RepairStationQualityManual LA

UNCONTROLLED COPY IF PRINTED
FAA Repair Station # 3LZR235N

REPAIR STATION QUALITY MANUAL

November 14, 2013

Revision Level: Original


Section I
Revision Level ORIGINAL
Revision Date 11/14/2013
Page 1 of 12
Repair Station Quality
Manual
INTRODUCTION
I. INTRODUCTION
A. LIST OF EFFECTIVE PAGES
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INTRODUCTION
B. RECORD OF REVISIONS

Section
Pages
Affected
Revision
Level
Summary of Changes Date
ALL ALL Original Original Issue 11/14/2013


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INTRODUCTION

C. TABLE OF CONTENTS
Section / Title Page(s)
I. INTRODUCTION 0 of 12
A. LIST OF EFFECTIVE PAGES 1 of 12
B. RECORD OF REVISIONS 3 of 12
C. TABLE OF CONTENTS 4 of 12
D. REVISION HIGHLIGHTS 9 of 12
E. GENERAL INFORMATION 10 of 12
1. RSQM Purpose 10 of 12
F. REPAIR STATION MANUAL ELEMENTS 10 of 12
1. RSQM Control Process 10 of 12
2. Temporary Revision Process 11 of 12
3. FAA Review & Acceptance 12 of 12
II. REPAIR STATION ELEMENTS 1 of 49
A. REPAIR STATION ORGANIZATION 1 of 49
1. General 1 of 49
2. Organizational Structure 2 of 49
3. Delegation of Authority Process 3 of 49
4. General Manager 3 of 49
5. Sr. Human Resources Manager 4 of 49
6. Vice President of Operati ons 4 of 49


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INTRODUCTION
7. Director of Maintenance 5 of 49
8. Program Manager 6 of 49
9. Project Manager 7 of 49
10. Supervisors (All Departments) 8 of 49
11. Intentionall y Left Bl ank 9 of 49
12. Hangar Lead Technician 9 of 49
13. Operations Manager 10 of 49
14. Manager of Tooling 11 of 49
15. Director of Pl anning and Production Control 11 of 49
16. Manager of Materials 12 of 49
17. Warehouse Manager 12 of 49
18. V.P. of Quality 13 of 49
19. Director of Quality Control 14 of 49
20. Manager of Quality Control 16 of 49
21. Inspection Supervisor 16 of 49
22. Lead Inspector 17 of 49
23. Manager of Quality Assurance 18 of 49
24. Repair Station Trainer 19 of 49
25. Director of Production/Pl anning 20 of 49
26. Production Control Lead 20 of 49
27. Liaison Engineer 21 of 49


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INTRODUCTION
B. GENERAL REPAIR STATION PROCEDURES 21 of 49
1. Personnel Rosters 22 of 49
C. REPAIR STATION FACILITY & OPERATIONS 23 of 49
1. Housing & Facilities 23 of 49
2. Physi cal Location/Hangar Descriptions 23 of 49
Lake Charles Maintenance Facil ity Floor Plan 27 of 49
3. Training Program 41 of 49
4. Work Performed Away From The Repair Station Facility 41 of 49
D. MAINTENANCE, PREVENTIVE MAINTENANCE, & ALTERATIONS 42 of 49
E. REPAIR STATION CAPABILITY LIST 43 of 49
F. CONTRACT MAINTENANCE PROVIDERS 44 of 49
G. REQUIRED RECORDS & RECORDKEEPING 45 of 49
H. NOTIFICATION OF HAZARDOUS MATERIALS AUTHORIZATIONS 46 of 49
I. PERSONNEL DUTY TIME LIMITATIONS (CFR 14 FAR 121.377) 46 of 49
J. REPAIR STATION WORK FLOW 47 of 49


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INTRODUCTION

Section / Title Page
III. QUALITY MANUAL ELEMENTS 1 of 22
A. INSPECTION SYSTEM 1 of 22
1. Receiving Inspection 1 of 22
2. Shipping Damage or Contamination & Preservation 1 of 22
3. Parts and Raw Materials 1 of 22
4. Physi cal Inspection 4 of 22
5 Shelf Life Limited Items 5 of 22
6. Material Tagging 5 of 22
7. Suspected Unapproved Parts Reporting 6 of 22
8. Tools & Equipment 6 of 22
9. Preliminary Inspection Process 7 of 22
10. Hidden Damage Inspection After Incident or Accident or Deterioration 7 of 22
11. In-Process Inspection 8 of 22
12. Inspection Personnel Proficiency 9 of 22
13. Inspector Proficiency 9 of 22
14. Receiving Inspector Profi ciency 10 of 22
15. Inspection Countermand Authority 10 of 22
16. Identification of Parts and Use of Tags 10 of 22
17. Technical Data & Document Control 11 of 22
18. Equipment, Material & Tools 12 of 22


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INTRODUCTION
19. Non-certificated Person 13 of 22
20. Final Inspection 13 of 22
21. Maintenance Release/Return-to-Service Approval 14 of 22
22. Record of Inspection (Method) 14 of 22
23. Record of Maintenance Release 15 of 22
24. Shift Turnover Logs 16 of 22
25. Tool/Equipment Calibrati on Program 17 of 22
26. Part Segregation 18 of 22
27. Taking Corrective Action on Deficiencies 18 of 22
28. Stamps 19 of 22
29. Service Difficulty Report 20 of 22
30. Vendor Approval 21 of 22
IV. FORMS 1 of 1


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INTRODUCTION

D. REVISION HIGHLIGHTS
N/A Original Release


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INTRODUCTION

E. GENERAL INFORMATION
1. RSQM Purpose
a. This RSQM is intended to provide repair station personnel guidance, information and
procedures used to ensure repair station processes comply with regulatory requirements.
b. This RSQM is a combination of the Repair Station Manual and Quality Manual. It contains
FAA-accepted policies and procedures for conducting maintenance, preventive
maintenance, inspections, and alterations under the authority of the AAR Aircraft Services
Lake Charles (ASL) air agency certificate for aircraft operated under 14 CFR Parts 91, 121,
125, 129, & 135.
c. This single-format, electronic manual contains associated repair station elements in four (4)
sections. Section I; Introduction, Section II; Repair Station Manual (RSM), Section III; Quality
Control Manual (QCM), Section IV; Forms.
d. AAR must conduct all maintenance, preventive maintenance, and alterations in accordance
with all applicable Federal Aviation Regulations (FAR) and must make its FAA Air Agency
Certificate and Operation Specifications (Op Specs) available on the premises for inspection
by the FAA, customers and other regulatory authorities. Additionally, ASL will allow the FAA
to inspect the repair station at any time to determine compliance with 14 CFR Part 145.
e. All applicable ASL repair station employees are responsible for adhering to the RSQM
policies and procedures at all times. If the current ASL RSQM is not available, the
employee(s) must stop work and notify their supervisor for further direction.
f. If any procedure specified in this manual is contrary to any applicable regulation, the
requirements of the regulation will prevail. If any portion of this manual is discovered to
show non-compliance with an FAR, the repair station shall cease the non-compliant activity
and initiate an expedited manual revision.

F. REPAIR STATION MANUAL ELEMENTS
1. RSQM Control Process
a. The V.P. of Quality has final authority for establishing, controlling, changing, and making the
decisions regarding the processes that govern the development, revision, distribution, and
acceptance of this manual.
b. The V.P. of Quality is authorized to make spelling and grammar corrections without FAA
acceptance as long as the corrections do not affect the intent of the sentence.
c. Any repair station employee can request a revision to the RSQM by completing and
submitting a Change Request, Form CR-001, to his immediate Supervisor.
The Supervisor routes the request to the V.P. of Quality for review and approval. At
the discretion of the V.P of Quality, the V.P of Operations and/or any person affected
by the change may be consulted for review and discussion of the requested change.
If the change request is disapproved, the form will be returned to the submitter with
an explanation for the rejection.


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INTRODUCTION
If approved, the V.P. of Quality will make the necessary RSQM revision. The
revised RSQM will be submitted to the FAA as described in paragraph F.2. of this
section with a copy sent to the Manager of Training.
Revisions can be completed for each section in lieu of submitting and revising the
entire manual. RSQM revisions are controlled and identified by using the following
methods:
a) The List of Effective Pages (LEP) provides a complete accounting of all manual
pages, including the revision date of each page.
b) The Record of Revision Page explains the changes for each revision level.
c) Revision Date and Revision Level blocks in the upper right-hand corner of each
revised page are updated with the new revision date and level.
Once the revision is accepted by the FAA, the Manager of Training will develop and
conduct any required training prior to implementation of the revision. The Manager of
Training will also ensure that any interfacing manuals (i.e., Repair Station Forms
Manual, Training Program Manual, etc.) and other applicable documents are updated as
necessary.
When all required training and/or other related tasks are complete, the Manager of
Training will notify the V.P. of Quality in writing/email. The V.P. of Quality will then
ensure that the revised RSQM and other documentation (as applicable), is uploaded to
the Technical Library home page on the computer server.
The repair stations system to ensure currency and consistency of the RSQM is to
maintain only one version, which will be made available to assigned personnel
electronically. Any paper copies of the RSQM are for reference only.
To prevent changes to the electronic version of the RSQM stored on the ASL computer
server, access to the electronic document will be password protected. Only the
Accountable Manager and V.P. of Quality using their ASL user names and passwords
will be allowed to make/upload revisions to the electronic manual.

2. Temporary Revision Process
a. Temporary revisions will be issued to incorporate informational changes to a procedure,
form, or the RSQM in a timely manner.
b. The V.P. of Quality or Chief Inspector will convert all Temporary Revisions into Permanent
documents, forms, or pages after 90 days from original date of issue or next manual review,
unless the FAA informs the V.P. of Quality that there is a concern with the revision.
(Reference The FAA Review and Acceptance Process RSQM Section 1, Page 13)
c. The V.P. of Quality or Chief Inspector will issue temporary revision after the revision has
been approved as outlined in the RSQM Change Request process.
d. The V.P. of Quality or Chief Inspector will issue a Temporary Revision into the Master Repair
Station Quality Manual (Electronic online).


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INTRODUCTION
e. The temporary revision will be identified by the paragraph(s) that have been revised
highlighted in (yellow).
f. The List of Effective Pages and Record of Revisions page will also indicate the temporary
revision.

3. FAA Review & Acceptance
a. Whenever the RSQM is revised, the V.P. of Quality will Email a printed copy of the revised
manual to the FAA Flight Standards District Office (FSDO) in Baton Rouge, LA for review
and acceptance.
b. If any submitted manual/revision is found to be unacceptable, the FAA will notify the V.P. of
Quality, in writing, of the reason(s) and request corrections. The V.P. of Quality coordinates
with the FAA and applicable ASL personnel to make the necessary changes and resubmits a
printed copy for FAA acceptance. The V.P. of Quality will also determine if any work is
affected by the unacceptable revised procedure(s) and ensure that any required rework to
customer aircraft is required.
c. Once the FAA FSDO finds the manual acceptable, it will provide written acceptance to ASL.
d. Receipt of FAA acceptance will be noted on the LEP in the FAA Acceptance Block.


Section II
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Manual
REPAIR STATION ELEMENTS
II. REPAIR STATION ELEMENTS
A. REPAIR STATION ORGANIZATION
1. General
This repair station primarily performs maintenance, preventive maintenance, and alterations on
transport category aircraft for air carriers and commercial operators. Therefore, this organization
segregates general maintenance from inspection functions establishing the appropriate
separation when required inspection item inspections are conducted.
All employees performing maintenance or other safety-related functions for an air carrier or
commercial operator certificated under 14 CFR Part 121 or Part 135 are included in an FAA-
approved anti-drug and alcohol program.

2. Organizational Structure
This repair stations organization is as shown in the following chart. The chart includes those
positions with duties and responsibilities relating to the management and operations of the repair
station under 14 CFR Part 145 regulations. Not all the positions listed are filled at any given
time; one person may be assigned to fulfill the duties and responsibilities of more than
one position.


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Organization Chart


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A. REPAIR STATION ORGANIZATION (CONTINUED)
3. Delegation of Authority Process
a. Individuals may delegate their authority; however, such delegation does not relieve them of
their responsibility. Whenever an individual will be temporarily unavailable to perform his /
her duties, that person must authorize another qualified individual to act on his / her behalf
for the duration of the absence.
b. Unless otherwise specified, when a position within the organization chart is vacant, the
responsibilities and authorities associated with that position are transferred to the person to
whom the vacant position reports.

4. FAA Accountabl e Manager/General Manager
The General Manager is responsible for all operations conducted by AAR-ASL. He or she is
responsible for the overall direction and operation of the facility and for ensuring adequate
resources are available to meet all requirements. Specifically, the General Manager is
responsible for:
Acting as the FAA Accountable Manager.
Providing adequate housing, facilities, equipment, materials, and data to support work
consistent with the repair stations ratings.
Providing and ensuring the repair station has a sufficient number of personnel to plan,
supervise, perform, and approve for return to service the maintenance, preventive
maintenance, or alterations performed under its certificate.
Providing feedback to employees regarding matters conducted at AAR-ASL.
Has authority over the policies and procedures that govern contract maintenance.
Has authority for policies and procedures related to the Capability List.
Has authority for the repair station physical plant, equipment, tools, materials, and support
infrastructure.
Has authority to establish, change, modify, and revise the organization, duties, and
responsibilities.
Has authority for the policies and procedures for accomplishing maintenance and
inspections away from the main base.
Has authority for the Human Factors program.
Ensuring AAR-ASL changes its certificate as required by 14 CFR 145.57.
Ensuring AAR-ASL returns its surrendered, expired, suspended, or revoked certificate to the
FAA when it is no longer needed.


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Ensuring AAR-ASLs repair station certificate and operations specifications are available on
the premises for inspection by the public and the FAA.
In the absence of the General Manager, the V. P. of Quality acts on his or her behalf.
In addition to the overall responsibilities listed above, this position has the following specific
duties:
Is the primary contact for all regulatory agencies
Responsible for the day-to-day management and overall quality and safety of the entire
organization
Is the final authority for the content and revisions of the FAA Op Specs
Ensures procedures are established that provide for the adequate safety of repair station
personnel, customers, and customer aircraft/components
Liaison with the local Airport Authority on facility issues.
Responsible for ensuring that repair station personnel follow all applicable regulations

5. Senior Human Resources Manager
The Senior Human Resources Manager is responsible for:
Administering AARs drug and alcohol prevention program
Maintaining Summary of Employment Forms
The Senior Human Resources Manager is also responsible for other duties as directed or
required.
In the absence of the Senior Human Resources Manager, a person designated by the General
Manager will act on his or her behalf.

6. Vice President of Operati ons
The V. P. of Operations is responsible for hangar operations. He or she is responsible for
managing and directing all maintenance functions provided under the repair station certificate
and operations specifications in his or her assigned area. The V. P. of Operations must be
thoroughly familiar with applicable regulations. Specifically, he or she is responsible for the
following in their assigned area:

Ensure there is sufficient number of personnel with the training or knowledge and experience
to perform the maintenance, preventive maintenance, or alterations.
Ensuring all maintenance is properly documented and accomplished with approved or
acceptable data.


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Responsible for the efficient layout of the repair station and for ensuring the facilities, tools,
equipment, and materials are adequate to perform all work under the repair station
certificate.
Ensuring all non-certificated individuals performing work for the repair station have the
appropriate abilities based on their knowledge, training, experience, or practical tests.
Being familiar with the methods, techniques, practices, aids, equipment, and tools used to
perform maintenance, preventive maintenance, or alterations.
Managing all maintenance activity in the repair station.
Has authority for policies and procedures related to maintenance operations.
Has authority to establish, change, modify, and revise the organization, duties and
responsibilities for his or her assigned area.
Ensuring AAR-ASL does not operate without or in violation of its certificate, ratings, or
operations specifications.
Ensuring established safety procedures are observed.
Ensuring established security procedures are observed.
Must approve any changes to the procedures that AAR-ASL uses in determining the
appropriate maintenance program for a customer.
In coordination with the V. P. of Quality, making final airworthiness determinations arising
from a dispute between the operations function and the inspection function.
The V. P. of Operations has overall responsibility for ensuring all work away from the main
base follow the procedures of the Repair Station.
Managing maintenance planning efforts.
Has overall responsibility to ensure special tools and test equipment are available for all
work performed.
Has authority for control of equipment, tools, and materials.
Performing other duties as directed or required.
In the absence of the V. P. of Operations, the Director of Maintenance (Hangar) acts on his or
her behalf.

7. Director of Maintenance
The Director of Maintenance is responsible for the operations of his or her assigned area at the
repair station. He or she is responsible for managing and directing all maintenance functions
provided under the repair station certificate and operations specifications in his or her assigned
area. The Director of Maintenance must be thoroughly familiar with applicable regulations. The
Director of Maintenance must be appropriately certificated per 14 CFR Part 65. Specifically, he
or she is responsible for:


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Ensuring there is sufficient number of personnel with the training or knowledge and
experience to perform the maintenance, preventive maintenance, or alterations.
Ensuring all assigned maintenance work is properly documented and accomplished with
approved or acceptable data.
Responsible for the efficient layout of the facilities in their assigned area and that equipment
is adequate to perform all work under the repair station certificate.
Being familiar with the methods, techniques, practices, aids, equipment, and tools used to
perform maintenance, preventive maintenance, or alterations.
Managing all assigned hangar maintenance activity of the repair station.
Ensuring established safety procedures are observed.
Acts as V. P. of Operations in their absence.
In the absence of the Director of Maintenance, a designated Manager acts on his or her behalf.

8. Program Manager
The Program Manager is responsible to the Director of Maintenance for the overall operation
and aircraft maintenance of their program. The Program Managers are responsible for their
respective projects within their program. They will interface with the customer and AAR senior
management on their assigned program. The Program Manager is responsible for all facets of
performance metrics for their assigned program. Specific duties include:
Determine staffing requirements and any over/under needs for labor allocation to his/her
program.
Review metrics for visit/project performance under their program:
o TAT (Turn Around Time)
o Aircraft Damage
o Personnel Injuries
o Hours Sold vs. Hours Applied for Projects
o Quality
o Environmental Health & Safety
Verify bay standardization and ensure all hangars are following plan
Ensure the posted status boards are up-to-date (power on, hydraulics on/off, etc.)
Review and take action on any safety or compliance issues.
Review and take action on any tooling, materials, engineering, and other support issues for
their program.


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Hangar cleanliness for their assigned hangars is being maintained.
Assist in coordinating all support for Project Managers in their program.
Train and assist subordinates in the use of proper procedures, methods, and practices to be
followed.

9. Project Manager
The Project Manager shall be responsible to the Program Manager for the overall operation of
the individual customer aircraft projects. In addition, the Project Manager shall:
Manage and direct their assigned project(s) efficiently to assure timely completion of the
project on schedule while meeting the airworthiness and quality standards required by the
Repair Station, FAA, and customer.
Promote the Repair Station philosophy regarding quality, safety, policy, and teamwork at all
times.
Assist in training and mentoring employees to use proper procedures methods and practices
for their respective duties and responsibilities to assure an efficient project that meets the
Repair Stations, FAAs and customers standard for Airworthiness and Quality.
Ensure all maintenance tasks are performed within the regulations and/or guidelines set
forth by government regulatory agencies (i.e., FAA, EPA, OSHA), as well as the Repair
Stations policies and procedures, customers requirements, and applicable aircraft manuals.
Ensure supporting departments are informed of Project schedules, priorities, and needs.
Ensure all necessary resources (i.e., tooling, materials, personnel) are available to create a
smooth and efficient workflow.
Direct personnel assigned to their project from all departments and provide technical
assistance to personnel, as required, to ensure a smooth and efficient workflow.
Ensure work areas are maintained in a clean and orderly manner.
Coordinate, supervise and direct Supervisors, Lead Technicians, as required, to ensure that
all necessary maintenance entries are properly executed by responsible mechanics on
proper maintenance forms and work orders used by the Repair Station and customer.
Interface with Customer Representatives.
Prepare for and manage Project Status meetings with Repair Station staff and customer
representatives.
Promote proper communication between departments and shifts (i.e., proper verbal and
written maintenance turnover).
Monitor total control over aspects of project management.
Monitor project milestones to ensure proper man-hour accounting and that maintenance
tasks are completed in a timely manner.


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Manage and account for all work hours, including overtime hours, ensuring proper
distribution and reducing overtime hours except when project schedules are jeopardized.
Manage employees indirect hours (i.e., PTO, vacation) to avoid abuse.
Coordinate with Supervisor to ensure that all personnel performance evaluations are
completed on time.
Issue administrative action to personnel when necessary.
The Project Manager may delegate duties to a qualified person as necessary. However, such
delegation shall not relieve the Project Manager of his or her overall responsibility.

10. Supervisors (All Departments)
Supervisors are responsible for supervising all functions assigned to them and providing
airworthy aircraft and/or components upon completion of maintenance. Each Maintenance
Supervisor must be appropriately certificated per 14 CFR Part 65 and are responsible for:
Being available for consultation on matters relating to work being accomplished on his or her
assigned aircraft.
Supervisory personnel are responsible for ensuring parts within their jurisdiction are properly
handled.
Ensuring all required paperwork is satisfactorily completed and signed and complies with all
existing regulations and procedures.
Ensuring all equipment is properly used and adequate safeguards are in place to protect the
customers aircraft and equipment.
Monitoring the work of personnel under his or her responsibility for proper work performance,
productivity, quality, and personnel safety.
Reviewing personnel for job qualifications and status and for maximizing the use of
manpower.
Performing on-the-job training for personnel.
Providing guidance and technical advice to lead technicians and technicians.
Coordinating with other appropriate departments to organize and control the customers
work package and any special considerations.
In the absence of a Supervisor, an appropriate Lead Technician as delegated by a manager acts
on his or her behalf.
11. Intentional l y Left Bl ank


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12. Lead Technician
The Lead Technician is responsible to his or her respective department supervisor for all
functions assigned to provide airworthiness of the aircraft upon completion of maintenance at the
facility. A Lead Technician is required to be a certified Airframe Technician, Powerplant
Technician, or hold a Repairman Certificate (as applicable to the work they are supervising).
Specifically, the Lead Technician is responsible for:
Utilize and carry out the 24/48/72 Hour Plan established by the Project Manager.
Provide feedback to Project Manager regarding aircraft and job status to assist with
planning and re-planning the 24/48/72 Hour Plan.
Keep technicians productive, clearing their road blocks.
Accountability of paperwork assigned to technicians.
Communicate with all appropriate parties and departments to ensure success of visits.
Set material requirements with accurate and honest due dates.
Ensure all required data is provided to Researcher and Buyers to ensure that correct and
effective parts are purchased.
Monitor and correct cards every shift.
Monitoring the work of personnel under his or her responsibility for proper work performance
and productivity.
Reviewing assigned personnel for task knowledge and qualifications to maximize
productivity.
Provide guidance and technical expertise to technicians.
Perform other duties as directed or required.
In the absence of the Lead Technician, the applicable Supervisor acts on his or her behalf.

13. Operations Manager
The Operations Manager is responsible for ensuring the work flow set by the Directors of
Maintenance and Program Managers is followed on weekends and off-shift (to include evening
and midnight shifts) by ensuring they remain informed of the status of the operation. The
Operations Manager must be appropriately certificated per 14 CFR Part 65. They must ensure
that all work groups are safe, compliant and are performing their assigned job duties as required.
Their responsibilities include but are not limited to:
Provide leadership for AAR-ASL to the employees on the off-shift and weekends.
To ensure the directives of the Director of Maintenance and, specifically, the Program
Managers are followed and executed.


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To ensure that the proper manpower required on a visit that has been deemed priority is
allocated to that visit.
Provide briefings, as required, to the V. P. of Operations, Director of Maintenance, and
Program Managers of status changes during their off-shift.
To hold accountable any individual that is not following AARs Policies and Procedures.
Provide a safe and compliant environment for the AAR-ASL work force.
Other duties as assigned.
In the absence of the Operations Manager a person delegated by the Director of Maintenance
acts on his or her behalf.

14. Manager of Tooling
The Manager of Tooling is responsible for the Operation of Tool Cribs and Tooling Support Staff.
The Manager of Tooling must be appropriately certificated per 14 CFR Part 65. Specifically, the
Manager of Tooling is responsible for:
Providing a plan for manpower that includes skill sets, required labor levels, and timing
suitable for scheduling the work in an efficient manner.
The tool calibration program.
Coordinate with Planning, Materials and Purchasing Departments to obtain tooling and test
equipment not located at the repair station.
Ensure support of Planning/Pre-planning Department on tooling and GSE items.
Ensure support of Operations/Production on tooling and GSE items.
In the absence of the Manager of Tooling, a person designated by the V. P. of Operations acts
on his or her behalf.

15. Director of Pl anning & Production Control
The Director of Planning and Production Control is responsible for the conversion of signed
sales contract to implementation of the operating plan. Specifically, the Director of Planning and
Production Control is responsible for:
Reviewing the work-scope and instructions from a customer and verifying that the
organizational linkages are in place to execute the work-scope.
Develop, implement and manage an integrated system of metrics, including:
Cycle time performance
Environmental, health & safety, and people performance
Materials service level performance


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New business development initiatives.
Bringing to the attention of the V. P. of Operations any discrepancies that would affect the
ability of the repair station to implement the work-scope in a timely fashion.
Maintaining the operational hangar schedule.
Prioritizing and planning appropriate segments of the hangar plan.
Ensuring the work scope and instructions from a customer and verifying the repair station
work order is consistent with the customers.
Responsible for providing technical data needed for the project to the Technical Publications
Administrator.
Coordinating with V. P. of Operations as necessary to ensure required resources are
available when needed.
Coordinating with the Manager of Tooling to ensure special tools or test equipment is
obtained prior to work on aircraft.
Responsible for determining the work to be accomplished, the details of the technical data,
procedures, record keeping requirements, and any special tools or test equipment.
Operation of the work control booth
Monitor and ensure security of work packages
Manage the resources in the Engineering Department to ensure that all needed engineering
support is provided in a timely and cost-effective manner
Assigning work to appropriate staff members.
Performing other duties as directed or required by the General Manager.
In the absence of the Director of Planning and Production Control, a person, designated by the
Director of Planning and Production Control, acts on his or her behalf.

16. Manager of Materials
The Program Manager of Materials is responsible for ordering, stocking, issuing, shipping, and
receiving parts and materials. In addition, he/she is responsible for the daily operations of the
Purchasing Department. Specifically, he or she is responsible for:
Identifying medium- to long-range customer requirements.
Liaising with customer planning departments and onsite Program Managers, as necessary.
Identifying surplus inventory.
In the absence of the Manager of Materials, the Warehouse Manager acts on his or her behalf.


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17. Warehouse Manager
The Warehouse Manager is responsible for the daily operations of the materials warehouse.
Specifically, he or she is responsible for:
Responsible for the shelf-life program.
Ensuring parts and materials are ordered when needed, properly inspected when received,
have all required documentation, stored to protect them from damage or deterioration, and
issued when necessary.
Ensuring all parts and materials are properly packaged and processed when shipped from
the facility.
Ensuring all of his or her employees understand how to issue parts and materials and how to
process all documentation.
Ensuring all of his or her employees are trained in accordance with Title 49, Code of Federal
Regulations and International Air Transport Association standards before being responsible
for properly processing and packaging materials to be shipped out of AAR-ASL.
Ensuring all safety and security procedures are met.
Monitoring the work of his or her employees for proper performance, productivity, and
quality.
Being continuously available for consultation on matters relating to the work being
accomplished.
Developing the department work schedule.
Ensuring parts within their responsibility are properly handled and stored.
Ensuring all required paperwork is satisfactorily completed, signed, and complies with all
existing FAA regulations and procedures.
Perform his or her work and the work flow of the crew.
Ensuring personnel is qualified for assigned tasks, and proper procedures, manual
references are followed and used in accomplishing assigned work.
Review personnel qualifications and status for maximizing manpower utilization and
requirements.
Review personnel on the job training.
Provide guidance and technical advice to leads and stores personnel.
In the absence of the Warehouse Manager, the Program Manager of Materials will appoint a
person to act on his or her behalf.

18. V. P. of Quality


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The V. P. of Quality is responsible for the operation of the quality assurance and quality control
functions of the repair station. He or she is responsible for establishing and directing inspection
standards, methods, and procedures used by the repair station in complying with all applicable
regulations and must be appropriately certificated per 14 CFR Part 65. He or she also is
responsible for the overall quality monitoring process. Specifically, the V. P. of Quality is
responsible for:
In coordination with the V. P. of Operations, making final airworthiness determinations
arising from a dispute between the operations function and the inspection function.
Coordinating with the FSDO for activities that require approval or acceptance of the FAA,
such as changes to the Operations Specifications and the Capability List.
Ensuring that the Capability List is current, including making revisions.
Setting policies that ensure the proper documentation of all parts and materials used by the
repair station.
Instituting a continual improvement process for inspection procedures and methods to
improve the quality and economic efficiency of the maintenance process.
Establishing and maintaining processes to ensure the airworthiness of all customer aircraft,
components, and constituent parts approved for return to service.
Facilitating FAA surveillance activities.
Assisting the FAA in obtaining responses to questions or requests for information.
Coordinating company responses to FAA letters of investigation.
Maintaining the record keeping system for reports and records required by 14 CFR 145.219
and 14 CFR 145.221.
Establishing the policies and procedures that govern the development, revision, and
distribution of this manual.
Ensuring all required revisions to manuals and lists supporting contract maintenance
functions are forwarded to the FSDO.
Ensuring contract maintenance follows all AAR-ASL procedures, policies, and regulatory
requirements and that a list of contract functions and facilities is maintained.
Ensuring that any change to the maintenance functions AAR-ASL contracts out receives
FAA approval before the effective date of the change.
Responsible for Quality Assurance, Quality Control, Environmental Health & Safety (EHS)
and Training departments.
Responsible and has authority for the Scrap Parts program.
Has authority for RII Program per customer requirements.
Has authority for Software control.
Has authority for Tool Calibration Program policies.


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Has authority for Repair Station Rosters.
Has authority for Inspection & Quality Assurance Processes.
Has authority and is responsible for Technical Data processes.
Acting on behalf of the Technical Publications Administrator in his/her absence.
In the absence of the V. P. of Quality, the Director of Quality Control acts on his or her behalf.

19. Director of Quality Control
The Director of Quality Control is the Chief Inspector and is responsible for the daily operation of
the Quality Control Department. He or she is responsible for managing the day-to-day details of
inspection standards, methods, and procedures used by the repair station. The Director of
Quality Control must be thoroughly familiar with applicable regulations and be appropriately
certificated per 14 CFR Part 65. Specifically, he or she is responsible for:
Ensuring all of his or her employees in Receiving Inspection is trained in accordance with the
RSQM and customer requirements.
Maintaining the roster of inspection/supervisor personnel and inspection/supervisor
personnel authorizations, including authority to sign a maintenance release for approving an
article for return to service in accordance with 14 CFR 145.161 (a) (2)(3)(4) and (b).
Maintaining the Stamp Roster.
Responsible for ensuring all required reports (Suspected Unapproved Parts, SDRs, etc.) are
filled out and filed with the FAA FSDO and coordinate reporting with the customer.
Ensuring all inspection personnel are trained, qualified, and authorized.
Ensuring the performance of inspection personnel.
Providing guidance and supervision to inspection personnel.
Responsible for Software control.
Responsible for RII Program per customer requirements.
Ensuring inspections are properly performed and that proper inspection records, reports, and
forms are properly completed before approving any product for return to service.
Developing and monitoring the receiving inspection procedures for examining incoming
products maintained by a vendor.
Ensuring proper inspection of:
Parts, supplies, and other incoming material to the repair station (Receiving
Inspection).
In-process inspections specified in the work package or technical data.


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Work completed by the repair station before approval for return to service (final
inspection).
Responsible for all inspection processes.
Ensuring all articles, parts, supplies and material are properly identified and tagged.
Responsible for Standards, Intervals and Procedures of the Tool Calibration Program.
EHS surveillance ensuring a safe and healthy workplace for all personnel.
Managing and maintaining the systems for records and reports required by 14 CFR 145.219
and 14 CFR 145.221.
In the absence of the Director of Quality Control, the V. P. of Quality acts on his or her behalf.

20. Manager of Quality Control
The Manager of Quality Control is responsible for managing the day-to-day details of inspection
standards, methods, and procedures used by the repair station. The Manager of quality Control
must be thoroughly familiar with applicable regulations and be appropriately certificated per 14
CFR Part 65. Specifically, he or she is responsible for:
Ensuring all of his or her employees in receiving inspection is trained in accordance with the
RSQM and customer requirements.
Responsible for ensuring all required reports (Suspected Unapproved Parts (SUP), MDRs,
SDRs, etc.) are filled out and filed with the FAA FSDO and coordinate reporting with the
customer.
Ensuring all inspection personnel are trained, qualified, and authorized.
Ensuring the performance of inspection personnel.
Providing guidance and supervision to inspection personnel.
Responsible for RII Program per customer requirements.
Ensuring inspections are properly performed and that proper inspection records, reports, and
forms are properly completed before approving any product for return to service.
Ensuring proper inspection of:
Parts, supplies, and other incoming material to the repair station (receiving
inspection).
In-process inspections specified in the work package or technical data.
Work completed by the repair station before approval for return to service
(final inspection).
Ensuring all articles, parts, supplies, and material are properly identified and tagged.
Ensuring a safe and healthy workplace for all personnel.


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In the absence of the Manger of Quality Control, the Inspection Supervisor acts on his or her
behalf.

21. Inspection Supervisor
The inspection supervisor is responsible for supervising all functions assigned to them and
providing airworthy aircraft/components upon completion of maintenance. Each supervisor must
be appropriately rated under 14 CFR Part 65 and is responsible for:
Available for consultation on matters relating to work being accomplished on assigned
aircraft.
Ensuring parts within their responsibility are properly handled.
Ensure all required paperwork/documents are satisfactorily completed and signed and that it
complies with all existing applicable FAA regulations and AAR-ASL procedures.
Ensures that all equipment is properly used and adequate safeguards are in place to protect
the customers aircraft and equipment.
Monitor inspection personnel work under his/her responsibility for quality, proper work
performance, productivity, and personnel safety.
Review personnel qualifications and status for maximizing manpower utilization and
requirements.
Review personnel on-the-job training.
Provide guidance and technical advice to lead technician and technicians.
Coordinate with other departments to organize and control customer work documents,
packages, and any special considerations.
Review completed work documents and work packages.
Maintain inspector proficiency through documentation of on-the-job and formal training.
Signs applicable documents/paperwork prepared for units overhauled, repaired or
functionally tested, and ensures that all forms are completed accurately.
Perform all duties as an Inspector.
Make appropriate Logbook entries in accordance with customer procedures.
Ensure FAA Form 337 for major repairs or alterations are completed.
Ensure SDRs are submitted in accordance with customer instructions, procedures, and
requirements.
Ensuring a safe and healthy workplace for all personnel.


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In the absence of the Inspector Supervisor, an appropriate Inspector may be delegated by the
Director of Quality Control to act on his or her behalf.

22. Lead Inspector
The Lead Inspector is responsible to the Inspection Supervisor for all functions assigned and to
ensure airworthiness of the aircraft upon completion of maintenance at the facility. The Lead
Inspector must be an appropriately rated per 14 CFR Part 65. Specifically, the Lead Inspector is
responsible for:
Coordinating inspection services.
Briefing technicians on quality and safety issues.
Performance of his or her own work and the work of the crew.
Ensuring the crew performs quality work.
Ensuring personnel are qualified for tasks performed and that proper procedures, manual
references, materials, and tools are used in accomplishing work.
Assuring all paperwork is completed and signed in compliance with all existing regulations
and procedures.
Signing the applicable paperwork prepared for units overhauled, repaired, or functionally
tested, and ensuring that all forms are completed correctly.
Performing all duties as an Inspector.
Make appropriate logbook entries in accordance with the customers procedures.
Completes FAA Form 337s for major repair or alterations.
Review and submit SDRs in accordance with customers instructions.
Ensuring a safe and healthy workplace for all personnel
A Lead Inspector may delegate his or her duties to other designated inspection personnel as
required, but such delegation does not relieve him or her of the overall responsibility.

23. Manager of Quality Assurance
The Manager of Quality Assurance is responsible for managing the quality assurance standards
and quality monitoring processes and procedures in the repair station and has overall
responsibility for the Human Factors Program. The Manager of Quality Assurance must be
thoroughly familiar with applicable regulations. The Manager of Quality Assurance must be
appropriately certificated per 14 CFR Part 65. Specifically, he or she is responsible for:


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Providing guidance and supervision to personnel assigned to the Quality Assurance
Department, including all auditing functions of the repair station.
Ensuring the accuracy of records and reports required by 14 CFR 145.219 and 14 CFR
145.221.
Reviews the FAA Inspection/Supervisor Roster and notifies the V. P. of Quality of any
changes.
Administering the Auditing and Analysis and Surveillance Programs.
Establishing the standards and procedures to initially qualify vendors.
Analyzing customer, FAA and auditing agencies feedback data/reports to evaluate the
quality of products of the Repair Station.
Representing the Repair Station during audits by outside agencies.
Prepare and provide training and communication material on human factors topics.
Shall conduct analysis on safety events from the AAR Performance Reporting Information
System (APRISe) reports and from audit data.
Develop and maintain human factors awareness program.
Assists local management and supervision in Maintenance Human Factors oriented
problems.
Coordinates Maintenance Human Factors efforts with customer as appropriate.
Monitor industry trends and activities with regards to human factors issues.
Maintain close liaison with FAA, NTSB, AAR Corp, and industry human factors
organizations.
Establish and maintain reporting system that provides for timely and free flow of human
factors information.
Lead Investigator for Quality/Safety Investigations keeping investigations on track.
Maintain APRISe database of incidents and reported events to monitor and analyze human
factors trends.
Provide regular reports on human factors trends to AAR Management.
Ensures compliance with EASA and FAA Part 145 Regulations.
Attends industry conferences as pertinent to Maintenance Human Factors.
EHS surveillance ensuring a safe and healthy workplace for all employees.
In the absence of the Manager of Quality Assurance, the V. P. of Quality acts on his or her
behalf.


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24. Repair Station Trainer
The Repair Station Trainer is responsible for coordinating all training requirements and for
overall management of the training program. Specifically, he or she is responsible for:

Maintaining the process to identify training needs for all personnel, both initial and recurrent
as outlined in the Training Program Manual.
Maintaining a current and accurate FAA-approved training program.
In conjunction with the V. P. of Quality, obtaining all required FAA approvals for the training
program and revisions.
Identifying options for training that meet the training needs, such as classroom, on-the-job,
distance learning, or computer-based instruction.
Coordinating the training process decisions with the V. P. of Quality.
Maintaining a system of recordkeeping for all technical training records.
Ensuring the training records are kept current and complete.
Initiating periodic audits of training records and ensuring correction of any discrepancies
found.
In the absence of the Manager of Training, the V. P. of Quality acts on his or her behalf.

25. Director of Production/Pl anning
This position reports to the Accountable Manager. The Director of Production/Planning follows
established ASL procedures directing flow and control in development of work packages for
customer aircraft and confirming ASL compliance with customer requirements.
Serves as liaison with customers to confirm all customer requirements in accordance with
customer FAA approved maintenance and inspection programs
Assemble work packages including applicable Airworthiness Directives and Service Bulletins
Identify required tools and equipment and determine availability
Coordinate with Inspection and Production departments for special needs generated by the
work package
Develop task cards as needed for aircraft
Monitor work force and material consumption and expense for each customer
Other requirements not identified above that may impact the ability of the Repair Station to
deliver an airworthy product in compliance with the customers GMM.


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26. Production Control Lead
This position reports to the Project Manager. The Production Control Lead is responsible for the
efficient operation of each production control booth. In addition, he is responsible for the
following:

Coordinates with Project Managers in scheduling and planning maintenance work loads
Schedules personnel for all shifts and hangar bays
Performs weekly audits of work packages
Informs Management of all work progress

27. Liaison Engineer
This position reports to the Director of Maintenance. Engineering is responsible for:
Provide technical support when required
Design SRM-based repairs and write work instructions. Perform stress calculations and
structural analysis and document damage on proposed repairs.
Design repair beyond SRM allowances for review and approval by FAA/DER
Perform liaison/interface between AAR-ASL and DER/OEM on repairs that require FAA
approval
Perform liaison/interface between AAR-ASL and Customers on repairs for each Customers
aircraft
Design and document minor repairs that do not require FAA approval
Provide technical support and guidance to AAR-ASL Repair Station personnel when needed
Performs stress calculations and structural analysis on proposed repairs
Responsible for determining if alternate tools and test equipment are equivalent to those
recommended by the manufacturer
Conducting and documenting the analysis for determining equivalency for tools and test
equipment
Provide support to all personnel in the operations with regard to technical issues or technical
data
In conjunction with the Director of Quality; working with the FAA on technical issues
Working with customer engineering or technical personnel to resolve issues such as
required technical data and proper documentation of alterations of products or standard
practices


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Troubleshooting any technical problems associated with repair station work reported by
customers
Performing other duties as directed or required

B. GENERAL REPAIR STATION PROCEDURES
1. Personnel Rosters
a. The Chief Inspector is responsible for maintaining the personnel rosters required by 14 CFR
145.161 that identify key management, supervisory, and inspection personnel authorized to
act on behalf of ASL.
The Roster of Management and Supervisory Personnel includes the names of the
repair station officials who are responsible for its management and the names of
supervisors who oversee maintenance functions
The Inspection Personnel Roster lists all inspection personnel
A roster of personnel authorized to sign a maintenance release approving a maintained
or altered article for service will be kept
Additionally, the Required Inspection Item (RII) roster lists Inspectors who are trained
and qualified for a Customers RII program
The Stamp Roster lists personnel who have been issued stamps and identifies the
active authorizations issued for each employee; including whether the individual is
authorized to sign a maintenance release for approving a maintained or altered article
for return-to-service
b. The Chief Inspector is accountable for the personnel and stamp rosters, the process for
designating each inspection authorization, and for ensuring the information on each roster
accurately reflects those designations.
c. All ASL rosters are generated from ASLs StAAR computer database. Rosters contain the
number of the stamp issued to, and a listing of the specific authorizations approved for, that
employee. Authorizations may include, but not limited to: receive inspect, RII, release-to-
service. The applicable roster will contain the specific information on the Authorizations
Section III, A, Inspection System, item 28, Inspection Stamps contains the procedure for
issuing stamps.
d. When an employee is hired or transferred into a key management, supervisory, or inspection
department position; or the status of an employee already in one of these positions changes;
the individuals supervisor must notify the Chief Inspector of the change within 2 business
days. This notification must include:
The individuals name and job title
The nature and scope of his/her duties (including any applicable changes)


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The reason for the change (ex: new hire, reassignment, termination, etc.)
The effective date of the change
e. The Chief Inspector will verify the qualifications of the employee for the position prior to
approving the personnel move. Verification may include, but not limited to, employment
history, completed training, certifications, and work experience.
f. The Chief Inspector removes authorizations from the system when so advised; however,
before adding an individual or authorization to the system, the Chief Inspector coordinates
with the V.P. of Quality and consults the persons Employment Summary Form (generated
by StAAR), which is maintained as a part of his/her training record, to ensure he/she is
appropriately qualified for the specific authorization(s) requested. The Employment
Summary Form includes:
The employees present title
Total years of experience and type(s) of maintenance work performed
Past relevant employers and periods of employment
Scope of present employment, type of certificate, and ratings held, if applicable
g. Within 5 business days of the change, the rosters required by FAR 145.61 must reflect
changes caused by termination, reassignment, change in duties or scope of assignment, or
addition of personnel.

C. REPAIR STATION FACILITY & OPERATIONS
1. Housing & Facilities
a. AARs housing and facilities are accepted by the FAA for the accomplishment of work
described on its Air Agency Certificate and Op Specs. Any changes to the housing /
facilities must be approved by the Accountable Manager. Any changes that could have a
significant effect on how the repair station performs the maintenance, preventive
maintenance, or alterations under its repair station certificate and operations specifications
must be accepted by the FAA before they are implemented.
b. All equipment, materials, and technical data needed for the work this repair station performs
will be available where the work is accomplished and be under the repair stations control
when the work is being performed.
c. The V.P. of Operations is accountable for the day-to-day utilization and overall quality of the
physical hangars.
2. Physi cal Location/Hangar/Non-Repair Station Areas/Facil ities Descriptions
Located at 1945 Merganser Street, Lake Charles, LA, 70615 ASL is located on the Chennault
International Airport property. Descriptions of the hangars located on the property are as follows:
Hangar D is capable of housing 3 wide body and 1 narrow body and is constructed of steel frames,
metal clad, and concrete blocks. Floors are of 17 inch concrete with ceramic tile bathroom floors.
The hangar is heated with gas fired units. Lighting is accomplished by overhead direct fixtures. Fire


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protection is accomplished by deluge, wet pipe and foam type systems. Office space in this hangar
includes Mezzanine office area 5,026 Sq. Ft., and hangar D annex office area 9,118 Sq. Ft.
Hangar floor space 149,600 sq. ft.
Hangar E is capable of housing 1 wide body aircraft and is constructed of steel frames, metal clad,
and concrete blocks. Floors are of 17 inch concrete with ceramic tile bathroom floors. The hangar is
heated with gas fired units. Lighting is accomplished by overhead direct fixtures. Fire protection is
accomplished by deluge type system, wet pipe. This hangar includes a shower area for men and
women and additional office area.
Hangar floor space 57,200 sq. ft.
Additional Area 2,000 sq. ft.
Hangar F is capable of housing 1 wide body aircraft and is constructed of steel frames, metal clad,
climate controlled with down draft forced air system. Lighting is accomplished by explosion proof
overhead direct fixtures. Fire protection is accomplished by deluge type system, wet pipe. This
hangar includes break and restroom areas and additional office area.
Hangar floor space 57,200 sq. ft
Additional Area 3,700 sq. ft
Hangar G is capable of housing 2 wide body aircraft and is constructed of steel frames, metal clad,
heated with gas fired units. Lighting is accomplished by overhead direct fixtures. Fire protection is
accomplished by deluge type system, wet pipe.
Hangar floor space 73,720 sq. ft
Due to the frequency of international customers from nations that do not have a bi-lateral agreement
in place with the FAA, certain areas of the facility can be temporarily designated a non-repair station
area (hereafter referred to as the NRSA) in order to remove that area from the jurisdiction of the FAA
and provide positive segregation of aircraft, parts, components, and materials.
Such designations will be temporary in nature, usually for the duration of the aircraft visit to the
facility. The non-repair station area designation will begin upon the induction date of the aircraft, and
will cease on the aircraft delivery date, at which time the area will revert to repair station status.
All relevant maintenance and operational paperwork, including maintenance release, will be
accomplished in accordance with the cognizant regulatory authority and/or the aircraft owner or
operator.
Designation of a portion of the facility as a non-repair station area will be accomplished only in those
instances where the FAA has no valid jurisdiction over the operation by either regulation or bi-lateral
agreement. As a courtesy, the FAA will, upon their request, be kept apprised of the status of the
aircraft in work.
The NRSA when designated, may be affected by any of a multiple of means at the discretion of the
Director of Maintenance. Suggested best practice options are as follows: 1. Signage affixed to all
entry doors of the hangar and stores areas, preferably metal approximately 1 square foot in area and


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affixed with the ability to remove without damage to the facility. 2. Use of rope, pylons and signage
surrounding the entire aircraft and work product areas if located in a shared building. 3. Use of a
temporary fence with limited access separating the NRSA from adjacent work product to ensure
segregation.
3010 Bldg. Sheet Metal Shop: This building is a climate-controlled building with forced air HVAC
system. Fire suppression is accomplished by a deluge type wet pipe system. It houses the machine
shop, a sheet-metal shop, and welding shop. The machine shop contains a digital read-out milling
machine and a metal lathe with a 12 chuck. The sheet metal shop includes a hydraulic sheet metal
break, a 4 manual break, metal rolling machines, metal stretching/shrinking machines, a 50 ton
hydraulic press, various cutting, grinding and sanders as well as a heat treat oven capable of holding
4 sections of metal. The welding shop houses a MIG/TIG welding machine.
Shop Space 6000 sq. ft

North Warehouse and Composite Shop: The North Warehouse and Composite shop area
constructed of steel frames, metal clad, and concrete blocks. Floors are of 17 inch concrete with
ceramic tile bathroom floors. The shop is heated with gas fired units. Lighting is accomplished by
overhead direct fixtures. Fire protection is accomplished by deluge type system, wet pipe. The
composite shop area contains two separate areas with a work area and a positive pressure clean
room for lay-up. The composite area contains a paint booth and a walk in oven for curing repairs.
Warehouse Floor Space 20,000 sq. ft
Composite Floor Space 10,000 sq. ft

Annex and Mezzanine Office Area: The Hangar D Annexes and Mezzanine area contain office
space utilized by production management, support personnel, Quality Assurance, Training, and
customers. The office space is lit with fluorescent lighting. Heating and cooling is provided by a
forced air system. Fire suppression is provided by a deluge type wet pipe system.
Office Area 21000 sq. ft

Building 3009: Building 3009 contains classrooms that may be utilized by the training department
and office space. The remainder is used for storage.
Office /Classroom Area 5000 sq ft

Hangar G Annex: The Hangar G annex is not currently in use.
Office and Classroom Area 1500 sq ft

Building 3102: Building 3104 contains work rooms for oxygen servicing and cad plating, along with
the NDT Shop and Battery Shop. Rooms are separated by walls for the different activities and tasks.
Total Building Area 1800 sq ft


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GSE Bui lding: The GSE Building contains a workshop area for company vehicles and various
ground support equipment, along with an area for tooling repair and test. Office areas are available
for paperwork and files.
Total Building Area 8000 sq ft

The ASL repair station maintains housing and facilities adequate for the ratings obtained from the
FAA. Specifically, there is:
Adequate housing for the repair stations personnel, equipment, and material needed to properly
perform the work authorized by its ratings
Adequate space for all work performed
Adequate facilities for properly storing, segregating, and protecting materials, parts, and supplies
so that work is protected from weather elements, dust, and heat
Adequate facilities to ensure workers are protected as to prevent impairment of their physical
efficiency
Suitable shop space for machine tools and equipment so that work is not done in an area that
may contaminate other parts or processes
Suitable assembly areas for the largest items to be properly worked on under the repair stations
ratings


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Lake Charles Maintenance Facil ity Floor Plan

HANGAR D

NOT TO SCALE


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HANGAR E


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HANGAR F


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HANGAR G


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Building 3010 Sheet Metal Shop


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HANGAR D EAST ANNEX FLOOR 1


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HANGAR D EAST ANNEX FLOOR 2


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HANGAR D MEZZANINE AREA


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HANGAR D WEST ANNEX


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NORTH WAREHOUSE / COMPOSITE


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BUILDING 3009

NOT TO SCALE


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GSE SHOP


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BUILDING 3102


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HANGAR G ANNEX

NOT TO SCALE

(Not in Use)


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C. REPAIR STATION FACILITY & OPERATIONS (CONTINUED)
3. Training Program
a. The ASL training program ensures that each repair station employee has the required
knowledge, skills, and capability to perform his/her assigned duties as they relate to
maintenance, preventive maintenance, and alteration within the scope of AARs air agency
certificate and Op Specs. The policies and procedures utilized to determine training
requirements and develop/revise the training program in accordance with 14 CFR 145.163
and 145.165 are addressed in the ASL FAA-Approved Training Program Manual which is a
separate manual from this RSQM.
b. When a revision is required to the Training Program Manual, the V.P. of Quality will forward
a revised copy to the FSDO for review. When the V.P. of Quality receives an approval letter
from the FAA, the V.P. of Quality will notify the Manager of Training to replace the current
manual with the newly revised and approved manual.

4. Work Performed Away From the Repai r Station Facility
a. ASL may perform work at a location away from the main repair station facility, but not
outside the U.S., on an occasional basis. ASL will not initiate the work until the FAA FSDO is
notified.
b. This section provides the procedures to be followed to ensure that all work is accomplished
with the same level of control as work performed at the main base.
c. When a request for special off-site work is received, the Accountable Manager, V.P. of
Operations, and V.P. of Quality work with the customer to verify the technical description of
the problem; the specific circumstances requiring the work; the specific customer-required
technical data, procedures, and paperwork to be utilized; and the location & expected
duration of the work.
d. The V.P. of Operations will research and develop a plan that identifies:
The Project Manager
The specific work that needs to be performed
The method for determining what technical data is required (including applicable
revision levels); and for ensuring data and this RSQM will be available on-site
Who will accomplish and inspect the work, including the method of verifying their
qualifications and authorizations to perform the specified work for that customer
The type of facilities, materials, equipment, and tools that will be required for the work;
including how they will be transported to the work site and any special handling
requirements
The estimated start and completion dates for the project
e. The V.P. of Operations distributes the plan via e-mail to the V.P. of Quality, Chief Inspector,
and the assigned Project Manager with a deadline for concurrence.


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f. The V.P. of Quality contacts the FSDO by telephone, and immediately follows up with an e-
mail, describing the circumstances requiring the work.
g. The V.P. of Quality must evaluate the housing and facilities where the maintenance is to be
performed to ensure the location meets the intent of 14 CFR Part 145. If no facilities are
available, the V.P. of Quality must determine how this will affect the work requested and if
the project is feasible.
h. When notified of approval, the Project Manager assigns qualified mechanics; and if
appropriately qualified inspectors are required, the Chief Inspector assigns them. The
Project Manager designates a team leader, with concurrence from the Chief Inspector.
i. While away, the Team Leader will maintain contact with the Project Manager. The Project
Manager will update the Accountable Manager, V.P. of Operations and the V.P. of Quality
with the progress of the project including any issues.
j. The paperwork and forms utilized off-site will be the same as at the home facility unless
directed and approved otherwise by the V.P. of Quality.
k. If there are any deviations to established procedures, the Team Leader will contact the
Project Manager, who will coordinate with the V.P. of Operations and V.P. of Quality before
any deviations take place. Once the information is reviewed, the V.P. of Quality will
determine, with FAA concurrence, if the deviation is authorized.
l. If the project continues beyond the original timeline, the V.P. of Quality submits a revised
plan to the FAA updating the original information and providing any new details on the
contracted maintenance.
m. The Team Leader ensures all activities are accomplished in accordance with the project
plan, proper record of the work is made, and copies of the records are returned to the Chief
Inspector at the repair station main base.

D. MAINTENANCE, PREVENTIVE MAINTENANCE & ALTERATIONS
1. Policy
a. ASL performs maintenance, preventive maintenance, alterations, and inspections for
customers conducting operations under 14 CFR Parts 121, 125, 129, and 135, ensuring that
it adheres to the performance standards of 14 CFR Part 43.13(a) or (c), as applicable. ASL
utilizes equipment, materials, and data that is approved and appropriate for the work being
accomplished.
b. ASL will not maintain or alter any product for which it is not rated. ASL will not maintain or
alter any article for which it is rated unless all appropriate technical data, equipment, and
facilities are available.
c. ASL will not approve for return to service:
Any article unless the maintenance, preventive maintenance or alteration was
performed in accordance with approved technical data or data acceptable to the FAA
Any article after a major repair or major alteration unless the major repair or alteration
was performed in accordance with applicable approved technical data


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Any experimental aircraft after a major repair or major alteration under 43.1(b), unless
the major repair or alteration was performed in accordance with methods and applicable
technical data acceptable to the FAA
d. The maintenance and inspection procedures contained in this RSQM are applicable when
performing maintenance, preventive maintenance, and alterations as part of the ASL
Operations Specifications. When performing maintenance, preventive maintenance,
alterations, or required inspections for air carriers or commercial operators holding a 14 CFR
Part 121, 125, 129 or 135 certificate, ASL will utilize the operator's FAA-approved
maintenance / inspection program, or continuous airworthiness maintenance program
(CAMP), including applicable parts of the customer's procedures manuals. To ensure this,
ASD requires customers to provide the correct specifications, instructions, and procedures to
be utilized when performing work for that customer; and must contact the customer directly
to obtain written instructions and approval before deviating from the customer's
specifications.
e. ASL does not currently perform line maintenance. If and when ASL is authorized on its FAA
Air Agency Certificate to perform line maintenance it will:
Perform such maintenance in accordance with the operators manual and FAA
approved maintenance program
Have the necessary equipment, trained personnel, and technical data to perform line
maintenance
Perform all work consistent with the authority and limitations of the ASL Operations
Specifications

E. REPAIR STATION CAPABILITY LIST
1. Policy and Procedure for Revising the Capability Li st
a. The purpose of the ASL Capability List (Form QA 9902-2) is to supplement the FAA Air
Agency Certificate and specifically list the make and model of the airframes and/or airframe
components that the repair station is authorized to inspect, repair, or overhaul.
b. ASL will make additions to the Capability List only when the proper housing, equipment,
experienced personnel, and technical data are available. ASL will make additions to the
Capability List by performing a Capability List Self-Evaluation (Form QA-9902-1) as outlined
in this procedure.
c. ASL will conduct a self-evaluation to:
Determine if an article can be added to the Capability List
Determine if an article should be removed from the Capability List
Review and validate the Capability List each calendar year
d. The V.P. of Quality is responsible for determining if an article is within the scope of ASLs
authority before adding an article to the Capability List.


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e. After the V.P. of Quality determines the need for a self-evaluation for a particular article, he
will request in writing that the V.P. of Operations conduct a self-evaluation using the
Capability List Revision Form, Form QA-9902-1.
f. The V.P. of Operations will complete the self-evaluation or assign personnel to complete the
self-evaluation.
Personnel performing the self-evaluation must fill out the form completely, with the
results of each area clearly marked and any supporting documentation attached, if
appropriate
Deficiencies noted in the self-evaluation process will be brought to the attention of the
V.P. of Operations and V.P. of Quality.
The copies of the completed form will be returned to the V.P. of Operations and V.P. of
Quality.
g. The V.P. of Quality and V.P. of Operations will review the results of the evaluation with the
Accountable Manager.
If deficiencies are found, they must be corrected and the correction validated before the
Capability List is revised
If approved, the V.P. of Quality will revise the Capability List in accordance with this
procedure
If the evaluation indicates that an article is not within the capability of the repair station,
the V.P. of Quality will consult with the V.P. of Operations and Accountable Manager to
decide if the necessary changes to the repair station will be made to facilitate the
addition of the article to the Capability List
h. The V.P. of Quality will retain the self-evaluation for 2 years after an item is evaluated for any
reason.
i. The V.P. of Quality will ensure that ASLs Capability List is reviewed each calendar year as
detailed in this procedure to identify articles that can be added or removed from the list
j. All changes to the Capability List will be noted with a date that article was added. In
addition, the date the Capability List was last revised will be indicated in the header section
of the List
k. The FAA will be notified, in writing, within 7 working days by the V.P. of Quality of any
changes to the Capability List. A printed copy of the revised Capability List will be mailed to
the FSDO.

F. CONTRACT MAINTENANCE PROVIDERS
1. Policy and Procedure for Maintaining and Revising Contract Maintenance
a. ASL may contract a maintenance function pertaining to an article to an outside source
provided:
The FAA approves the maintenance functions to be contracted to the outside source
ASL maintains and makes available to its FSDO a list of the maintenance function
contracted to each outside facility


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b. The V.P. of Quality will maintain an Approved Contracted Maintenance Functions List, Form
204.
c. ASL may contract work to both FAA certificated and non-certificated sources.
When contracting to non-certificated source, the non-certificated entity must follow a
quality control system equivalent to the ASL system
Additionally, ASL will remain directly in charge of work contracted to a non-certificated
facility and will verify (through test and/or inspection) that the work was performed
satisfactorily and the article airworthy before approving it for return to service
d. ASL will not contract out any maintenance function that is not first FAA-approved for
contracting to outside sources.
e. ASL will not use a contracted source until an evaluation (mail-in audit survey, QA1-011, on-
site audit etc.) is performed and found the vendor to be satisfactory.
f. The revised Contracted Maintenance list and a cover letter will be sent to the FAA FSDO for
approval.
g. The cover letter will provide in detail, the circumstances and the reason for such a request.
h. The FAA reviews the information and, once approved, returns a signed List of FAA-
Approved Contract Maintenance Functions to the V.P. of Quality.
i. The V.P. of Quality initiates procedures to contract the function to a vendor only after
obtaining a signed List of FAA-Approved Contract Maintenance Functions that includes the
specific function to be contracted.

G. REQUIRED RECORDS & RECORD KEEPING
1. Policy
a. A detailed record of all work performed by the repair station shall be maintained for each
article undergoing maintenance or alteration. The description of the work performed shall be
set forth in the work order package documents.
b. All repair station maintenance records required under 14 CFR Part 43 are retained in the
English language under the recordkeeping system for a minimum of 2 years after the date of
the maintenance record close-out, and are made available for inspection by the FAA or
NTSB upon request.
c. The Chief Inspector is responsible for maintaining the recordkeeping system. The Chief
Inspector is empowered to establish, direct, control, change, and make key decisions
regarding the process governing required records and the recordkeeping system.
d. Contents of the completed record must include a description of the work performed,
including references to approved data, date the work was performed, name of the person
performing the work, signature / stamp / initials (as required) of the person performing the
work, employee number, if required, and any required inspection signoffs.
e. When records and other documents are completed, the Production Controller will organize
them into a work order box. The work order box encompasses all forms specifically required
by the customer, including but not limited to; FAA 8130-3, 8110-3, manufacturers technical


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engineering data, service bulletins, and/or airworthiness directives, special inspections, any
repair station generated documents, etc. If a FAA Form 337 was completed and sent to the
FAA, a copy will also be included into the work order package
f. No aircraft or unit may be released for return-to-service until the work records package has
been reviewed for completeness and final acceptance by the Chief Inspector, or his
designee.
g. When the aircraft maintenance records package is complete, a clerk digitally scans and
copies all documents, audits the scanned copies for readability, places the originals in
appropriate boxes marked with the work order number, and ships them to the customer.
h. The clerk also prepares a CD copy of the package for storage marked with the work order
number, and retains the CD and electronic copies for a minimum of 2 years after the date of
the work package close-out. CD and electronic copies of records are retained in alternate
locations.
i. This repair station is authorized to maintain electronic records per its FAA Op Specs,
paragraph A025. All electronic records created and maintained by the repair station are
backed up daily. Electronic data is stored on tapes and stored remotely.
j. A Network Administrator controls access to the AAR computer server through an on-line
Network Management Utility. Accessing the AAR network requires a unique user name and
password along with granting access rights to use an application by the Network
Administrator.

H. NOTIFICATION OF HAZARDOUS MATERIALS AUTHORIZATIONS
1. Policy
a. ASL will comply with all FAA, DOT, and other applicable regulations, in processing
shipments.
b. All materials or products shipped from ASL will comply with the appropriate requirements for
shipping hazardous/dangerous goods and all employees involved in any shipping operation
are trained to recognize, properly handle, and ship materials or products in a manner
consistent with appropriate regulations.
c. Prior to performing work on behalf of a Part 121 or 135 operator, the V.P. of Quality will
acknowledge receipt of the required notification letter from the certificate holder and notify
ASL employees, as applicable. Notification may be through dedicated training, sign and
return memo, or another similar method.

I. PERSONNEL DUTY TIME LIMITATIONS (CFR 14 FAR 121.377)
1. Policy
a. Pursuant to 14 CFR 121.377 it is the policy of ASL, that any person performing maintenance
or preventive maintenance be relieved from duty for a period of at least 24 consecutive
hours during any seven consecutive days or the equivalent in any one (1) calendar month.


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b. All technicians must be familiar with 14 CFR 121.377 Personnel Duty Time Limitations and
this RSQM procedure. It is the technicians responsibility to contact his supervisor to avoid
exceeding duty time.

J. REPAIR STATION WORK FLOW
1. Procedure
a. All aircraft maintenance induction/arrival work performed by ASL will be accomplished using
customer/owner provided work cards from their FAA approved maintenance program or a
work package set-up by ASL planning department as pre-arranged with the customer/owner
in advance of aircraft induction.
b. Upon aircraft induction at ASL work will commence with preliminary inspections and hidden
damage inspections as outlined in Section III of this RSQM. Discrepancies generated during
these inspections are recorded on the associated preliminary/hidden damage forms and
entered into the work order system (StAAR) to create non-routine work cards (NRWC), Form
RS3E.
c. All work performed at ASL is controlled and tracked using work cards. This includes
customer provided work cards, engineering orders, ADs, and SBs.
d. Production Control Leads will enter the non-routine discrepancies that are generated by
preliminary inspections into StAAR by Aircraft, Work Order, and Zone/Item Number. The
non-routine work card back copy will be kept in the Production Control booth. The back Copy
will be utilized as a control copy.
e. Mechanics and Inspectors are required to clock onto the cards as they are worked.
f. Production Control Leads will:
Update work card status in StAAR.
Audit the work card package to ensure that all assigned paperwork is accounted for
g. Inspection verifies and/or identifies RII on all work cards in accordance with the customers
program.
h. ASL issues a non-routine work card (NRWC) or customer provided non-routine work cards
for all discrepancies found during work. If a task is not completed by the end of a shift, the
technician will record the work that was completed on the area dedicated on the non-routine
card form for partial work.
i. Before ASL works a NRWC that exceeds the estimated hours specified by the customer,
Supervisors will coordinate with the customer to ensure the customer wants AAR-ASL to
accomplish the NRWC. If a customer decides not to work a discrepancy, the Supervisor will
notify the Chief Inspector, who will ensure an appropriate logbook entry is made in
accordance with the customers procedures and route the NRWC back to Production Control
Lead. It is the Leads responsibility to ensure that there is not an open routine card or NRWC
that already exists that covers the discrepancy.


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j. Supervisors or Leads set up the daily work assignments and issue the work cards (routine
and non-routine) for that day.
k. Upon completion of work, each mechanic will sign off on the work card or NRWC. Partial
work documents are used during maintenance checks to record maintenance and partial
work accomplished on Non-Routine Work Orders (RS3E) or Routine Task Cards with
customers approval. When partial work or additional partial work pages are required, attach
a Record of Partial Work Accomplishment (RS3CE) to the generating document. The
RS3CE provides work continuity and accountability for each completed maintenance action
including any Inspections buy backs.
l. The mechanic will return the completed work card or NRWC to the Lead Mechanic for
auditing prior to Final Inspection Audit.
m. A Lead Mechanic or higher will audit the work card or NRWC. This audit will consist of the
following:
A review of the paperwork for correct documentation of work performed
A review of the paperwork for completeness. This review will include, but not be limited to
signatures, references, and dates
The completion of the audit will be documented by either the Lead Mechanic stamping (or
the Supervisor and above initialing) the lower right-hand corner of the work card or
document or the space provided on Non-Routine Form RS3E.
n. In the event an inspector finds work is not acceptable, the inspector will note that the work is
unsatisfactory and will return the work card to production control. If the rejected work is on a
routine card, a NRWC will be created. If the work is on a NRWC that has not been
completed, the Inspector will reject the work in the Work in Progress area.
o. All rework will be reviewed and signed off by inspection.
p. At the end of each shift, all work cards are returned to the Production Control Lead. If the
work card is complete, Production Control Lead will change the status in StAAR and route
the work card or NRWC to an area designated by the Chief Inspector.
q. The Final Inspection Audit will be conducted by the Chief Inspector or a delegated Inspector
and consist of the following:
A review of the paperwork for correct documentation of work performed
A review of the paperwork for completeness. This review will include, but not be limited to
signatures, references, and dates
When the Final Inspection Audit is complete and accepted, the auditing inspector will stamp
the upper right hand corner of the document or the space provided on Non-Routine
Form RS3E.
r. When the Final Inspection Audit is complete, Production Control Lead will close the work
card or NRWC in StAAR.
s. Production Control will route the work card or NRWC to the record storage area, where a
Records Clerk will:
Physically receives the work card or NRWC


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Enters Receive into the StAAR System showing disposition of the physical location of the
card
Checks paperwork for missing signatures, stamps, and dates
If any discrepancies are noted during the audit, the clerk will notify the responsible
department for corrections
When the work cards or NRWCs have been audited with any corrections made, the clerk
will enter audited into the StAAR system and file them in the drawer
When all work cards or NRWCs have been audited, the Records Clerk will scan the work
package and send the original package to the customer


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QUALITY MANUAL ELEMENTS
III. QUALITY MANUAL ELEMENTS
A. INSPECTION SYSTEM
1. Receiving Inspection
This section covers the minimum requirements for receiving raw materials, parts, shelf life
materials, and tools purchased or supplied for use during aircraft maintenance, preventive
maintenance, and alteration at ASL.

2. Shipping Damage or Contamination & Preservation
When a part, material or tool is delivered to ASL, the Receiving Inspector first inspects the
shipping container and/or packaging. If shipping damage or contamination is noted, or if the
packaging shows signs of tampering or alteration, the Receiving Inspector:
Ensures the delivery person notes the damage or contamination on the shipping
documentation (if possible)
Takes pictures (if possible)
When authorized by Inspection, opens the package or container in such a manner as to
save the damaged/tampered/altered section (if possible)
Inspects the item for obvious damage, tampering, alteration, and/or contamination, taking
additional pictures (if possible)
Fills out and attaches a Quarantined tag Form 502 and places the item in Quarantine until
proper disposition (such as return to overhaul, tear down for repair, or cleaning) has been
established
The Chief Inspector or his designee will determine disposition of quarantined parts and
notify Purchasing of requested action

3. Parts and Raw Materials
a. A serviceable aircraft part is one that has been through at least one FAA-approved Quality
Department process and has successfully passed the inspection criteria of that process.
Parts returned from approved, non-certificated vendors must be approved for return-to-
service before being received into inventory.
b. When receiving undamaged parts and materials, the Receiving Inspector first verifies that
the item has the appropriate paperwork supporting traceability to an FAA-approved source;
and that the documentation reflects the same information as the purchase/repair order
regarding part number, serial number, and historical information (as applicable). All
incoming aircraft parts and materials to be used on aircraft undergoing maintenance,
preventive maintenance, or alteration at ASL, MUST have accurate traceability
documentation.
c. The following table, from Advisory Circular 20-154, provides guidance to the Receiving
Inspector regarding documentation requirements for acceptance of a part, article,
component, materials, etc., (See AC 20-154 for more details and information).


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A. INSPECTION SYSTEM (CONTINUED)

Type of
Part Supplier
Condition
Rotable, Repairable,
Expendable
(Note 1, 2 & 3)
Standard Part
or Material
Commercial Part
or Material
Production Certificate (PC) Holder/Licensee New/Rebuilt PC PC or CS PS
Parts Manufacturer Approval (PMA) Holder or
Technical Standard Order Authorization (TSOA)
Holder
New/Rebuilt PS CS PS
United States Registered Air Carrier, or Certificated
Domestic Repair Station, or Certificated Repair
Station located outside the United States, or
Production Approval Holder (PAH), or
Supplemental Type Certificate/Type Certificate
(STC/TC) Only
New/Rebuilt FL or FR CS PS
Repaired FR - -
Overhauled FL or FR - -
Foreign Air Carrier/ Certificated Repair Station
located outside the United States, or Foreign
Manufacturer
New/Rebuilt J L or J R CS PS
Repaired J R - -
Overhauled J L or J R - -
Distributor Serviceable PA CS PS
Any Other Source (+) AS IS PS PS PS

LEGEND:
PC Shipping ticket, Packing Slip, Invoice, etc. from the PC holder/licensee with the PC number listed.
Include PAH part number, name, or CAGE Code on the documentation. Optional: Use FL or J L.
FL FAA Form 8130-3 left side signed that lists manufacturers name or CAGE Code. Note: A CAGE
Code is a controlled identifier used by the Department of Defenses (DOD) to identify the
manufacturer of a part or product produced under a Government contract.
FR FAA Form 8130-3 right side signed for return-to-service. Include approval reference. XYZ will verify
airworthiness and return part to service if form is signed only for work performed.


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JL European Aviation Safety Agency (EASA) Form 1 (valid after 11/28/04), Transport Canada Form 24-
0078, or equivalent form from Bilateral Airworthiness Agreement (BAA) country with left side signed
that lists manufacturer name or CAGE Code.
JR EASA Form 1 (valid after 11/28/04), Transport Canada Form 24-0078, or equivalent form from
Bilateral Aviation Safety Agreement (BASA) country with right side signed for return-to-service.
Include approval reference. Item cannot be accepted without BASA unless the person/organization is
authorized by the FAA, and is so indicated on the form. Operator will verify airworthiness and return
part to service if form is signed only for work performed.
CS Certification Statement on packing slip or attachment that lists manufacturers name or CAGE code.
The statement must indicate the part or material meets the applicable specifications.
Optional: Use Certification of Conformance (C of C), Material Certification, FL, or J L.
PS Packing slip that lists manufacturers name and date of manufacture or batch/CAGE code.
Unmarked PMA/Technical Standard Order (TSO) piece parts require FL, FR, J L, or J R. (+) Parts
procured AS IS will be treated as UNSERVICEABLE until conformity is accomplished.
PA Packing slips attachments showing traceability through documentation to an approved source listed
in the Table. Part markings (i.e. part number, mfg. name, PAH stamp, etc.) may be used in lieu of
paper documentation. Optional: Use FL, FR, and J L, J R


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A. INSPECTION SYSTEM (CONTINUED)

NOTES
1.For Life-Limited parts, the seller must supply documentation indicating the current status of the
part, including items listed in Notes 2 and 3. There must be a sufficient degree of certainty
that the parts status is current.
: For Additional Documentation Requirements for Rotable, Repairable, and Expendable Parts or
Components Life-limited Part means any part for which a mandatory replacement limit is
specified in the type design, the Instructions for Continued Airworthiness, or the Maintenance
Manual. Aircraft life-limited parts are those parts identified by the aircraft manufacturer or
production certificate holder as having a total mandatory life limit of some increment counted in
hours, cycles, landings, or by calendar. Documents for these type parts must contain this
information prior to receiving into the inventory system.
2.For Time Controlled parts, the seller must list hours, cycles, and/or days since last overhaul
and the record of work accomplished with approval references.
3.Airworthiness Directive (AD) and Service Bulletin (SB) modification status must be provided if
applicable.

4. Physi cal Inspection
a. All parts and materials must be visually inspected to ensure that they are free from visible
irregularities (e.g., altered or unusual surface, absence of required plating, evidence of prior
usage or in an accident, excessive heat damage, rough handling, scratches, new paint over
old, attempted exterior repair, pitting, or corrosion), other defects, and malfunctions; are in a
good state of preservation; and have no other obvious condition that might affect their
serviceability. A random sampling must be conducted of standard hardware packaged in
large quantities in a manner which corresponds to the type and quantity of the parts.
b. Part identification must also be checked to ensure the part has not been tampered with.
Indications of tampering include:
Serial numbers that have been scratched out or stamped over
Improper or missing data plates or other part/serial number labels
Vibro-etching or serial numbers located at other than the normal location. For detailed
guidelines on the identification of replacement parts, refer to FAA AC 20-62 latest
revision
c. Incoming hazardous materials may only be handled by Receiving Inspectors who have been
properly trained and authorized.
d. Parts in special packaging for Electro-Static Discharge (ESD) material must be inspected at
an ESD workstation. The ESD workstation must be calibrated and tested as necessary with
results recorded on Forms 312 1A Wrist Strap and Cords, and 1B Mats and Work Surfaces
ESD Logs.


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5. Shelf Life Limited Items
a. Receiving Inspectors should pay particular attention for shelf life limits on containers of items
such as adhesives, chemicals, coatings, lubricants, rubber goods, sealant, solvents, and
other inventory materials that have a limited shelf life, or a limit to the period of the materials
usability after its containers seal has been broken (useful / shelf life).
b. Parts that have a specific shelf life (a limit as to how long they are eligible to be used) must
be identified when they are received to ensure that they are not used in the maintenance,
preventive maintenance, or alteration of aircraft after their expiration date.
c. When receiving materials, the Receiving Inspector checks the applicable Material Safety
Data Sheet (MSDS) for handling/storage instructions.

6. Material Tagging
a. If the Receiving Inspector finds the item to be acceptable, he/she utilizes their inspection
stamp to stamp or initial the items certification documentation, enters the items part
number, serial number, associated work order/card number reference, and other information,
as applicable, into the inventory database, prints the appropriate computer-generated
inventory tag(s) and attaches it/them to the item
Form 8902-2D prints out for general items not reserved for a specific job or aircraft
Form 8902-2F prints out for items that are reserved for a specific job, aircraft, etc.,
is printed and attached to the item. When these items are entered, the system
alerts the project manager for the aircraft requiring the part/material that it is in
stock.
Form 9811-7 (do not use after) is also printed out for shelf life limited items.
b. The Receiving Inspector then routes the items to their assigned
staging areas, as indicated by the system and files their traceability
documentation.
c. If the Receiving Inspector finds something that is questionable, or if
the item is found to be un-airworthy or unserviceable, he/she still
enters the items information into the database as above, but
includes the discrepant information or status, and the system
automatically prints out Form 8902-2E containing the discrepant
information along with one or more reject codes. The Receiving
Inspector attaches the tag, fills out and attaches a Quarantined tag
and, quarantines the item.


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7. Suspected Unapproved Parts Reporting
a. Unapproved Parts - this term includes parts that may fall under one or more of the following
categories:
Parts shipped directly to the user by a manufacturer, supplier, or distributor, where
the parts were not produced under the authority of (and in accordance with) an FAA
production approval for the part (e.g., production overruns where the parts did not
pass through an approved quality system)
NOTE: This includes parts shipped to an end user by a Production Approval
Holders (PAH) supplier who does not have direct ship authority from the PAH
New parts that have passed through a PAHs quality system which do not conform
to the approved design/data
Parts intentionally misrepresented, including counterfeit parts
b. Reference FAA Advisory Circular 21-29, as revised.
c. If a Receiving Inspector suspects a part is unapproved, the part
must be quarantined immediately and notify the Chief Inspector.
The Chief Inspector will research the FAA Suspected Unapproved
Parts Program website:
http://www.faa.gov/aircraft/safety/programs/sups as required, and
report the part by filling out and submitting the electronic FAA Form
8120-11 in accordance with the directions on the website.
8. Tools & Equipment
a. Receiving inspection for tools and equipment is similar to that for parts and materials.
Damaged packages or containers are handled in the same way. All tools and equipment
must be visually checked to ensure that they are free from defects or malfunctions, are in a
good state of preservation, and have no other obvious condition that might affect their
suitability for effective use.
b. Borrowed Tooling
Borrowed tooling will be coordinated through the Chief Inspector. When borrowed tooling
arrives at ASL, a Receiving Inspector will inspect it for:
1) Obvious defects or damage
2) If its calibrated equipment, that the tool has a current calibration sticker and Certificate.
(Tooling supplied by another AAR MRO facility is exempt from the Certificate
requirement, but in all cases the Certificate of Calibration will be made available upon
request by the Chief Inspector to the owner of the calibrated tool.)
3) If the tool fails any of the above inspections, the Chief Inspector will be notified and the
tool shipped back as required.


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Upon a successful inspection, the tool is inducted into the StAAR computer system and
given a unique identifier. The tool will be identified in StAAR that it is on loan and who the
owner of the tool is along with the date received
The tool will then have a label attached to it with the StAAR number and the name of the
owner
When the tool is no longer needed, StAAR will be updated accordingly indicating the return
status of the tool and the date it was sent back. The StAAR ID tag is removed from the tool
and the tool is then routed down to the shipping area for return to the owner

9. Preliminary Inspection Process
a. Authorized inspectors perform preliminary inspections on all articles, including aircraft
inducted for maintenance, preventive maintenance, and alterations to determine the
condition, airworthiness of the articles.
b. These inspections must be performed prior to any maintenance or alteration on articles for
which the repair station is rated. Preliminary inspections must be accomplished in
accordance with the work scope/work instructions provided by the customer for the article
being repaired.
c. Discrepancies generated during the process of accomplishing the preliminary inspections
are entered into the work order system that creates non-routine work cards.
d. Preliminary inspection findings are also forwarded to the responsible Project Manager to
review with the customer for disposition. All recorded discrepancies must be corrected
before the article is submitted for final inspection and return-to-service. The corrected non-
routine work cards are retained as part of the work record package.
10. Hidden Damage Inspection after Incident or Accident or Deterioration
a. Inspection personnel must perform the hidden damage inspections on all articles that have
been involved in an accident, incident, or have experienced a level of deterioration that may
have adversely affected their airworthiness. Customers are required by contract to report
this history to ASL; however, inspectors should look for this evidence even when it is not
reported.
b. The hidden damage inspection will be conducted using routine work cards supplied by the
customer or created by ASL. If damage is found during this inspection process, the scope of
the inspection will be extended to ensure that all damage is identified.
c. Hidden damage inspections should not be limited to the area of obvious damage of the
reported or known incident or accident. They should also include a thorough inspection of all
areas adjacent to the damaged area of the reported or known incident or accident including
a thorough review of similar materials or equipment in a given system or structural area. The
scope of this type of inspection will be governed by the type of unit involved with
consideration to:
Previous operating history
Malfunction or Defect Reports, SDRs
Service Bulletins


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Airworthiness Directives applicable to the unit involved
d. Inspection results must be entered into the work order system to create a non-routine work
card, if required.
e. The hidden damage inspection findings must then be given to the responsible Project
Manager to review with the customer for disposition, as necessary. This record is retained by
AAR as part of the final work record package.
f. Additionally, absent of any input by the customer regarding articles involved in accidents or
incidents, ASL will conduct an incoming damage inspection on each aircraft that arrives at
the facility.

11. In-Process Inspection
a. While an article is undergoing alteration, repair, rework, or overhaul, authorized Inspectors
may make inspections to ensure ASL is conducting work in accordance with the regulations
and manufacturer, customer, & ASL requirements.
b. In-process inspections may be required by a maintenance manual, be requested by the
customer and be part of the customers work package or be an additional inspection required
by ASL.
c. ASL will conduct all in-process inspections using routine task cards, Form RS2E, and non-
routine task cards, Form RS3E.
d. In-process inspections are conducted at various stages of the maintenance process in
accordance with the frequency provided in the applicable maintenance manual, instructions
for continued airworthiness, or AD work order.
e. In-process inspections will be conducted as necessary so that any final inspection to
determine airworthiness will not require disassembly.
f. In-process inspections may include visual inspection, dimensional measurement, non-
destructive testing, or functional test.
g. The inspector will verify data applicability, materials, calibrated tooling etc. as necessary to
complete the inspection.
h. The inspector will record the results of all in-process inspections on the work cards which will
be retained with the completed work package.
i. The inspector will record any discrepancies on a non-routine work card Form RS3E.
j. All discrepancies must be corrected and the work re-inspected for acceptance.
k. The inspector must not clear the item for its final inspection until all discrepancies have been
cleared.
l. If there is a conflict between a manufacturer requirement and a customer requirement, and
the customer has an approved maintenance program, ASL must follow the customers
approved maintenance program in accordance with 14CFR 145.205.


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12. Inspection Personnel Proficiency
a. 14 CFR 145.155(a)&(b) require inspection personnel to be thoroughly familiar with the
applicable regulations in 14 CFR Part 145 and the inspection methods, techniques,
practices, aids, equipment and tools used to determine the airworthiness of the articles
undergoing maintenance, preventive maintenance or alteration. This section explains
inspection personnel selection, qualifications and proficiency requirements.
b. The V.P. OF QUALITY is empowered to establish, direct, control, change, and make key
decisions regarding inspection personnel proficiency.
c. The Chief Inspector is responsible for the day-to-day management and overall proficiency of
inspection personnel.

13. Inspector Proficiency
a. AAR controls the selection, qualification, and proficiency of its inspectors through pre-
employment testing, recurrent training, and monitoring the daily activities of inspectors. The
Chief Inspector has established the minimum qualification requirements for inspection
personnel/supervision in accordance with 14 CFR 145.153, 145.155, and 145.157 by:
Ensuring that candidates hold the appropriate certification or can be recommended for
certification, in accordance with 14 CFR Part 145 and 14 CFR Part 65 Sub-parts D &
E
Conducting interviews with direct-hire personnel, in person or by phone
Reviewing resumes and training records from previous employment
Giving all potential new hire inspectors a written test consisting of general knowledge
questions related to different areas of aircraft maintenance. A minimum passing grade
of 70% is required
b. In addition, within seven days from the start date, the Chief Inspector will insure that any new
hire, full time, Inspector is administered the following:
Additional testing or training to ensure the new Inspector is proficient with measuring
and test equipment they may be required to use
Familiarization with tool and FOD policy/procedures
Additional supervision and OJ T until the inspector is determined to be qualified on the
aircraft
c. Initial and Recurrent training of inspection personnel will be in the following areas:
14 CFR Part 121 / 135 customers procedures, processes, Required Inspection Items
(RII) and requirements in accordance with each customers CAMP
Required Inspection Items (RII) and Airworthiness Release training in accordance with
the customers CAMP


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14. Receiving Inspector Profi ciency
a. Receiving Inspectors will be trained on 14 CFR Parts 43, 65, 145, 49 CFR Part 172 Sub-
part H, as well as applicable FAA Orders, Advisory Circulars, and other regulations as
required by the FAA.
b. All training will be documented on AAR training forms and filed in the employees training
records.
c. The inspection proficiency requirements contained in 145.211(c)(1)(iv), may be met by
adhering to individual customers recurrent training requirements for inspectors and AAR
recurrent training as outlined in the ASL Training Manual.

15. Inspection Countermand Authority
a. The Inspection Countermand Authority process is to provide a procedure to prevent
Inspection decisions from being countermanded by persons other than quality
supervisory/management personnel. How Inspection handles acceptance of a process,
procedure or sign-off is outlined in this and other procedures in this manual.

b. Only Inspection personnel designated in the countermand authority list can countermand a
decision covered in this paragraph made by an inspector making the decision. If the process
goes all the way to the Vice President of Quality, the V.P. OF QUALITYs decision is final
and may not be reversed.

16. Identification of Parts and Use of Tags
a. Unserviceable Repairable Tag (Green Tag) Unserviceable Repairable Tag, Form 501, is
attached to parts requiring repairs or test outside of ASL. The tag may also be used for core
exchange purposes (rotable parts).
b. Quarantined Tag (White/Red Tag) Quarantined Tag, Form 502, is attached to parts,
tooling, materials etc. that are suspected to be in an unserviceable condition due to a
possible physical discrepancy, missing certification paperwork, broken tooling, suspected of
being out of calibration or other reason that warrants quarantining the item. Items tagged
with Form 502 will be removed from the work area on hangar floor to prevent its unintended
use.


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c. Rejected Tag (Red Tag) Rejected Tag, Form 503, is attached to rejected parts pending
final disposition. Normally, rejected parts are those parts that cannot be repaired. Parts
tagged with a red tag will be segregated from other parts to prevent inadvertent use.
d. Warning Tag (Red & White Tag) Warning Tag, Form 504, is used to prevent the operation
of an aircraft system, ground equipment or other machinery because of an unsafe item or
condition. The tag should be attached to the control that would cause the component to
operate.
e. Identification Tag (Yellow/Green/White Tag) Identification Tag, Form 8902-1, is used to
identify any parts that are removed off an aircraft, aircraft engine, appliance or assembly.
This form may be attached to the component / part or to a container holding the
disassembled unit. When used with hardware, the completed form may be attached to a
parts bag.

17. Technical Data & Document Control
a. AAR maintains current FAA-approved / accepted technical data for all work performed under
the repair station certificate, on the Technical Library computer server. ASL provides enough
computer workstations so that all personnel have access to the data while performing their
duties. Master copies of technical information on CD-ROM are maintained in the Manager of
Trainings office. New revisions are normally uploaded to the library within three (3)
business days; however, this process is expedited as necessary to ensure current data are
available prior to the initiation of maintenance, preventive maintenance, or alterations on
received customer articles.
b. The Planning Supervisor is empowered to establish, direct, control, change, and make key
decisions regarding the technical control process.
c. The Manager of Training is responsible for the day-to-day management and overall quality of
the technical data.
d. When notified of an aircraft coming in for maintenance, the Planning Supervisor works with
the customers Technical Publications personnel to obtain the customers current manuals
and other required technical data.
e. This information should come directly to the Manager of Training; however, any person
receiving technical documents from outside the facility, other than documents received for
planning/bidding purposes, must immediately route them to the Manager of Training for
logging, distribution and control. All documentation that must be current and includes:
Applicable Airworthiness Directives (AD)
Instructions for Continued Airworthiness (ICA)
Maintenance Manuals
Overhaul Manuals
Standard Practice Manuals


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Service Bulletins (SB)
Engineering Documents and Drawings
Other data acceptable to or approved by the FAA
f. When the Manager of Training receives a new revision to the above data, he/she reviews it
for applicability, date-stamps it, and routes it for upload to the Technical Library server,
making it available to the applicable maintenance and inspection personnel.
g. The Manager of Training maintains a technical data revision file in the training office and
verifies that the documents loaded onto the server are available to repair station personnel
on the appropriate Technical Library home page.
h. Customers with Continuous Airworthiness Maintenance Programs (CAMPs) will provide the
appropriate technical data for the inspection, maintenance, preventive maintenance, or
alteration work to be accomplished at ASL. It is the responsibility of ASL to ensure that all
technical data/documents supplied by customers is correct, current, applicable, and
approved for the work to be accomplished.
i. Copies of valid documents may be made and used on the production floor only if the date is
written or printed on every page of the copy. That copy must only be used for that
aircraft/work order, and the document must be stapled to the appropriate work card when
work is completed.
j. Documents and copies (of any revision level and in any media form) may be retained if
clearly marked Reference Only. It is primarily intended that Reference Only copies will
remain in office areas but reference only data is acceptable in the shop production areas,
only if they are NOT used as work instructions, (e.g., panel charts and fastener charts are
not used as work instructions and are an acceptable form of Reference Only data kept in
production areas). The process for Reference Only documents applies to all documents,
both external and internal.
k. All personnel must ensure that no copies that are not clearly marked with a date (written or
printed) on each page exist on the production floor.

18. Equipment, Material & Tools
a. This repair station will use the equipment, materials, and tools recommended by the
manufacturer of the articles or equipment, materials, or tools equivalent to those suggested
by the manufacturer. ASL will have the required equipment, tools and materials on-site and
in its control when performing maintenance, preventive maintenance, or alterations
b. It is the responsibility of Engineering to determine equivalency and document that
determination. When an equivalent equipment, material or tool is contemplated, a file will be
created. Equivalency of equipment and tooling will be determined by reviewing in detail the
manufacturers recommendation and thereafter performing a comparative analysis of the
specific usage for the equipment, material, or tool. The evaluation will include a review of
the maintenance manual to determine the exact requirements of the equipment, material, or
tool. Appropriate sections of the manual will be copied and made part of the equipment,
material, or tool file. Additionally, the specific function of the equipment, material, or tool will


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be noted, i.e. the technical requirements of the material, the parameters of the test, the
expectations of the work to be performed by the tools or equipment. The file will also contain
the appropriate drawings and specifications that define the configuration, the type of
material, and specific dimensions of the substitute material, tool, or equipment.
c. Customers must approve the use of equivalent tools or materials prior to use.

19. Non-certificated Persons
a. All non-certificated technicians performing work in the repair station must be under the direct
supervision of an appropriately rated certificated individual.
b. Non-certificated individuals will sign for their own work.
c. The certificated individual supervising the non-certificated technicians work is responsible
for ensuring that the work has been properly completed and that all work related documents
are properly filled out.
d. Supervisors are responsible for evaluating assigned personnel for job qualifications and
status (certificate/non-certificated) prior to work assignment. An employees initial
qualifications are determined by employment history, completed training, certifications,
experience, and written and practical tests (when and if applicable).

20. Final Inspection
a. Prior to approval for return-to-service, the Chief Inspector will:
b. Ensure that any repair or alteration was made in accordance with the requirements of 14
CFR 43.2, 43.3, 43.9, 43.11, 43.12, 43.13, and the air carrier /operator requirements (or
customer-authorized deviations to customer requirements) in accordance with 14 CFR
145.205.
c. Ensure that all inspectors performing the task of final inspection are qualified and on the
Inspection Roster in accordance with the procedures detailed in Personnel Rosters.
d. Determine that if the final inspection for any work card or item was previously rejected that
the discrepancy has been corrected.
e. Review the status of all ADs and completion documentation.
f. Ensure that the aircraft maintenance records have been audited to determine that all
documents are accounted for and have been completed, as required, by the air
carriers/operators CAMP/FAA-approved maintenance program.
. Determine that any and all test or measurements were properly accomplished and
documented.
h. Review and ensure that all major repairs and/or alterations have been satisfactorily
completed and recorded.
i. Discrepancies found during the final inspection process will be resolved utilizing ASLs
corrective action process, as applicable.


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j. Once the paperwork audit is completed, the Chief Inspector will authorize an appropriately
authorized Inspector to approve the aircraft or article for return-to-service.
k. The formal means of recording the final inspection may vary and may include but are not
limited to: FAA Form 337, FAA Form 8130-3 and/or a logbook entry. Any final inspection
document must comply with 14CFR Part 43.9 and 43.11, as appropriate. In addition, the
requirements of Part 43.13(c) for articles maintained under a CAMP must be observed.

21. Maintenance Release/Return-to-Service Approval
a. The V.P. OF QUALITY or Chief Inspector will designate personnel from the repair station
who will be authorized to make appropriate entries in the aircraft log or sign the Approval for
Return to Service. The repair station may only approve for return-to-service those articles
for which it is rated.
b. Each individual that is authorized to perform an Approval for Return to Service must be
properly FAA certificated in accordance with 14 CFR Part 65, meet the requirements of 14
CFR 145.155, 145.157, and be listed on the Inspection Roster.
c. The Chief Inspector will maintain a list of personnel authorized to perform an Approval for
Return to Service. The list will be maintained and updated to reflect any personnel changes
and additional capabilities acquired by the authorized persons.
d. At the request of a customer, FAA Form 337 may be completed for a major repair or
alteration (instead of the maintenance release approval) for the return-to-service in
accordance with 14 CFR Part 43 Appendix B, and 14 CFR 43.9.
e. ASL will complete FAA Form 337 for all major repairs and alterations in accordance with the
procedures Appendix B to 14 CFR Part 43 or per the customers maintenance program.

22. Record of Inspection (Method)
a. The following is an example of Record of Inspection statement to be used when recording
inspections of aircraft maintenance, preventive maintenance or alterations under 14 CFR 91,
125, 135.411(a)(1), and 135.419. The entry will constitute APPROVAL FOR RETURN TO
SERVICE in accordance with 14 CFR 43.5, 43.11, 43.15, and the requirements of 14 CFR
145.205 and 145.213(b)


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"EXAMPLE OF"
I certify that this aircraft has been inspected in accordance with the instructions and procedures set forth in
[insert the inspection program for the aircraft being inspected and type of inspection (i.e. A, B, C, D, etc.)] inspection,
and was determined to meet applicable airworthiness requirements.
RECORD OF INSPECTION PERFORMED
Pertinent details of the repair are on file at this Repair Station under
Work Order .

Date__________________ Aircraft Total Time________________

Signed (only designated personnel may sign for the Repair Station)

for
AAR AIRCRAFT SERVICES - LAKE CHARLES
Lake Charles, LA 70615
CRS # 3LZR235N

*NOTE: If the aircraft is not to be approved for return to service because of needed
maintenance, noncompliance with applicable speci fications, ai rworthiness directives
or other approved data, the following or a similarl y worded statement: I certify that
this aircraft has been inspected in accordance with (insert type) inspection and a list
of discrepancies and un-airworthy items dated (date) has been provided to the aircraft
owner or operator.

23. Record of Maintenance Release
a. The following is example of Record of Maintenance Release statement to be used when
recording aircraft maintenance, preventive maintenance or alterations. The entry will
constitute APPROVAL FOR RETURN TO SERVICE in accordance with 14 CFR 43.5, 43.11,
and the requirements of 14 CFR 145.205 and 145.213(b).


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"EXAMPLE OF"
MAINTENANCE RELEASE

The (use only applicable aircraft rating or ratings) aircraft, airframe, aircraft engine, propellers, or appliances identified
above, was repaired and inspected in accordance with current Regulations of the Federal Aviation
Administration and is approved for return to service.

Pertinent details of the repair are on file at this Repair Station under Work Order.

No. (insert No. here). Date: (insert the date of release)

.
Signed (only designated personnel may sign for the Repair Station) for

AAR AIRCRAFT SERVICES-LAKE CHARLES

Lake Charles, LA CRS # 3LZR235N

24. Shift Turnover Logs
a. Shift Turnover Log can be accomplished either by entering it electronically into StAAR or
completing hard copy forms. The Shift Turnover Log is used to inform the incoming shift of
the maintenance work in progress. The respective department manager/supervisors will
review the shift turnover logs on a daily basis as to ensure accurate and complete
documentation and to ensure the paper copy turnover log has been signed by the incoming
and outgoing Lead technician and or his/her designee. The electronic copy will be
automatically signed when the lead or alternate lead reads the turnover either in StAAR or
via the time clock.
b. The Shift Turnover Log, Form 411, is the hard copy form.
c. The Shift Turnover Log is NOT
d. All maintenance personnel are required to document in detail all work started but not
completed on the applicable in progress portion of the work document, Non-routine Form
RS3E or RS3CE. All work accomplished will be recorded in detail on the specific task card,
non-routine card, customer engineering authorization, etc.
to be used to document work accomplished.
e. The respective lead mechanic is responsible to ensure that the Turnover Log is completed
and signed at the end of each shift.


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f. The respective Supervisor will review the Turnover Log on a daily basis to ensure accurate
completion and to plan the next shifts work.
g. If more than one page is required, the Lead will write Continued in the Submitted By
signature area of the form. A signature in the Submitted By area will indicate the last page
of that shifts turnover.
h. At the end of the aircraft visit, the Turnover Log will be sent to the Chief Inspector. The Chief
Inspector will retain the Turnover Log for 90 days. After 90 days the Turnover Log will be
shredded/destroyed.

25. Tool/Equipment Calibrati on Program
a. All calibrated tooling and precision measuring equipment (PME) in day to day use is subject
to wear, and other degrading effects that may deteriorate its accuracy or serviceability.
ASLs tool and equipment calibration program is designed to ensure that quantitative
measurement certainty is known and is consistent with the required measurement capability
whenever conformance with product requirements is being demonstrated.
b. The V.P. OF QUALITY is empowered to establish, direct, control, change, and make key
decisions regarding the tool and equipment calibration program. The Chief Inspector is
responsible for the day-to-day management and overall quality of the tool and equipment
calibration program.
c. If any PME is found to be out of calibration, it must be turned in to the Chief Inspector for
disposition.
d. If any PME is found to be out of calibration and work was performed using this tool, the V.P.
OF QUALITY must be notified immediately. The V.P. OF QUALITY will implement a
corrective action process to eliminate any risk to airworthiness.
e. Newly purchased PME must be calibrated before use unless it is received with an
acceptable certificate of calibration.
f. Initially, PME is placed on an annual calibration schedule. Calibration dates are tracked by
month and year, calibration being required by the end of the month for which it is due. The
calibration period must be shortened if the manufacturer notifies ASL and recommends a
shorter period. The calibration data for all PME will be maintained in the StAAR computer
system.
g. Prior to the end of the month, the Chief Inspector, or his designee, will review the list of
calibrated tools in StAAR and send a notification to the supervisors of areas with tools that
are due for calibration. The tools to be calibrated will be collected and stored in a segregated
area of the Stores/Tooling area until it is sent to an outside vendor for calibration.
h. Once the PME is returned to ASL following calibration, the calibration records are validated
and the tool inspected to ensure that the tool was not damaged in transit and that a new
calibration sticker is attached. The Chief Inspector, or his designee, updates the StAAR
database.


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i. All PME calibration vendors must use methods and standards that are traceable to a
manufacturers standard or other FAA-acceptable standard such as the National Institute of
Standards and Technology (NIST).
j. The records/certificates of calibration must identify, at a minimum who performed the
calibration, standards used, environmental conditions, procedure used, equipment
identification, date calibrated, accuracy required, error found, and final condition of the
equipment.
k. No one may use a calibrated tool after the calibration date has expired in the StAAR system.
l. Tools or test equipment that must be calibrated before each use will be labeled as such.
m. A copy of the certificate of conformity or calibration record will be provided by any company
who leases PME to ASL.
n. The Chief Inspector retains all tooling and equipment certifications and conformity
documentation, along with ASL service orders for at least 2 years after the calibration was
completed.
o. All repair station employees are prohibited from using personally owned PME unless it is
included in the ASL Tool Calibration Program.

26. Part Segregation
a. All parts, components, and accessories removed from an aircraft or awaiting installation
must be properly tagged and protected to prevent contamination or damage.
b. An unserviceable part is one that is deemed beyond economical repair and is likely to be
scrapped. Examples include, parts with obvious non-repairable defects, parts that have
reached life limit or those exposed to extreme forces from fire or heat.
c. Unserviceable parts that cannot be used on an aircraft must be tagged with a Red Tag,
Form 503 and remain segregated from all serviceable parts.
d. Segregated storage areas in the repair station will be clearly identified as such. Segregated
areas may include marked shelves, cabinets or caged areas.
e. Parts removed from an aircraft that are determined to be repairable will be tagged with a
Green Tag, Form 501.
f. Serviceable and unserviceable parts must not be stored together.
g. Customer parts and materials shall also be segregated from other customer parts.

27. Taking Corrective Action on Deficiencies
a. When a non-conformity is identified through the quality monitoring program (audits or
analysis of inservice experience), or through a report or observation of an event not directly
related to any audit, ASL will take certain steps depending on the severity of the non-
conformity. ASL will evaluate involved personnel, procedures, and tools to determine the
root cause.


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b. The degree of corrective or preventive action investigation/response will be based on the
potential impact of the nonconformance (or potential nonconformance) on safety, production,
quality costs, performance, reliability, and customer satisfaction.
c. The V.P. OF QUALITY or designee will review the reported nonconformance to determine if
corrective action is required.
d. If required, the V.P. OF QUALITY or designee then initiates an event in APRISe (AARs
corrective action tracking database) which identifies the Owner of the event (person who
will evaluate the corrective actions; normally the V.P. OF QUALITY) and the Assigned To
(personnel responsible to answer the APRISe event). The corrective action event is required
to be answered within 14 calendar days.
e. The APRISe Assigned To person determines the following information and submits their
response prior to the Response Date.
Root Cause of nonconformance
Short and Long Term Corrective Actions
Target date of completion for planned actions
Assignment of responsibilities for planned actions
f. When an extension of an APRISe Internal Response Date or Target Date of Completion
is necessitated, the appropriate supervisor will make a request for extension (via e-mail) to
the Owner. The request will be sent prior to the event due date and include a new due date
and brief explanation of why an extension is needed. Requests will be evaluated, and
granted on a case by case basis.
g. The Owner reviews the event response, using the APRISe link and verifies an
appropriate response has been entered.
h. The Owner or designee reviews the answered event, determines if adequate corrective
action has been taken and if required, assigns it for re-audit, if required, within 30 days of the
Corrective Action Due Date. If the corrective actions are inadequate, the Owner or
designee rejects the response and the APRISe is returned to the Assigned-To Person with
the reason it was rejected. The process then starts over from Step d. of this procedure.
i. Verification portion to the APRISe will be completed after the assigned auditor verifies the
corrective action is in place and is working.

28. Stamps
a. ASL Lead Mechanics, Certificated Airframe and/or powerplant Mechanics, Inspectors, Lead
Inspectors, Supervisors, Planners, and Production Controllers may use stamps except when


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customers maintenance programs do not allow their use. In those instances, the customer
maintenance program will dictate what method(s) of sign-off or acceptance are to be used.
b. Stamps are controlled and recorded using the Stamp Log, Form 750.
c. The Chief Inspector will issue each person a stamp as required.
d. Each person is responsible for the safekeeping, proper use, and legibility of his or her stamp.
As soon as a stamp becomes illegible, the person must immediately contact the Chief
Inspector for a new one.
e. In lieu of his/her stamp, any person issued a stamp may accept work performed using the
stamp number assigned to him/her along with his/her signature, first initial, last name, and
employee number. This will be permitted for a period of up to seventy-two hours. The stamp
holder is responsible for reporting his/her stamp lost as soon as they are aware it is lost.
f. Loss of Stamp
g.
: If a person loses a stamp, he/she must notify the Chief Inspector
immediately. The Chief Inspector must then note that the stamp has been lost on the Stamp
Log, Form 750. A new, replacement stamp will be issued to that person. If that stamp is later
found it will be handled as a retired stamp and cannot be issued for a period of not less than
6 months.
Returned Stamp

: When a person no longer requires the use of a stamp (because of a
change in job, termination etc.) the Chief Inspector will collect the stamp and annotate on the
Stamp Log, Form 750, that it was returned. Returned stamps cannot be re-issued until 6
months have passed since it was returned.
29. Service Difficulty Report
a. The Service Difficulty Report (SDR) program is an information system designed to provide
assistance to aircraft owners, operators, maintenance organizations, manufacturers, and the
FAA in identifying aircraft problems, encountered during service. These programs provide for
the collection, organization, analysis, and dissemination of aircraft service information and
ensure improved service reliability of aeronautical products. The primary sources of
information are the aircraft maintenance facilities, owners, and operators.
b. When a mechanic or inspector discovers a serious failure, malfunction, or defect of an
article, he/she must immediately advise his/her Supervisor. If the Supervisor concurs that the
discovery represents a condition that must be reported under the SDR program, the
Supervisor will coordinate with the V.P. OF QUALITY to complete the carriers SDR Form.
The V.P. OF QUALITY will retain a copy and take the original Customer SDR form to the on-
site customer representative.
c. The V.P. OF QUALITY will also complete and submit FAA Form 8070-1, Service Difficulty
Report, to the local FAA FSDO. The V.P. OF QUALITY will provide this information via email
to the FAA FSDO within 2 business days of problem identification and mail a completed,
printed form to the FSDO within 5 business days. A copy of the completed Form 8070-1 will
also be provided to the on-site customer representative.
d. Regardless of the SDR form used, the report should contain as much as the following
information as is available:
Aircraft registration number


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Type, make, model of the article
Date of the discovery of the defect or failure
Nature of the defect or failure
Time Since Overhaul (if applicable)
Apparent cause of failure
Other information as necessary for identification or corrective action
e. Copies of SDRs are attached to the associated work cards in the final work package, and
are audited with the rest of the package.

30. Vendor Approval
a.
Vendor - Those who provide products and services directly related to the core business of
ASL. For the purpose of this manual, Vendors are divided into Contract Maintenance
Providers and Supplier.
DEFINITIONS:
Contract Maintenance Provider Companies which provide work in support of the repair
station in cases where it does not have adequate housing, facilities, materials, or equipment
available. ASL maintains responsibility for the work performed by issuing the approval for
return to service.
Supplier - A supplier of parts or product that is not subcontracted but rather purchased in
whole or in part, unprocessed or processed to specification. An over-the-counter parts
purchase is a typical example of Suppliers/Distributors.

b.
Vendors must be approved prior to issuing a purchase or repair order. If not already
approved, personnel can request approval of a new vendor by submitting a written request
to the V.P. OF QUALITY and provide the necessary information to identify the vendor.
APPROVAL OF VENDORS
The V.P. OF QUALITY will determine if an on-site audit or postal audit will be utilized.
On-site Audit: The V.P. OF QUALITY will contact the respective company and establish an
audit date. The audit will be conducted utilizing the CASE 1A checklist or another similar
checklist.
Postal Audit: The V.P. OF QUALITY will send out the Postal Survey Form (Form QA1-011)
to the vendor. The vendor is then given 60 days to complete the form and return it to the
Quality Assurance Department for review and acceptance.
After the successful completion of an audit (On-Site or Postal) the vendor will be added to
the Approved Vendor List (AVL).
Vendor Disapproval: Vendors will be disapproved (made Inactive) for one or more of the
following reasons:
Failure to respond to audit, postal survey (60 Days) or on-site (30 Days)


Section III
Page 22 of 22
Manual
Non-Compliance of AAR or FAA specifications
The V.P. OF QUALITY will file all audit forms and required documentation from all vendors
and subcontractors while on the AVL and for at least two years after the vendor is removed
from the AVL.
NOTE: AAR Aircraft Services-Lake Charles will accept AAR Aircraft Services-Miami
vendor approvals and disapprovals for use for purchases and Repair Overhaul Vendors
at the Lake Charles facility. The conduct of audits (on-site or postal) and all audit
documentation created by AS-Lake Charles is identical to that required by AS-Miami for
approving vendors.

c.
In order to validate that a maintenance provider has a quality system equivalent to AAR-
ASL, the following documents will need to be supplied to determine if a Contract
Maintenance Provider is properly qualified.
APPROVAL OF CONTRACT MAINTENANCE PROVIDERS
For FAA Certificated Repair Station:
A Repair Order Vendor Postal Survey (Form QA1-011) must be completed by the
vendor
The vendor FAA Op Specs along with the Quality Manual will be reviewed by the
V.P. OF QUALITY
Any industry accepted quality certifications and standards
For non FAA Certificated Repair Station
A Repair Order Vendor Postal Survey (Form QA1-011) must be completed by the
vendor
Proof of an FAA approved Anti-Drug & Alcohol Misuse Prevention Program
A copy of the vendor Quality Manual
Any industry accepted quality certifications and standards
All supplied documentation will be reviewed by the V.P. OF QUALITY


Section IV
Date Issued 11/14/2013
Page 1 of 1
Manual
FORMS

IV. FORMS
The Repair Station Forms Manual is kept as a separate document but is mai ntained in the same
manner as this RSQM.

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