result section 2.2.4 amended, in particular subsection entitled Issuing the PC and Production Limitation Record (PLR): ● Three introductory paragraphs and a new subsection Certificate Numbers added (pages 2-14 to 2-15) ● Sample Production Approval Templates included (pages 2-18 to 2-19)
1.0
May 2000
4.1.5
New section Automatic Production Process inserted and remaining sections renumbered. This necessitated a change in section 4.1.2, list item 7 under ‘Inspector’ to insert the new section 4.1.5.
5.2
APMA Approval Letter revised.
All
New manual
■
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Production Approval Procedures Manual Revision History Approved by Executive Manager, Aviation Safety Standards
Blank page
RH-2
Version 2.0: August 2004
STATEMENT OF CONFORMITY Section I – Aircraft 1. Manufacturer:
2. Model Designation:
3. Aircraft Serial Number:
4 Place and Year of Manufacture:
5. Registration Mark: VH-
Section II - Engine 1. Manufacturer:
2. Model Designation:
3. Engine Serial No:
Section III - Propeller 1. Manufacturer:
2. Hub Model Designation:
3. Blade Model Designation:
4. Hub Serial No.
5. Blade Serial Numbers:
Section IV – Aeronautical Product 1. Manufacturer:
2. Product:
3. OEM Part Number:
4. Manufacturer’s Part Number.
5. Design Data:
Section V – Certification I hereby certify that: (a)
The requirements of subregulation 21.033(1) of the Civil Aviation Safety Regulations (1998) have been complied with for the product described above.
(b)
The aircraft described above, produced under a type certificate only [CASR Part 21, Subpart F of the Civil Aviation Safety Regulations (1998)], conforms to its type certificate number.
, is in
condition for safe operation, and was flight checked on
/
/
(Date)
(c)
The *engine or *propeller described above, presented herewith for type certification, conforms to the type design.
(d)
The *engine or *propeller described above, produced under type certificate only [CASR Part 21, Subpart F of the Civil Aviation Safety Regulations (1998)], conforms to its type certificate number, is in condition for safe operation and was subjected by the manufacturer to a final operational check on
(e)
/
/
(Date)
The requirements of subregulation 21.303(8) (APMA) or 21.605(2)(a) (ATSOA), as applicable, of the Civil Aviation Safety Regulations (1998) have been complied with for the product/part described above. The final inspection and test were completed on
/
/
(Date)
Tick (!) box/boxes appropriate to certification. * delete item not applicable. Deviations:
Signature of Certifier:
Position in manufacturing organisation:
Printed Name: Manufacturing Organization
Date:
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Form 724 08/2004
Statement of Conformity
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Page 1 of 2
INSTRUCTIONS This form should be submitted to CASA under the following circumstances: • By the applicant for a type certificate or a supplemental type certificate at the time an aircraft or parts is/are presented to CASA for tests. • By the applicant for a type certificate or a supplemental type certificate for each engine or propeller submitted for type certification. • By the type certificate holder or licensee manufacturing products under a type certificate only, upon the initial transfer by him of the ownership of each product or upon application for the original issue of an aircraft airworthiness certificate, or an Authorised Release Certificate Form 917. • By the applicant for an aeronautical product submitted for design, production approval and installation as applicable. This form should be completed as follows: Section I.
Aircraft.
Complete the pertinent part of any of this section when certification covers an aircraft or part thereof.
Section II.
Engine.
Complete this section when certification covers an engine.
Section III. Propeller.
Complete this section when certification covers a propeller.
Section IV. Aeronautical product.
Complete this section when certification covers an aeronautical product or aircraft part.
Section V.
Certification. Item (a).
Check this block when an aircraft or part thereof is presented for flight or ground tests during type certification or supplemental type certification.
Item (b).
Check this block when the holder or licensee of a type certificate only, initially transfers the ownership of an aircraft manufactured under the type certificate, or applies for the original issuance of an airworthiness certificate.
Item (c).
Check this block when an engine or propeller is presented for type certification.
Item (d).
Check this block when an engine or propeller is presented for airworthiness approval and insert the date the product completed a final operational check.
Item (e).
Check this block when an aeronautical product is presented for airworthiness approval and insert the date the product completed final inspection/test.
An authorised person who holds a responsible position in the manufacturing organisation must sign the certification.
Form 724 08/2004
Statement of Conformity
Page 2 of 2
Production Approval – Application Name and Address of Applicant Application Made for: (Attach evidence of certificate of Production under Type incorporation or business name registration) Production Certificate APMA ATSOA Phone: .....................................................
Amendment
Product:
❑ ❑ ❑ ❑ ❑
Aircraft Engine Propeller Other
❑ ❑ ❑ ❑
(Detail)
Fax: ......................................................... Details of Existing Approval or ARN (PC, APMA, ATSOA No.)
Details of Application Design (attach evidence of ownership or licence details)
Type/STC:
Model:
Other:
Location of Production Facilities
Certification I/WE CERTIFY THAT THE ABOVE STATEMENTS IN THIS APPLICATION ARE TRUE AND CORRECT IN EVERY PARTICULAR. (To be signed in respect of an incorporated company by the public officer of the company or executed under the company seal; in respect of an unincorporated organisation, by all members or nominated members of the organisation; in respect of an individual, by the person seeking approval or his/her authorised agent.) Signature of the Applicant(s): ............................................................................................................. For and on behalf of: ..............................................................................
............ / ......... /.........
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form 849 05/2000
Manufacturing - Application - Production Approval Application
Hrs
Mins
Page 1 of 1
1.
Revision History
Conformity Inspection Record
1. Project Number, TIA/Request Date: _________________
4. Beginning Date: 6. Model: 8. Item No.
2. Sheet ____ of
sheets
5. Ending Date: 7. Inspected By:
9. Nomenclature of Item Inspected
10. Drawing, Document, Specification, etc.
11. Revision and Date
12. No. of Items Determined Satisfactory
13. Comments
Unsatisfactory
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Form 882 05/2002
Production Approval - Record - Conformity Inspection Record
Hrs
Mins
Page 1 of 2
INSTRUCTIONS 1.
List the CASA assigned project number along with date of TIA or Request for Conformity, as applicable.
2.
List the number of this sheet and the total number of sheets.
3.
List the applicant or the manufacturer, or both. (The manufacturer may be the party producing or responsible for the product.)
4.
List the date the inspection began.
5.
List the date the inspection ended.
6.
If inspecting an aircraft, list the make, model, registration-number, and serial number. For an engine or propeller, list the make, model, and serial number.
7.
Airworthiness safety inspectors must type or print and sign their name, and enter the office identification. Authorised persons must type or print and sign their name, and list their identification number.
8.
Assign consecutive numbers for each item inspected.
9.
List the name or description of the part, appliance, assembly, drawing, document, specification, or name of the process being evaluated.
10. List the technical data that describes the item listed in Block 9—i.e., drawing number, document number, process specification number, etc. 11. List the revision level and date of the technical data described in Block 10. 12. List the number of items that were determined satisfactory or unsatisfactory. Do not record individual characteristics. (NOTE: An item is a single article or unit containing one or more dimensional characteristics or features.) 13. Enter comments in this block that will support any information given in Blocks 8 through 12—i.e., unsatisfactory conditions, corrective actions taken, reference to other item numbers listed, serial numbers, type of inspection accomplished, destination of exported products, buyer furnished equipment, parts processed through manufacturer’s maintenance facility, part new or newly overhauled, condition of part or assembly, etc. 14. To be used for supplementing items 1–13. NOTE: Unsatisfactory conditions are corrected in one of two ways: Method 1: If action is presented to correct an unsatisfactory condition, the action is entered in Block 13 and the number in the UNSAT column of Block 12 is lined through and initialed. The number of items now determined satisfactory is entered in the SAT column next to the corrective action entry. Method 2: If corrective action is not presented, the inspector may continue the inspection by entering the next item inspected. When corrective action to the unsatisfactory condition is eventually presented, assign the item a new number and record the number in Block 8. Complete Blocks 9 and 10, enter a new revision and date if data has changed, and enter the number of items determined satisfactory in Block 12. Record both the corrective action taken and the item number of the unsatisfactory condition in Block 13. Place the item number in parenthesis. Next, line through and initial the number in the UNSAT column located next to Block 13 containing the unsatisfactory condition. Record the corrective action entry item number along with the unsatisfactory condition statement and place the number in parenthesis. 14.
Continuation Block
Form 882 05/2002
Production Approval - Record - Conformity Inspection Record
Page 2 of 2
Production Approval Assessment Control Document MANUFACTURER:
PROJECT OFFICER: ASSOCIATE: AREA OFFICE:
PRINCIPAL FACILITY: Contact:
Telephone:
Fax:
Telephone:
Fax:
OTHER FACILITIES/SUPPLIERS: Contact: PRODUCTION ASSESSMENT BASIS: PC
APIS
APMA
ATSOA
SUPPLIER
❑
❑
❑
❑
❑
PRODUCT/PART/APPLIANCE/ARTICLE DESCRIPTION AND REFERENCE NUMBER
PRELIMINARY ASSESSMENT RESULTS Satisfactory YES
Comments
NO
Quality System Data – STAGE 1
Quality System – STAGE 2
Design Data
form 883 05/2000
Production Approval - Production Approval Assessment Document
Page 1 of 2
DETAIL CORRECTIVE ACTIONS TAKEN BY APPLICANT:
PROJECT OFFICER’S RECOMMENDATION: Issue Approval
Not Issue Approval
❑
❑
Signature:
Date: _______ / _____ / ______
ASSOCIATE’S SIGN OFF
Signature/s:
Date: _______ / _____ / ______ PCB REVIEW (APIS AND PC ONLY) Nonconformance
Corrective Action
PCB RECOMMENDATION: Issue Approval
Not Issue Approval
❑
❑
Signature:
Date: _______ / _____ / ______
Approval Issue Date:__________/ _______ / _____
Approval No.:
Signature:
Printed Name:
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form 883 05/2000
Production Approval - Production Approval Assessment Document
Hrs
Mins
Page 2 of 2
REQUEST FOR CONFORMITY INSPECTION (Please see next page for instructions on how to complete this form)
To(1): ...................................................................................... ...................................................................................... ...................................................................................... Request for Conformity Inspection
(2)
(3)
Project No. : ............................................................................
! Part Conformity..............................................................................
(4)
Date : .........../............. / ..............
! Installation: .................................................................................... ! Other:............................................................................................. A conformity inspection pertaining to the subject is requested for the following: (5)
Applicant Name : (6)
Company Name : Street: Suburb/Town:
State:
(7)
Postcode:
! Applicant will contact CASA(8)
Time/Date Available : (9)
Type of Installation : (10)
Make/Model
(11)
:
Quantity
Design Data: (with Revision/Date) Special Instructions
(14)
Contact Name
(13)
(16)
:
:
:
CASA Project Manager Remarks
(12)
:
at (Phone number): (15)
:
at (Phone number):
:
! T.I.A Issued(17)
! CASA Form 882 Required(20)
! T.I.R Required(18)
! CASA Form 724 Required(21)
! 917 ARCs Required(19) Note: Please return this request for conformity to the Project Manager together with the CASA conformity document.
The Federal Government TimeSaver initiative aims to assess the time taken to complete Government Forms. Please indicate the approximate time taken to complete this form. Form 1248 08/2004
Request for Conformity
Hrs
Mins
Page 1 of 2
Instructions on completing this form (refer superscripted numbers against each item on the previous page) Item 1 Item 2
Item 3 Item 4 Item 5 Item 6 Item 7 Item 8 Item 9
Item 10
Item 11
Item 12
Item 13
Item 14
Item 15
Item 16
Item 17 Item 18 Item 19
Item 20 Item 21
To: Enter the CASA inspector or Engineer to whom the conformity inspection is to be delegated. Part Conformity / Installation / Other: Determine the type of inspection to be performed and check the applicable boxes. Part Conformity – this block should be checked when the parts or assemblies are to be conformed. Installation – this block should be checked when conformity inspection of an installation of conformed parts or assemblies are on an aircraft. Other – this block should be checked when test articles, test coupons, test setup, etc. are to be conformed. Also write the word test articles, test coupons, test setup, etc. in the line next to the block. Project No: Enter the CASA Project number. Date: Enter the date the form is initiated (in the form dd/mm/yyyy). Applicant Name: Enter the full name of the applicant seeking Type or Production Certification (eg, The Boeing Company, Western International Aviation). Note: This is not the place to enter the supplier’s name. Company Name: Enter the full name of the company/supplier manufacturing the prototype part/assembly or test article. Enter the address where the actual conformity inspection work is to be preformed. Time/Date Available: Enter the approximate time and date when the inspections are scheduled to take place. However, this time and date does not constitute a commitment by CASA. Applicant will contact CASA: Always put a x in this box. Type of Installation: Enter a brief description of the part, test article, or installation for which the conformity inspection is being requested. (eg, fuselage panel installation, flight management computer installation, test article part etc). Make / Model: Enter the make and model of the aircraft, engine, or propeller for which the conformity inspection is being requested. (eg, McDonnell Douglas DC-9-82, Boeing 747-400, Robinson R44 etc). This make and model should match those referenced on TCDS. Quantity: Enter only the quantity of parts, assemblies or installations necessary to complete the certification program. (eg, 1 shipset, 5 test samples, 4 wing assemblies) If more than one is necessary to complete the test program, then that quantity should be agreed upon in advance with the Project Manager. For test articles the quantities are usually called out in a test plan that is approved in advance by the CASA project manager. In these cases, write “per test plan” in this section. Design Data: (with Revision / Date): Enter a complete description of design data for the parts, installation, or test articles. References to software revisions, if not incorporated in production drawings are required. If there are multiple drawings, the information may be entered on a separate attached sheet with a note in this section that states “See attached sheet(s)”. For installation conformity inspections, an entry of a master drawing list is usually adequate without additional information. This information is very important to an inspector because it defines the relevant design data and revision level. Special Instructions: Enter any special instructions that may aid the inspector conducting the inspection (eg, Test part not intended for use on an aircraft; Perform software conformity in accordance with RTCA DO-178A; Perform review process conformity in accordance with CASA Order 8110.4a etc). Contact: Enter the person’s name and title and phone number at the site identified in Item No 6. This is the person who is responsible for coordinating the inspection with CASA and Designee. This contact usually corresponds with the information in Item 6. CASA Project Manager: Enter the name and phone number of the Manufacturing Inspector or Engineer who initiated the conformity inspection request. This is the person who will answer any technical questions concerning the conformity request. This person will review the deviations listed on the form 724. This is also the person to whom the completed Conformity Inspection Report package is to be returned. Remarks: Enter any applicable information that may help the conformity inspection be conducted in a timely manner. eg, “applicant wishes to use a particular Authorised Person, to conduct conformity inspection” or “Applicant wishes to use a foreign NAA to conduct the conformity inspection” TIA Issued: Check this block when the request is being utilised to supplement a TIA. TIR Required: Check this block to have this conformity request and conformity inspection report placed in the TIR when a TIA has been issued. 917 ARCs required: Check this box when the inspection articles will be moved or shipped from one location to another and evidence of the conformed article is desired. Also check this box when it is desired to have evidence of a conformed article prior to an on-site test. CASA Form 882 Required: Check this box with every request. CASA Form 724 Required: Check this box with every request.
Form 1248 08/2004
Request for Conformity
Page 2 of 2
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