Training

1
If You Think Training Is Expensive
Try Ignorance
2
Introductions

• Facilitators/Instructors

3
Agenda

• C.A.S.E. 1A Standard
• Why do we have the Standard
• Some Fundamentals
• Review
• Test-70 min passing closed book test

• No Exceptions-waiting period min 3 months

4
Lets Get Started

• It just wont work without class participation-we
  facilitate
• Speak up, voice your opinion, ask your questions
• Were all going to be working together in the
  future, lets loosen up and get started!

5
Fundamental Rules of Auditing

• The FAA specifies that only CASE sustaining
  member airlines may use the Register to satisfy
  the requirement to perform an on-site audit in
  accordance with FARs and Continuing Analysis and
  Surveillance. FAR 121.373, 135.431
• The FAA regards any contract maintenance as an
  extension of the Air Carriers maintenance
  program.

6
Fundamental Rules of Auditing

• 2. Auditing is a function of management. The
  audit will review a facility for regulatory
  compliance based on sampling techniques.

7
Fundamentals Continued

1. The persons performing the audits must be
   qualified to accomplish the task. It is not
   necessary that the person be totally qualified in
   every area audited.

8
Fundamentals Continued

1. Audits must be performed against defined
   standards. Audits should also ensure that the
   organization stays in compliance as standards are
   changed.

9
Fundamentals Continued

1. Any conclusions drawn from an audit must be based
   on FACT. The professional auditor removes any
   opinions from findings during the audit process.

10
What do we audit

• Policies and Procedures
• Policy- A defined set of rules.
• Procedures-The method of
  accomplishing defined tasks.
• Quality Systems
• Work Processes
• Facilities
• Tooling and Equipment
• Housing

11
The C.A.S.E. 1A Standard

• General
• Quality Program
• Inspection
• Technical Data Program
• Shelf Life Program
• Tool/Test Equipment Calibration Program
• Training

12
The C.A.S.E. 1A Standard

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scraped Parts

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

13
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety/Security/Fire Protection
• Storage
• Work Processing
• Shipping
• Scrapped Parts

14
General

• This standard is intended to be a supplement
  to applicable FARs. It is not meant to be a
  restatement or replacement for the FARs.

15
General Contd

• This standard, in conjunction with applicable
  FARs, describes the minimum requirements for a
  component repair/overhaul vendor's quality
  program. It is designed to aid surveillance of a
  vendor who performs maintenance, preventive
  maintenance or alteration on aircraft, engines,
  propellers, or component parts thereof. This
  standard may be used to determine the adequacy of
  the vendor's quality program CASE.

16
General Contd

• Compliance with this standard does not
  necessarily accept a vendor for entry into the
  CASE Register. Vendors that are accepted for
  listing in the CASE register must continue to
  meet the requirements of this standard. Vendors
  listed in the CASE register may not advertise
  their CASE status or use the CASE logo. Refer to
  CACS/ARSS 7. CASE

17
CACS/ARSS 7

• Turn to the appropriate appendix in your PP
  for a sample of this form.

18
General Contd

• D. Vendors are subject to a technical audit at
  any time during normal working hours. The
  audit may be conducted by the customer or by
  another CASE member. The audit may encompass the
  entire technical portion of the vendor's
  operation or any part thereof.

19
General Contd

• D contd
• Normally, the auditor will notify the vendor and
  arrange the audit so as to cause minimal
  interference with the vendor's operation.
  However, should circumstances dictate, the
  auditor may arrive unannounced. CASE

20
General Contd

• E In addition to complying with this standard,
  all activities shall be accomplished in
  accordance with applicable portions of Federal
  Aviation Regulations Parts 43, 145, 121 Subpart
  L, 135 Subpart J, and regulations referenced
  therein. 145.2, 145.53 145.57

21
General Contd

• F The Original Equipment Manufacturer (OEM) may
  modify or rebuild parts manufactured under the
  manufacturer's authorization (PMA, PC, TSO,
  etc.), but must have a repair station certificate
  or be a Manufacturers Maintenance Facility (MMF)
  to overhaul or repair a part it manufactures.

22
General Contd

• F cont,d
• An MMF must meet all the requirements of the 1A
  standard (regardless of the exemptions in FAR
  145) in order to be considered for update or
  addition to the CASE register. 145.1, 43.2,
  43.3

23
General Contd

• An acceptable audit result does not relieve the
  vendor of its responsibility to provide an
  acceptable product. CASE

24
General Contd

• All CASE listed vendors shall maintain for a
  period of three years, audit findings and
  corrective actions resulting from a 1A Standard
  Audit. This file shall be accessible to any CASE
  authorized auditor on request. CASE
• Review the file for repeat findings, proper
  corrective action, and implementation of root
  cause analysis procedures.

25
General Contd

• Definitions FAR 1.1
• (1) Maintenance - Means inspection, overhaul,
  repair, preservation, and the replacement of
  parts, but excludes preventive maintenance.
• (2) Person - Means an individual, firm,
  partnership, corporation, company, association,
  joint-stock association, or governmental entity.
  It includes a trustee, receiver, assignee, or
  similar representative of any of them.

26
General Contd

• Any license or certification required by Federal
  Aviation Regulations of any individual,
  equipment, or facility shall be kept current and
  shall be available for inspection. 145.39,
  145.103, 145.17

27
General Contd

• Vendors that deal in non-aircraft parts,
  materials, or maintenance activities shall
  segregate the aircraft function from other
  functions to preclude getting unapproved parts or
  materials on an aircraft unit. 145.35
• What are some examples of segregation methods?

28
General Contd

• Examples
• Bar Coding
• Id Tags
• Physical Separation
• Floor Markings
• Shelf Identification

29
General Contd

• L The vendor shall display its Air Agency
  Certificate and ratings at a place in the repair
  station that is normally accessible to the public
  and is not obscured. 145.19
• Ensure ROV is working to its Operation
  Specifications and in the case of a Limited
  Rating, the limited capability list is approved
  by the FAA and documented on the Ops Spec.

30
General Contd

• M The U.S. Domestic repair stations shall have an
  active, FAA approved anti-drug alcohol testing
  plan that complies with FAR 121, appendix I and
  J. The plan may be the vendor's plan, a
  consortium plan to which the vendor subscribes,
  or an air carrier customer's plan. The
  Anti-Drug/AMPP program should include the
  following

31
General Contd

• M Contd
• 1. Program Manager
• Has program knowledge and is still employed by
  the company
• 2. Copy of the program certification letter
• reflecting the following
• FAA acceptance
• Number of covered employees
• Identification of Medical Review Officer
  (MRO)
• Plan Number
• ROV name and certificate number

32
General Contd

• M contd
• The vendor shall provide proof of membership in
  the plan and FAA acceptance of the plan. Letters
  of acceptance or exemption must be from the Drug
  Abatement Branch, Office of Aviation Medicine,
  Washington, DC. not from regional offices.

33
General Contd

• M. The US. domestic repair stations shall have an
  active, FAA approved anti-drug alcohol testing
  plan that complies with FAR 121, Appendix I. The
  plan may be the vendor's plan, a consortium plan
  to which the vendor subscribes, or an air carrier
  customer's plan. The vendor shall provide proof
  of membership in the plan and FAA acceptance of
  the plan. Letters of acceptance or exemption
  must be from the Drug Abatement Branch Office of
  Aviation Medicine, Washington, DC, not from
  regional offices

34
General Contd

• All programs (e.g. shelf life, technical data,
  tool calibration, and scrap parts) that require a
  person by title, to be responsible for the
  effectiveness of the program must have a back-up
  person, by title, to ensure the programs
  continuity during the primary individuals
  absence. CASE

35
General Contd

• Each certificate holder (or person performing
  maintenance or preventive maintenance functions
  for it) shall relieve each person performing such
  work from duty for a period of at least
  twenty-four consecutive hours during any seven
  consecutive days, or the equivalent thereof
  within any one calendar month. 121.377

36
General Contd

• CACS-20 or ARSS-20 is the CASE checklist
  associated with this standard.
• REFER TO YOUR PP FOR A SAMPLE OF THE FORM

37
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

38
Quality Control Program

• A. The vendor shall have an established quality
  control program adequate to assure a quality
  product or service that complies with customer
  specifications and applicable Federal Aviation
  Regulations. 145.2, 145.45

39
Quality Control Program

• B. The quality control program, including
  procedures and operations, shall be described
  in detail in a quality control manual or other
  appropriate document. The document shall
  include, but shall not be limited to, a detailed
  description of 145.45

40
Quality Control Program

• 1) The Quality Control Department, including an
  organizational chart showing the relationship of
  quality control to the rest of the organization.
  121.365
• Confirm by reviewing Organizational Chart/Duties
  and Responsibilities.
• 2) Duties, responsibilities and reporting
  relationship of the inspectors. 121.365,
  145.45, CASE
• Confirm by reviewing Organizational Chart/Duties
  and Responsibilities.

41
Quality Control Program

• 3) Manuals and other technical data distribution
  and revision control system. 145.57
• Confirm Technical Data is current and ROV has a
  procedure to maintain currency.
• Examples of Technical Data
• CMMs, Wiring Diagrams, Drawings, Air Carrier
  Specifications, or any other data used to return
  an aircraft or aircraft component to service.

42
Quality Control Program

• 4) Return-to-service procedure, documents, and
  signature requirements. 43.5, 43.9, 145.59,
  145.61
• Signature roster
• Stamp Control
• 8130-3 or equivalent
• 5) Record keeping system and retention times.
  43.5, 43.9, 145.61, 121.380
• Two years
• Stated in ROVs IPM
• Files are stored to prevent loss or damaged
• Electronic Format
• Back-up Procedure
• Accepted by the FAA

43
Quality Control Program

• 6) Personnel training requirements and records.
  121.375, 145.39, 145.45, 145.59
• Documentation
• Record Retention
• 7) Shelf life control program. 43.13
• Documentation
• Record Retention
• 8) Procedure/control of rejected and/or scrapped
  parts. 145.35
• Documentation
• Record Retention
• Return and/or mutilation procedure

44
Quality Control Program

• 9) Receiving inspection procedures. 145.45
• Documentation
• Record Retention
• Approved vendor list Access
• Training and authorization for Inspectors

45
Quality Control Program

• 10) A system for identifying customer materials
  parts and units throughout the repair/overhaul
  process. CASE
• 11) Tool and test equipment, calibration
  program. 145.47

46
Quality Control Program

• 12) Housing and storage facilities. 145.35
• Description
• Adequate for work performed
• 13) Facility environmental controls, as
  appropriate for work performed. 145.35
• NOTE If forms are used in the accomplishment of
  any of these programs they must be
  included in the IPM with instructions for
  completion and revision control to include
  date and form number.

47
Quality Control Program

• C. The Quality Control manual or document shall
  be kept current and be readily available to
  employees and to the customer's auditor or
  designee. 145.45
• It must be given to all supervisors and
  inspection personnel.
• There must be distribution list by title.
• D. The vendor shall have an internal audit and
  surveillance function that CASE, 145.57

48
Quality Control Program

• 1) Periodically reviews its programs to assure
  that the programs have procedures in place that
  assure compliance with customer specifications,
  regulatory requirements, and good industry
  practice.
• Review ROV checklist and audit schedule

49
Quality Control Program

• 2) Verifies that operations are being conducted
  in accordance with these programs.
• Review recently completed audit files
• 3) Verifies that work performed by a
  sub- contractor is a quality product that meets
  customer specifications and legal requirements.
  The vendor shall be responsible for any work
  performed by a sub-contractor.
• Verify procedures for receiving parts from
  non-FAA certified sources. (use approved vendor
  list)

50
Quality Control Program

• E. The vendors' internal audit and surveillance
  function shall contain provisions to assure that
  appropriate corrective action is taken promptly
  to CASE
• 1) Correct the discrepancies reported.
• 2) Locate and correct similar discrepancies, if
  they exist, in areas not audited

51
Quality Control Program

• 3) Correct the root cause of the problem
  evidenced by the discrepancies.
• NOTE Root cause is not to be a re-
  statement of the corrective action.

52
Quality Control Program

• F. For vendors that perform Required Inspections
  Items (RII) as defined in FAR 121, the vendor's
  company structure shall be organized such that
  the inspection function shall be separate from
  the maintenance repair and overhaul function.
  The separation shall be below the level of
  administrative control at which overall
  responsibility for the inspection function and
  maintenance, repair, and overhaul function is
  exercised. 145.2, 121.365

53
Quality Control Program

• G. The ROV shall maintain a list of its
  certified sub-contracted maintenance providers.
  In addition, the ROV must identify in its IPM
  those providers that are non-certificated.
  145.11, 145.47
• Sample certificated sub-contractor files, for
  proof of Air Agency Certificate and Operations
  Specification.
• Sub-Contractor list shall include
• Function (work performed)
• Form
• Repair Station Number

54
Quality Control Program

• H. Records of sub-contracted work must show
  145.47
• 1) Proof that the sub-contractor is a
  certificated repair station or,
• 2) If the sub-contractor is not a certificated
  repair station, the vendor himself shall
  determine the airworthiness of the article
  involved by inspection or test.
• Sample sub-contractor work package for
• Appropriate support and control
• Tooling, Test Equipment, and Tech Data

55
Quality Control Program

• I. The vendor shall have a documented procedure
  in effect to report defects and unairworthy
  conditions to the customer and the FAA.
  121.703, 145.63

56
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

57
Inspection

• A. Each person performing required inspections
  must be appropriately certificated, properly
  trained, and authorized to do so. 145.39,
  145.43, 145.45, 121.371

58
INSPECTION Contd

• B. Inspection personnel must be thoroughly
  familiar with the inspection methods,
  techniques, and equipment used in their
  specialty to determine the quality of
  airworthiness of the article being repaired or
  overhauled. They must 145.45, 145.59

59
INSPECTION Contd

• 1) Maintain proficiency in those skills,
• 2) Have available and understand all applicable
  and current tolerances and procedures, and
• 3) Be able to properly identify defects.

60
INSPECTION Contd

• C. The vendor shall maintain an up-to- date
  roster of supervisory and inspection personnel.
  The roster shall include 145.43, CASE

61
INSPECTION Contd

• 1) Its supervisory personnel, including names of
  officials that are responsible for its
  management and the names of technical
  supervisors, such as foreman and crew chiefs.
• 2) Its inspection personnel, including the names
  of the chief inspector and those inspectors who
  make final airworthiness determinations before
  releasing an article to service.

62
INSPECTION Contd

• 3) The names of all personnel authorized by the
  repair station for return to service of
  aircraft, engines, propellers or components
  thereof.
• 4) The inspections for which they are
  authorized, including RII, if applicable.

63
INSPECTION Contd

• 5) Repairman's or mechanic's certificate
  numbers, if applicable.
• 6) Current examples of inspector's signatures,
  initials and/or ID stamp, as applicable.

64
INSPECTION Contd

• D. The station shall provide a summary of
  employment for all personnel listed on the
  repair station roster. It shall include
  145.43

65
INSPECTION Contd

• 1) The persons present title,
• 2) Their total years of experience in the type
  of work he/she is doing,
• 3) Their past employment record with names of
  places and term of employment by month and year,

66
INSPECTION Contd

• 4) The scope of their present employment, and
• 5) The type and number of the mechanic or
  repairman certificate that he/she holds and the
  ratings on that certificate.

67
INSPECTION Contd

• E. The vendor shall have a satisfactory method
  of assuring that 145.45
• 1) Incoming parts and materials comply with
  specifications.
• 2) The part is free of defects or malfunctions,
  and
• 3) The part is in a good state of preservation.

68
INSPECTION Contd

• The vendor shall maintain a record of inspections
  and tests used to make this verification.

69
INSPECTION Contd

• F. The vendor shall have a system for
  controlling inspection stamps, and production
  stamps if applicable, that includes the
  following CASE

70
INSPECTION Contd

• 1) A facsimile of each stamp type,
• 2) A means of identifying who stamps are issued
  to,
• 3) A policy for stamps that are lost or stolen,
• 4) And a requirement that no stamp will be
  reissued within a six month period to two
  different employees.

71
Questions From Section 3 Inspection

• 5. INSPECTION
• A. Are RII inspectors properly trained and
  certified? (3A, B)
• B. Is there proper separation of maintenance and
  inspection responsibilities for vendors that
  perform required inspections? (2F)

72
Questions From Section 3 Inspection

• C. Does ROV maintain a list of RII items each
  inspector is authorized to inspect? 3C(4)
• D. Does ROV perform any required inspections
  (RII) for any customers?
• E. Does repair station roster identify all
  supervisory and inspection personnel? (3C)

73
Questions From Section 3 Inspection

• F. Does the roster identify all personnel
  authorized for return to service? (3C)
• G. Does the repair station have an employment
  summary for all personnel listed on the repair
  station roster? (3D)
• H. Does the ROV have an acceptable receiving
  inspection system? (3E)

74
Questions From Section 3 Inspection

• I. Does the ROV have an acceptable procedure
  to identify customers parts? 2B(10), 11C
• J. Does ROV maintain traceability certification
  on all parts and raw materials?2B(9), 3E, 10H
• K. Are acceptable sampling procedures adequate
  to ensure quality? (3E)

75
Questions From Section 3 Inspection

• L. Does the vendor have an acceptable system for
  controlling stamps, for both inspection and
  production personnel? (3F)

76
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

77
Technical Data Control

• A. All maintenance actions shall be accomplished
  in accordance with customer's manuals. This
  shall include 145.2
• 1) Technical data originating with or provided
  by the customer

78
Technical Data Control

• 2) OEM data as modified by the customer, or
• 3) Unmodified OEM data if so specified by the
  customer.
• 4) Technical data developed by the vendor which
  is approved by the customer prior to use.

79
Technical Data Control

• NOTE "Manuals" in this context include any
  technical data required to perform the required
  maintenance action, e.g..... drawings, wiring
  diagrams, test specs., etc...

80
Technical Data Control

• B. The vendor shall have a documented system to
  assure that 145.57
• 1) All technical data is kept current and there
  is a record of revisions received and filed,
• 2) Only the latest technical data is available
  to persons performing maintenance actions, and,

81
Technical Data Control

• 3) The technical data used by persons performing
  maintenance actions is appropriate for the work
  being done, readily available, in good
  condition, and in adequate quantity.

82
Technical Data Control

• C. If the vendor maintains a master copy of each
  "manual" in addition to the working copies used
  for maintenance actions, the working copies
  shall be revised at the same time as the
  masters. 145.57

83
Technical Data Control

• D. Technical data shall be properly identified
  as to applicability and stored in a manner that
  will protect it from dirt and damage. 145.57

84
Technical Data Control

• E. Where technical data is on microfilm,
  microfiche, or electronic device, an
  appropriate viewing device must be provided.
  It shall be 145.53, CASE

85
Technical Data Control

• 1) Maintained in good working order,
• 2) Protected from dust, dirt, water and damage,
  and,
• 3) Available and convenient to the persons
  performing maintenance actions.

86
Technical Data Control

• F. Specific individual(s), by title, shall be
  named as responsible for CASE
• 1) Maintaining an adequate quantity of the
  appropriate technical data up-to- date and
  properly distributed.
• 2) Maintaining the technical data in an
  environment that will protect it from loss or
  damage.

87
Technical Data Control

• 3) Maintaining viewing devices, if required, in
  good working order and protected from damage.

88
Technical Data Control

• G. Should the vendor deviate from OEM data via
  their SFAR-36 authority, the vendor shall have a
  system for approval (including customer's) and
  control of these revisions.

89
Questions From Section 4 Technical Data Control

• 6. TECHNICAL DATA CONTROL
• NOTE "Manuals" in this context includes any
  technical data, i.e... drawings, wiring diagrams,
  test specs., necessary to perform the required
  service.

90
Questions Tech Data Contd

• A. Does the ROV have the required shop manuals
  and specifications to perform the repair/overhaul
  in accordance with customer requirements? (4A)
• B. Are there established approved procedures
  controlling revisions in manuals deviating from
  OEM specifications? e.g..... EO or EA. (4A)

91
Questions Tech Data Contd

• C. Does the ROV have a system to ensure
  technical data is current? (4B)
• D. Does ROV have records of manual revisions?
  4B(1)
• E. Are manual revisions up to date? 4B(1)

92
Questions Tech Data Contd

• F. Are component overhaul manuals properly
  identified and available to mechanics? (4B)
• G. Does ROV have a system to control working
  copies of manuals to ensure they are revised
  with the masters? (4C)
• H. Is technical data stored in a manner that
  will protect it from dirt and damage?(4D)

93
Questions Tech Data Contd

• I. Are adequate viewing devices in good
  condition available for viewing the
  technical data? (4E)
• J. Is a specific individual, by title,
  responsible for the Technical Data Program?
  (4F)
• K. If the ROV has SFAR 36 authority, does he
  have a system for receiving customer approval
  prior to use of the data? (4G)

94
Questions Tech Data Contd

• L. Does the ROV have an approved SFAR 36 manual
  and roster? (4G)

95
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

96
Shelf Life Program

• 5. SHELF LIFE PROGRAM 43.13, 145.45, CASE

97
Shelf Life Program

• A. If the vendor uses materials that have a
  shelf life he shall describe in his manual a
  program, procedures, and a detailed listing of
  parts and materials that are subject to shelf
  life. The listing may be maintained as a
  document separate from the manual but the
  manual must describe the listing or reference
  it and identify the person, by title,
  responsible for maintaining it.

98
Shelf Life Program

• B. The program shall identify a particular
  individual, by title, that is responsible for
  assuring an effective program.
• C. The program shall include a means of
  identifying the expiration date of each shelf
  life limited item.

99
Shelf Life Program

• D. Any part or material that is past its
  expiration date shall not be used in the
  maintenance action of a customer's unit or any
  spare unit that may be used on an aircraft.
• E. The program shall specify a system that will
  assure that no expired material or part will be
  issued.

100
Questions From Section 5 Shelf Life Program

• 7. SHELF LIFE PROGRAM
• A. Does ROV have a documented shelf life
  program? 2B(7), 5A
• B. Does the program list parts and materials
  that have self life limits? 5A

101
Questions Shelf Life Contd

• C. Does the program assign program
  responsibility to a specific person by title?
  (5B)
• D. Does each shelf life item have the shelf life
  expiration limit displayed? (5C)
• E. Is there an adequate system to assure that no
  item will be issued or used past its expiration
  date? 5D, 5E
• F. Were items sampled for shelf life within
  limits? 5D, E

102
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

103
Tool/test Equip Calibration Program

• A. Tools and test equipment used to comply with
  or verify specifications must be calibrated
  periodically to assure their accuracy.
• B. The program shall identify the
• individual(s) responsible, by title, for
  the operation of the calibration program.

104
Tool/test Equip Calibration Program

• C. The calibration program shall include
  identification of the tools and test equipment
  in the program, the frequency of
• calibration, and the applicable
  tolerance or
• specification.
• D. Standards used in calibration shall be
  traceable
• to the controlling government agency
  or to a
• standard provided by the equipment
  
• manufacturer, e.g. (N.I.S.T).

105
Tool/test Equip Calibration Program

• E. The program shall provide a system for
  identifying the calibration status of each piece
  of equipment in the calibration program and
  their calibration due dates.

106
Tool/test Equip Calibration Program

• F. Tools and test equipment that are in the
  calibration program, but are out of calibration
  or are past due calibration check, shall be
  identified in a manner that will prevent
  maintenance personnel from using them.
• G. Personal tools or equipment used in verifying
  or complying with specifications shall be
  included in the program.

107
Tool/test Equip Calibration Program

• H. Records shall
• 1) Show the date the item was calibrated or
  checked.
• 2) Show the date the next calibration is due.
• 3) Identify the individual or the vendor, if an
  outside company, that accomplished the
  calibration or check.

108
Tool/test Equip Calibration Program

• 4) Contain a certificate of calibration for each
  item calibrated by an outside agency, and
• 5) Record the details of any adjustment or
  repair required.
• 6) Identify the standard, including the part
  number and serial number, used to calibrate the
  tool.

109
Questions From Section 6 Tool/test Equipment
Calibration Program

• 8. TOOL TEST EQUIPMENT CALIBRATION
• A. Does ROV have a tool calibration program? 2B
  (11), 6A
• B. Does the ROV have a person, by title,
  responsible for the tool calibration program?
  (6B)

110
Questions Tool Test Contd

• C. Are all tools in use listed on the tool
  calibration list? (6C)
• D. Are standards used to calibrate tools
  traceable to the controlling government agency,
  e.g..... The National Institute of Standards
  and Technology? (6D)
• E. Is there a system to identify each tool in
  the program, its calibration frequency and its
  calibration due date? (6C, 6E)

111
Questions Tool Test Contd

• F. Does ROV have a procedure for controlling
  and/or preventing out-of- service and
  due-for-calibration tools equipment from being
  used? (6F)
• G. Does the ROV have a procedure to control the
  calibration of personal tools?(6G)

112
Questions Tool Test Contd

• H. Did a sample check of the calibrated tooling
  indicate that the tooling is within calibration?
  6A
• I. Are the tools and test equipment in a
  serviceable condition? 11A (2)

113
Questions Tool Test Contd

• K. Do records? 6H
• 1. Show date calibrated?
• 2. Identify individual or vendor that performed
  calibration or check?
• 3. Show calibration due date?

114
Questions Tool Test Contd

• 4. Contain a calibration certificate for each
  item calibrated by an outside agency?
• 5. Record details of adjustments and repairs?
• 6. Show the P/N and S/N of the standard used to
  perform the calibration?

115
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

116
Training

• 7. TRAINING 145.39, 145.45, 121.371, 121.375,
  CASE
• A. The vendor shall assure that each employee is
  properly trained for the work he/she is to
  perform.
• B. The vendor shall document both formal
  (classroom) and on-the-job (OJT) training.

117
Training

• C. Employee training records for mechanics,
  inspectors, and supervisors shall be retained
  for two years after the employee has left the
  company. The records shall be available for
  inspection.

118
Questions From Section 7 Training

• 9. TRAINING
• A. Does ROV have a documented training program?
  2B(6), 7A, 7B
• B. Does it include all mechanics, inspectors and
  technical supervisors? 3A,3B,7A
• C. Is formal and OJT training documented? 7B

119
Questions Training Contd

• D. Are training records for mechanics,
  inspectors and supervisors retained for two
  years after the person leaves the company? 7C

120
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

121
Housing and Facilities

• 8. HOUSING AND FACILITIES 145.35
• A. The vendor shall provide suitable
• 1) Housing for its necessary equipment and
  material.
• 2) Facilities for properly storing, segregating
  and protecting materials, parts, and supplies.

122
Housing and Facilities

• 3) Facilities for properly protecting parts and
  sub-assemblies during storage, disassembly,
  cleaning, inspection, repair, and assembly.
• 4) Filtered air or clean rooms as required.

123
Housing and Facilities

• B. The housing and facilities shall protect
• 1) Parts, materials, and customers' units from
  weather, dust, heat/cold, damage, theft, fire,
  and contamination from other shop activities,
  e.g.... Paint spraying, grinding, and plating
  fumes.

124
Housing and Facilities

• 2) The workers, such that the quality of their
  workmanship is not impaired by their physical
  efficiency.

125
Housing and Facilities

• C. Housing and facilities shall have adequate
  space for the work to be accomplished and
  adequate lighting so that the quality of work is
  not impaired. The vendor shall exercise good
  housekeeping practices to prevent loss, damage,
  and contamination of customer parts and
  equipment and for personnel safety.

126
Housing and Facilities

• D. The vendor shall provide suitable storage
  facilities used exclusively for storing parts
  and materials. The area must be separated from
  the shop and work space and organized such that
  only acceptable parts and supplies are issued
  for any job.

127
Housing and Facilities

• E. The areas for receiving and for shipping
  customer units shall have adequate space,
  lighting, shelving, security, and fire
  protection to accommodate customers' units in a
  manner that will preclude damage, loss, and
  theft.

128
Housing and Facilities

• F. There shall be an adequate and appropriate
  storage area to safely store customers' reusable
  shipping containers and to protect them from
  environmental damage. CASE

129
Questions From Section 8 Housing And Facilities
145.35

• 10. HOUSING AND FACILITIES
• A. Does ROV have a facility of adequate size to
  house all necessary tooling, equipment, material
  and parts to perform work? 8A, 8D

130
Questions Housing Facilities Contd

• B. Does the housing adequately protect parts,
  materials, and customer units from damage, theft
  and contamination? (8A, 8B, 8C)
• C. Is the environment appropriate to protect
  workers so that the quality of workmanship is not
  impaired by physical efficiency? 8B (2)

131
Questions Housing Facilities Contd

• D. Does facility have adequate lighting? (8C)
• E. Are storage facilities separate from shop and
  work areas? (8D)
• F. Do shipping and receiving areas have
  adequate space, lighting, shelving, security
  and fire protection? (8E)

132
Questions Housing Facilities Contd

• G. Is there adequate and appropriate storage
  space to safely store customer's shipping
  containers and protect them from damage? 8F
• H. Is the work area, including supervisors'
  offices, clean? 8C

133
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

134
Safety, Security, and Fire Protection

• 9. SAFETY/SECURITY/FIRE PROTECTION
• A. The housing and facilities shall provide
  adequate security and protection from fire.
  CASE
• B. Security systems shall be reviewed
  periodically by vendor management or by a
  qualified outside firm to assure that the
  system is still adequate. CASE

135
Safety, Security, and Fire Protection

• C. Fire protection devices and systems shall be
  inspected periodically. NFPA 10
• D. Fire fighting equipment and its locations
  shall be well identified and maintained in
  serviceable condition. NFPA 10

136
Safety, Security, and Fire Protection

• E. Walkways, doors, and fire extinguishers shall
  be clear of obstructions and easily accessible.
  NFPA 10

137
Safety, Security, and Fire Protection

• F. Appropriate safety devices shall be
  maintained in good condition and shall be used.
  CASE
• G. Operations shall be conducted in a safe
  manner and in a safe environment that will avoid
  personnel injury and damage to customer
  property. 145.35, CASE

138
Questions From Section 9 Safety/security/fire
Protection

• 11. SAFETY/SECURITY/FIRE PROTECTION 9
• A. Does ROV provide adequate security for
  customer parts in his possession?
• B. Is the security system reviewed periodically
  by management or an outside vendor?

139
Questions Safety Security Fire Protection
Contd

• C. Are fire protection devices inspected
  periodically?
• D. Are fire stations identified and
  extinguishers in serviceable condition?
• E. Are fire lanes, doors and fire extinguishers
  clear of obstruction?

140
Questions Safety Security Fire Protection
Contd

• F. Are safety guards in place on power
  equipment?
• G. Are ROV shop operations conducted in a safe
  manner and environment?

141
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

142
Storage

• A. Parts and materials shall be properly
  identified so that only acceptable parts and
  supplies will be issued for any job. 145.35
• B. Serviceability status of parts and materials
  shall be indicated in a manner that readily
  identifies serviceable parts and materials from
  the unserviceable. 145.35

143
Storage

• C. Rejected parts and materials, including
  questionable items awaiting disposition, shall
  be identified as rejected and stored separately
  from usable stock to preclude them from being
  issued for any job or shipped to the customer
  as serviceable. 145.35

144
Storage

• D. Parts and material shall be protected in
  storage and during transit, until installation,
  in a manner that will prevent damage,
  contamination, loss, or substitution. 145.35,
  145.37
• E. Flammable, toxic or volatile materials shall
  be stored in a fire proof cabinet or facility.
  145.35 NFPA 30

145
Storage

• F. Sensitive parts and equipment, e.g.... oxygen
  parts, "o" rings or electrostatic sensitive
  devices, shall be properly packaged, stored,
  identified, and protected from contamination and
  damage. 145.35

146
Storage

• G. High pressure bottles must be correctly
  labeled and properly stored and secured. CASE
• H. The vendor must maintain traceability records
  for parts and raw material. CASE

147
Questions From Section 10 Storage

• 12. STORAGE
• A. Are parts and material properly identified
  and properly stored? (10A)
• B. Does the ROV have a quarantine area for
  rejected parts and materials awaiting
  disposition? (10C)

148
Questions Storage Contd

• C. Do parts in bin match part number on bins?
  (10A)
• D. Are parts and material properly protected
  from damage and deterioration? (10D)
• E. Are flammable, toxic or volatile materials
  properly identified and stored?(10E)

149
Questions Storage Contd

• F. Are sensitive parts and equipment (oxygen
  parts, o-rings, electrostatic sensitive
  devices, etc..) properly packaged, identified
  and stored to protect from damage and
  contamination? 10F
• G. Are oxygen and other high pressure bottles
  correctly identified and stored? 10G

150
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

151
Work Processing

• 11. WORK PROCESSING
• A. No vendor may perform any maintenance action
  unless the person performing that maintenance
  action 145.39, 145.41, 145.45, 145.5, 121.375

152
Work Processing

• 1) Is properly trained, authorized, and
  certificated if required.
• 2) Has available the appropriate tools and test
  equipment in good condition and properly
  calibrated, the correct parts, and current
  technical data.

153
Work Processing

• Should any of the above requirements be lacking,
  the vendor shall refuse the work or take
  appropriate corrective action to correct the
  deficiency.

154
Work Processing

• B. OEM/non-OEM designated equipment 43.13
• For either OEM or non-OEM test equipment, the
  vendor shall
• Have an operating manual and maintenance manual
  for the equipment.
• Perform maintenance, preventive maintenance, and
  servicing as required by the operating and/or
  maintenance manual.

155
Work Processing Contd

• Maintain records for two years of maintenance,
  preventive maintenance, and servicing, if any if
  required.
• If appropriate, list the test equipment in its
  calibration program .

156
Work Processing Contd

• Where non-OEM designated test equipment is used,
  the vendor shall
• Provide written certification that the equipment
  adequately performs the tests required by the OEM
  manual. The certification shall be signed by the
  OEM of the part(s) being tested, or an outside
  firm qualified to make such a determination, or
  an engineer on the vendors staff qualified to
  make such a determination.

157
Work Processing

• Show written evidence that the equipment is
  acceptable to the FAA. Acceptance may be shown
  as follows
• Listed in the repair station's FAA accepted
  inspection procedures manual,
• Listed on the repair stations Operations
  Specifications,
• A letter from the FAA

158
Work Processing

• NOTE This section does not apply to standard
  test equipment such as volt/ohm meters,
  oscilloscopes, power supplies, etc.., that is
  equivalent to the equipment called out in the
  component maintenance manual.

159
Work Processing

• C. The vendor shall have a system for
  identifying a specific customer's parts,
  materials, or units throughout the entire
  maintenance action process, including storage
  before and after the repair, overhaul, or
  modification. This system shall include
  complete identification of the part by
  nomenclature, part number, serial number, model
  number, as appropriate, and legible records of
  all work accomplished. CASE

160
Work Processing

• D. Where there is work turned over from one
  shift to another, there shall be a system of
  documentation that assures continuity of the
  work and that the complete bill-of-work is
  accomplished. 121.369, CASE

161
Work Processing

• E. There shall be adequate procedures and
  controls of processes, and adequate checks,
  inspections, and tests to assure a good quality
  product that complies with customer
  specifications. 145.45, 145.55, 145.57, 145.61

162
Work Processing

• F. The vendor shall prohibit smoking, eating, and
  drinking or storing food and drink in any area
  where parts or customer units are stored or
  worked (e.g. fuel controls, hydraulic units,
  instruments, or electronic components), or have
  a written procedure ensuring parts or units have
  adequate protection against contamination or
  damage from such activity. 145.35

163
Work Processing

• G. Fluid dispensers used in the shop areas shall
  be properly marked and stored to prevent
  spillage.
• H. The vendor shall maintain adequate records of
  all work performed including 145.61, 43.9

164
Work Processing

• 1) The description of the work performed or
  reference to data acceptable to the
  administrator.
• 2) The date of completion of the work performed.
• 3) The name of the person performing the work.
• 4) The name of the person inspecting the work.

165
Work Processing

• 5) The name of the certificated mechanic or
  repairman who performed or supervised the work.
• 6) The signature, certificate number, and type
  of certificate of the person returning the
  article to service.
• NOTE The person, as stated above, may be one or
  more individuals.

166
Work Processing

• I. The vendor shall provide a return to service
  document with a component that has been made
  serviceable. The document shall include the
  signature (not printed name or inspection
  stamp/symbol, signature) of the individual
  authorized by the repair station to return the
  article to service. The document must include
  43.9, Part 43, Appendix B

167
Work Processing

• 1) A description of the work performed or
  reference to data acceptable to the
  administrator.
• 2) The date of completion of the work performed.
• 3) The name of the person performing the work if
  different than the person specified in item 4
  below.

168
Work Processing

• 4) The signature, certificate number, and kind
  of certificate held by the person approving the
  work. The signature constitutes the approval
  for return to service only for the work
  performed.
• 5) In addition, major repairs and major
  alterations shall be entered on a form in
  accordance with Part 43, Appendix B.

169
Work Processing

• NOTE The serviceable parts tag is the most
  common document used for the return to service or
  maintenance release statement. This information
  or release may also be included on the work order
  or other document and is acceptable. In any
  case, a copy of the work order or maintenance
  record must also be sent with the part.

170
Work Processing

• J. The vendor shall retain each record of a
  maintenance action for at least two years after
  the work to which it applies is done. 145.61

171
Questions From Section 11 Work Processing

• 13. WORK PROCESSING
• A. Does ROV have adequate tooling and test
  equipment to perform the work? (11A)
• B. If ROV uses test equipment that differs from
  the OEM specified equipment (11B)

172
Questions Work Processing Contd

• 1. Is it properly certified as equivalent?
• 2. Does ROV have operating and maintenance
  manuals?
• 3. Is maintenance and servicing performed per
  the manual?
• 4. Is maintenance and servicing recorded and
  records retained for two years?

173
Questions Work Processing Contd

• 5. Is the equipment listed in the calibration
  program?
• 6. Has the equipment been accepted by the FAA?

174
Questions Work Processing Contd

• C. Are mechanics, inspectors and supervisors
  properly trained, authorized and certificated,
  if required, for the work they perform? 3A,
  7A, 11A
• D. Are adequate tools and current manuals
  available or at the mechanics' work stations?
  11A (2)

175
Questions Work Processing Contd

• E. Are customers' parts properly identified
  throughout the maintenance actions and in
  storage? 11C
• F. Is there a work turnover procedure used?
  12D
• G. Does the shop segregate serviceable from
  unserviceable components? 2B(8), 10B

176
Questions Work Processing Contd

• H. Does the facility provide adequate protection
  of parts in work? e.g.... filtered air or clean
  room depending on type of part. 8A
• I. Are smoking, eating and drinking forbidden
  in the work area, or does the vendor have a
  written program to ensure units are protected
  from contamination? 11F
• J. Are fluid dispensing cans and servicing units
  properly identified?11G

177
Questions Work Processing Contd

• K. Are ROV work records complete, in order, and
  legible? 11H, 12B
• L. Do the records contain 11H
• 1. The description of the work performed or
  reference to data acceptable to the
  administrator?
• 2. The date of completion of the work performed?

178
Questions Work Processing Contd

• 3. The name of the person performing the work?
• 4. The name of the person inspecting the work?

179
Questions Work Processing Contd

• 5. The name of the certificated mechanic or
  repairman who performed or supervised the work?
• 6. The signature, certificate number, and type
  of certificate of the person returning the
  article to service?

180
Questions Work Processing Contd

• M. Are all test and inspection records in work
  package? 11H
• N. Does ROV record keeping system and retention
  time meet FAR requirements? 11H, 11J
• O. Does ROV's return-to-service documents meet
  customer and FAA requirements? 2B (4), 11J

181
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

182
Shipping

• 12. SHIPPING
• A. Components shall be returned to the customer
  in an appropriate shipping container or one
  required y the customer. CASE

183
Shipping

• B. Serial number (S/N) and part number (P/N) or
  model number, including dash numbers or letters
  on the documentation for the part shall match
  the identification information on the part data
  plate. CASE

184
Questions From Section 12 Shipping

• 14. SHIPPING
• A. Are components returned in an appropriate
  shipping container or as specified by the
  customer?
• B. Does the ROV verify that identifying data
  (P.N./SN/nomenclature/mod. no.) on the parts tag
  and the data plate match?

185
The C.A.S.E. 1A Standard

• General
• Quality Control
• Inspection
• Tech Data Control
• Shelf Life Program
• Tool/Test Equip Calibration Program
• Training

• Housing and Facilities
• Safety, Security, and Fire Protection
• Storage
• Work Processing
• Shipping
• Scrap Parts

186
Scrap Parts

• 13. SCRAPPED PARTS
• A. The vendor shall have a documented procedure
  in place to either return scrapped parts to
  their owner or to mutilate them by drilling,
  grinding, cutting or other appropriate means.
  Parts shall be mutilated to the extent that
  will preclude the possibility of their being
  restored and returned to service. CASE

187
Scrap Parts

• B. The procedure shall identify by title the
  individual responsible for verifying that parts
  were adequately damaged before discard. CASE

188
Scrap Parts

• C. The vendor shall maintain a record of all
  life limited parts scrapped out The record
  shall contain a description of the part, its
  part number, and serial number, if applicable,
  and the date of the part was scrapped. The
  vendor shall retain this record for at least two
  (2)years. The vendor may retain the
• records for a longer period if desired.

189
Questions From Section 13 Scrapped Parts

• 15. SCRAPPED PARTS (13)
• A. Does the ROV have a documented procedure to
  assure that scrapped parts are either returned
  to the customer or mutilated beyond repair?

190
Questions From Section 13 Scrapped Parts

• B. Does the program identify an individual, by
  title, responsible for verifying that mutilation
  is accomplished?
• C. Does the ROV maintain a record of life
  limited parts scrapped for two years?
• 1) Does the record include the P/N and
  S/N of the part and the date scrapped?

191
1a Standard Review

• LETS GET IT CLEARED UP
• Now is the time to clarify any concerns you might
  have.
• Ask the questions now, not after youve missed it
  on the test.
• 70 min score re