REPAIR STATION PROCEDURE
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1 REPAIR STATION PROCEDURE Subject Number: Revision: Page: Inspection Procedures Manual RSP002 F 1 of 2 FAA Approved Repair Station No. LD7R612J Original signatures on file with EDC: Approved: Rick Phillips Date: REVISIONS Sym. Reason/Description Requested/ Changed By B C D RCD CHG Updated all pages of all sections to conform to online maintenance RCD CHG Updated duties and responsibilities in TOC and section 4; Added Retention paragraph section 3 RCD CHG Updated sections 4 & 5 for personnel responsible for scrap material; updated all other sections and forms to reflect current operations Date R. Phillips R. Phillips R. Phillips E RCD CHG Updated sections 5 and 6, FAA order and R. Phillips clarified certain paragraphs. Updated section 7, JAA Supplement - Quality Monitoring System, clarified certain paragraphs. F RCD CHG Update per AC 145-MAN R. Phillips
2 TABLE OF CONTENTS SECTION TITLE PAGE RSP002 SECTION I SECTION II REPAIR STATION PROCEDURE Inspection Procedure Manual Title Page 1 Table of Contents 2 through 4 Introduction 5 Definitions 6 Manual Control 7 HOUSING & FACILITIES Title Page 1-1 Housing and Facilities 1-2 Facility Floor Plan 1-3 COMPANY ORGANIZATION Title Page 2-1 Organization Chart 2-2 Repair Operation Flow Chart 2-3 SECTION III PERSONNEL & TRAINING Title Page 3-1 Personnel and Training 3-2 Proficiency of Inspection Personnel 3-3 Roster of Authorized Personnel 3-4 Sample Roster 3-5 SECTION IV DUTIES & RESPONSIBILITIES Title Page 4-1 Repair Station Manager 4-2 through 4-3 Chief Inspector 4-4 through 4-5 Stockroom Manager 4-6 Quality Assurance Manager 4-7 Manufacturing Manager 4-8 Personnel Duty Time Limitations 4-9 K:\EDCPUB\CURRENT\RSP\RSP002.DOC PAGE 2
3 TABLE OF CONTENTS (continued) SECTION TITLE PAGE SECTION V SECTION VI INSPECTION SYSTEM Title Page 5-1 General 5-2 Inspection Personnel 5-2 Inspectors, Mechanics and Supervisors 5-3 Repair Receiving Policy 5-3 General Test Requirements 5-3 Shipping Process 5-4 Returned Goods Report 5-4 Preliminary Inspection 5-4 Inspection for Hidden Damage 5-5 Repair, Alteration and Overhaul Accessories and Appliances 5-5 In-Process Inspection 5-5 Tagging and Identification of Parts 5-6 Final Inspection and Approval for Return to Service 5-6 Work Sign-Off 5-7 Performance of Maintenance, Preventive Maintenance, Alterations and Required Inspection Under the Continuous Airworthiness Requirements of FAR Parts 121,125,127, and 135 Repair Station System (RSS) 5-7 through 5-31 FORMS Title Page 6-1 FAA Form Returned Goods Report (RGR) 6-3 Returned Goods Report- Rework RGR 6-4 Unserviceable Parts Tag 6-5 Miscellaneous Tags 6-6 Return Authorization 6-7 Shipper/Shop Report 6-8 through 6-9 K:\EDCPUB\CURRENT\RSP\RSP002.DOC PAGE 3
4 TABLE OF CONTENTS (continued) SECTION TITLE PAGE SECTION VII QUALITY Title Page 7-1 Stamp Control Procedure 7-2 Corrective Action System for Deficiencies 7-3 Capability List 7-4 Work Performed at Another Location 7-4 Subcontractor Maintenance 7-4 Maintenance and Preventive Maintenance Performed for Air Carriers Under Parts 121, 125, 129, and Calibration of Measuring and Test Equipment 7-6 Equipment and Materials 7-7 Incoming Material Inspection 7-8 through 7-9 Current Technical Data 7-10 Records Retention 7-11 Malfunction / Defect Report 7-12 Mechanical Reliability Report 7-12 Quality Maintenance System, AS APPENDIX 1 REFERENCE DOCUMENTATION Internal Reference Documents 1-1 External Reference Documents 1-1 K:\EDCPUB\CURRENT\RSP\RSP002.DOC PAGE 4
5 INTRODUCTION This inspection procedures manual has been prepared in accordance with the current Code of Federal Regulations (CFR), the policies of L-3 Communications Corporation, and is in compliance with 14 CFR 145 SUBPART D (current revision). This manual explains the internal inspection in detail, including the continuity of inspection responsibility. It gives samples of inspection forms used and their method of execution. The manual gives a detailed explanation of the following portions of the inspection system: in-coming materials, preliminary inspection, hidden damage, inspection continuity and final inspection of the article being maintained or altered at this facility. The general repair, overhaul or alteration of products will be performed in accordance with the current Federal Aviation Regulations, manufacturer's data, drawings, specifications and bulletin's, airworthiness directives or other technical data approved by the Administrator for the particular appliance. The Repair Station will not maintain or alter any item for which it is not rated, and will not maintain or alter any article for which it is rated if it requires technical data, equipment, materials, facilities or trained personnel that are not available. (14 CFR current revision). The technical library and this inspection procedures manual, required for operation of this Repair Station, will be maintained in a current status at all times. Each supervisor, the chief inspector, and all inspection personnel working for this Repair Station will be provided a current copy of this manual and should thoroughly understand its content. It will also be available to other Repair Station personnel. The repair station manager is responsible for revisions to the IPM. The IPM, including the quality section, shall be reviewed for revision update on a 12-month cycle or as determined necessary. The CHDO will be notified when a revision change is called for. If an IPM revision is required, the repair station manager will initiate and implement the changes and submit the revision change to the CHDO for their review and comments. If the IPM section requires CHDO s approval, the implementation will be after receipt of CHDO s approval. K:\EDCPUB\CURRENT\RSP\RSP002.DOC PAGE 5
6 DEFINITIONS ARPP ARSP CA CAB CFR CHDO CM CMM EDC ESD FARF FOB FSB IPM ISO L-3AR MIS MRA MRB OVS PA QA QAP RA RFM RGR RO RSP RSS ULB VP Aviation Recorders Technical Publications Procedures Table of Contents. Product Support Procedures. Corrective Action. Corrective Action Board. Code of Federal Regulations. FAA Certificate Holding District Office. Configuration Management. Component Maintenance Manual. Engineering Document Center. Electro Static Discharge. Factory Authorized Repair Facility. Free on board. Aviation Recorders Field Service Bulletin. Inspection Procedures Manual. International Standards Organization. L-3 Communications Aviation Recorders. Management Information Systems. Material Review Area. Material Review Board. Outside Vendor Service. Preventive Action. Quality Assurance. Quality Assurance Procedures. Return Authorization. Request for material. Return Goods Report, Repair Order. Repair Station Procedures. Repair Station System. Underwater Locator Beacon. Vice President. K:\EDCPUB\CURRENT\RSP\RSP002.DOC PAGE 6
7 MANUAL REVISION AND CONTROL RESPONSIBILITIES The origination of new procedures, and revisions or deletions of existing procedures shall be the responsibility of the Repair Station Manager. The Repair Station manager will submit revisions to the FAA for review and acceptance. The Repair Station Chief Inspector shall assure that the procedures and actual practices comply with each other. The Engineering Document Center (EDC) shall be responsible for L-3 s master copy and the distribution of the Inspection Procedures Manual (IPM). PROCEDURE The signatures of the FAA Inspector and the Repair Station Manager shall indicate the approval of Inspection Procedures Manual (IPM) revisions. Revision status of procedures shall be indicated through the use of alpha characters prominently displayed on each page. Manuals (hard copies) will have a control number, with records kept by EDC and the Repair Station Manager of the personnel on distribution. The FAA will receive its hard copy of the IPM from the Repair Station manager via mail. EDC will collect any previous revision hard copy IPM upon distribution of the new hard copy IPM revision for accountability of IPM revisions at L-3 Communications. Electronic notification and posting of revision changes for network server users of the IPM will be through the L-3 Communications intranet Smart Web, Job Skill Documents. The Chief Inspector will provide training for the repair station personnel with regards to the IPM on the network server. The Chief Inspector shall once per year audit the IPM to verify procedures are current and issue a report to the Repair Station manager. K:\EDCPUB\CURRENT\RSP\RSP002.DOC PAGE 7
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