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If You Think Training Is Expensive

If You Think Training Is Expensive. Try Ignorance. Introductions. Facilitators/Instructors . 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. Let’s Get Started.

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If You Think Training Is Expensive

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  1. If You Think Training Is Expensive Try Ignorance Revision #38 1/2/2002

  2. Introductions • Facilitators/Instructors Revision #38 1/2/2002

  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 Revision #38 1/2/2002

  4. Let’s Get Started • It just won’t work without class participation-we facilitate • Speak up, voice your opinion, ask your questions • We’re all going to be working together in the future, lets loosen up and get started! Revision #38 1/2/2002

  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 FAR’s and Continuing Analysis and Surveillance. [FAR 121.373, 135.431] The FAA regards any contract maintenance as an extension of the Air Carrier’s maintenance program. Revision #38 1/2/2002

  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. Revision #38 1/2/2002

  7. Fundamentals Continued • 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. Revision #38 1/2/2002

  8. Fundamentals Continued • Audits must be performed against defined standards. Audits should also ensure that the organization stays in compliance as standards are changed. Revision #38 1/2/2002

  9. Fundamentals Continued • Any conclusions drawn from an audit must be based on FACT. The professional auditor removes any opinions from findings during the audit process. Revision #38 1/2/2002

  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 Revision #38 1/2/2002

  11. General Quality Program Inspection Technical Data Program Shelf Life Program Tool/Test Equipment Calibration Program Training The C.A.S.E. 1A Standard Revision #38 1/2/2002

  12. 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 • Scraped Parts Revision #38 1/2/2002

  13. 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 The C.A.S.E. 1A Standard Revision #38 1/2/2002

  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. Revision #38 1/2/2002

  15. General Cont’d • 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]. Revision #38 1/2/2002

  16. General Cont’d • 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] Revision #38 1/2/2002

  17. CACS/ARSS 7 • Turn to the appropriate appendix in your P&P for a sample of this form. Revision #38 1/2/2002

  18. General Cont’d 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. Revision #38 1/2/2002

  19. General Cont’d D cont’d 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] Revision #38 1/2/2002

  20. General Cont’d 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] Revision #38 1/2/2002

  21. General Cont’d 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. Revision #38 1/2/2002

  22. General Cont’d 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] Revision #38 1/2/2002

  23. General Cont’d • An acceptable audit result does not relieve the vendor of its responsibility to provide an acceptable product. [CASE] Revision #38 1/2/2002

  24. General Cont’d • 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. Revision #38 1/2/2002

  25. General Cont’d • 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. Revision #38 1/2/2002

  26. General Cont’d • 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] Revision #38 1/2/2002

  27. General Cont’d • 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? Revision #38 1/2/2002

  28. General Cont’d • Examples Bar Coding Id Tags Physical Separation Floor Markings Shelf Identification Revision #38 1/2/2002

  29. General Cont’d LThe 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. Revision #38 1/2/2002

  30. General Cont’d 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: Revision #38 1/2/2002

  31. General Cont’d M Cont’d 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 Revision #38 1/2/2002

  32. General Cont’d M cont’d 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. Revision #38 1/2/2002

  33. General Cont’d 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 Revision #38 1/2/2002

  34. General Cont’d • 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 individual’s absence. [CASE] Revision #38 1/2/2002

  35. General Cont’d • 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] Revision #38 1/2/2002

  36. General Cont’d • CACS-20 or ARSS-20 is the CASE checklist associated with this standard. REFER TO YOUR P&P FOR A SAMPLE OF THE FORM Revision #38 1/2/2002

  37. 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 The C.A.S.E. 1A Standard Revision #38 1/2/2002

  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] Revision #38 1/2/2002

  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] Revision #38 1/2/2002

  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. Revision #38 1/2/2002

  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. Revision #38 1/2/2002

  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 ROV’s IPM • Files are stored to prevent loss or damaged • Electronic Format • Back-up Procedure • Accepted by the FAA Revision #38 1/2/2002

  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 Revision #38 1/2/2002

  44. Quality Control Program • 9) Receiving inspection procedures. [145.45] • Documentation • Record Retention • Approved vendor list Access • Training and authorization for Inspectors Revision #38 1/2/2002

  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] Revision #38 1/2/2002

  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. Revision #38 1/2/2002

  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] Revision #38 1/2/2002

  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 Revision #38 1/2/2002

  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) Revision #38 1/2/2002

  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 Revision #38 1/2/2002

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