Vous êtes sur la page 1sur 46

GO AIR

CAR-145
AN INTRODUCTION
CAR-145
• APPROVED MAINTENANCE ORGANISATIONS
• Revision 0, 26 January 2005
• Rule 133B of the Aircraft Rules 1937 requires
that organizations engaged in the maintenance
of aircraft and aircraft components be approved.
• The current requirements for the approval of
organizations including maintenance
organizations are stipulated in Civil Aviation
Requirements (CAR) Section 2, Series E.
• This CAR is issued under the provision of
Aircraft Rule 133A.
CAR-145
• In order to harmonize these requirements with
international requirements it has been decided
to introduce, after careful consideration,
regulations based upon JAR 145 in respect of
the approval of maintenance organizations.
• Recognizing that the aviation maintenance
industry will need time to adopt CAR-145, it is
considered necessary to retain CAR Section 2,
Series E. However, maintenance organizations
are encouraged to seek approval of their
organization under CAR-145.
CAR-145
• This CAR 145 is issued on the 26th
January 2005 and becomes effective
forthwith.
• This CAR 145 is a requirement for
maintenance organizations involved in
maintenance of aircraft and aircraft
components operated for commercial air
transport with an effective date of the 26th
January 2005.
CAR-145
• A CAR-145 approval may be issued by
DGCA at any time the applicant
demonstrates compliance with this CAR.
• Any aircraft or aircraft components used
for commercial air transport is required to
be maintained in accordance with CAR-
145 or in accordance with CAR Section 2
Series E.
CAR-145
• The grant of approval is indicated by the
issue of an approval certificate to the
organization by the DGCA. The approval
certificate will specify the extent of
approval.
• The CAR-145 approved maintenance
organization exposition must specify the
scope of work deemed to constitute the
approval.
CAR-145
• Accountable Manager means the manager who has
corporate authority for ensuring that all maintenance
required by the customer can be financed and carried
out to the standard required by DGCA.
• The accountable manager acceptable to DGCA is
responsible for establishing and promoting the safety
and quality policy
• The accountable manager must nominate a senior
person, with responsibility for monitoring the CAR-
145.65(c) quality system including the associated
feedback system. Such senior person must have the
right of direct access to the accountable manager to
ensure that the accountable manager is kept properly
informed on quality and compliance matters.
CAR-145
• The CAR-145 approved maintenance organization must have a
maintenance man-hour plan showing that the organization has
sufficient staff to plan, perform, supervise, inspect and quality
monitor the organization in accordance with the approval.
• In addition the organization must have a procedure to reassess work
intended to be carried out when actual staff availability is less than
the planned staffing level for any particular work shift or period.
• The competence of personnel involved in maintenance,
management and/or quality audits must be established and
controlled in accordance with a procedure and to a standard
acceptable to DGCA. In addition to the necessary expertise related
to the job function, competence must include an understanding of
the application of human factors and human performance issues
appropriate to that person’s function in the organization.
CAR-145
• Any CAR-145 approved maintenance organization maintaining
aircraft must have;
In the case of aircraft line maintenance, appropriate aircraft type
rated certifying staff qualified in accordance with DGCA’s licensing
requirements plus CAR-145.35.
• In addition such CAR-145 approved maintenance organizations may
also use appropriate task trained certifying staff qualified in
accordance with CAR-145.35 plus appropriately qualified persons to
carry out minor scheduled line maintenance and simple defect
rectification.
• The availability of such certifying staff does not replace the need for
DGCA qualified licensed engineers to guide the staff certifying minor
scheduled maintenance including defect rectification except that
such DGCA qualified licensed engineers need not always be
present at the line station during minor scheduled line maintenance
or simple defect rectification.
CAR-145
• The accountable manager is responsible for
ensuring that all necessary resources are
available to accomplish maintenance in
accordance with CAR-145.65(b) to support the
organization's CAR-145 approval.
• To be accepted, the accountable manager
should demonstrate a basic understanding of
CAR-145 and the responsibilities associated
with being accountable manager.
CAR-145
• With regard to the accountable manager definition, it is
normally intended to mean the chief executive officer of
the CAR-145 approved maintenance organization, who
by virtue of position has overall (including in particular
financial) responsibility for running the organization.
• The accountable manager may be the accountable
manager for more than one organization and is not
required to be necessarily knowledgeable on technical
matters as the maintenance organization exposition
defines the maintenance standards.
• When the accountable manager is not the chief
executive officer, DGCA will need to be assured that
such an accountable manager has direct access to chief
executive officer and has a sufficient maintenance
funding.
CAR-145
• For a CAR-145 maintenance organization,
located outside India, the organization may use
certifying staff qualified in accordance with the
national aviation regulations of the State in
which the organization is based subject to DGCA
being satisfied that such regulations result in a
standard of qualification comparable with ICAO-
Annex 1 standards and additional DGCA
licensing requirements, where specified.
CAR-145
• For a repetitive pre-flight Airworthiness Directive
which specifically states that the flight crew may
carry out such Airworthiness Directive,
• the CAR-145 approved maintenance
organization may issue a limited CAR-145
certification authorization to the aircraft
Commander and/or the Flight Engineer subject
to being satisfied that sufficient practical training
has been imparted to ensure that such aircraft
Commander or Flight Engineer can accomplish
the Airworthiness Directive to the required
standard.
CAR-145
• The CAR-145 approved maintenance organization must
ensure that all aircraft release certifying staff are
involved in at least 6 months of actual aircraft
maintenance experience in the preceding 2 year period.
• The CAR-145 approved maintenance organization must
ensure that all certifying staff receive sufficient
continuation training (refresher training) in each 2 year
period to ensure that such certifying staff have up to date
knowledge of relevant technology, organization
procedures and human factor issues.
• The CAR-145 approved maintenance organization must
establish a program for the continuation training and a
procedure to ensure compliance with the relevant
subparagraphs of CAR-145.35 as the basis for issue of
CAR-145 certification authorization to certifying staff.
CAR-145
• The CAR-145 approved maintenance organization must issue a
CAR-145 certification authorization that clearly specifies the scope
and limits of such authorization to those staff that it nominates as
certifying staff on behalf of the organization
• The manager or person responsible for the quality system must also
remain responsible on behalf of the CAR-145 approved
maintenance organization for issuing CAR-145 certification
authorizations to certifying staff. Such manager or person may
nominate other persons to actually issue the CAR-145 certification
authorization in accordance with a procedure acceptable to DGCA.
• The CAR-145 approved maintenance organization must maintain a
record of all certifying staff which must include details of any
licenses issued by DGCA, all training completed and the scope of
their CAR-145 certification authorization.
• Certifying staff must be provided with a copy of their CAR-145
certification authorization. The copy may be in either a document or
electronic format.
CAR-145
• The CAR-145 approved maintenance
organization must have the necessary
equipment, tools and material to perform
the approved scope of work.
CAR-145
• The CAR-145 approved maintenance organization must
have a system appropriate to the amount and complexity
of work to plan the availability of all necessary personnel,
tools, equipment, material, maintenance data and
facilities in order to ensure safe completion of the
maintenance work.
• The planning of maintenance tasks, and the organizing
of shifts, must take into account human performance
limitations.
• When it is required to hand over the continuation or
completion of a maintenance action for reasons of a shift
or personnel changeover, relevant information must be
adequately communicated between outgoing and
incoming personnel in accordance with a procedure
acceptable to DGCA.
CAR-145
• The CAR-145 approved maintenance organization must
record all details of work carried out in a form acceptable
to DGCA.
• The CAR-145 approved maintenance organization must
provide a copy of each certificate of release to service to
the aircraft operator, together with a copy of any specific
approved repair/modification data used for
repairs/modifications carried out.
• The CAR-145 approved maintenance organization must
retain a copy of all detailed maintenance records and
any associated maintenance data for two years from the
date the aircraft or aircraft component to which the work
relates was released from the CAR-145 approved
maintenance organization.
CAR-145
• A certificate of release to service must be
issued by appropriately authorized
certifying staff on behalf of the CAR-145
approved maintenance organization when
satisfied that all maintenance of the
aircraft or aircraft component has been
properly carried out by the CAR-145
approved maintenance organization in
accordance with the procedures specified
in the Maintenance organization exposition
CAR-145
• A certificate of release to service must contain basic
details of the maintenance carried out, the date such
maintenance was completed and the identity including
approval reference of the CAR-145 approved
maintenance organization and certifying staff issuing
such a certificate.
• Used aircraft component release certificates issued by
an organization, prior to the CAR-145 approval, shall
remain valid. However, the CAR-145 approved
maintenance organization shall satisfy itself that the
particular aircraft component may be fitted to an aircraft
when different modifications and/or airworthiness
directive standards may be applicable.
CAR-145
• when an aircraft is grounded at a location other than the
main line station or main maintenance base due to the
non availability of an aircraft component with the
appropriate release certificate, it is permissible to
temporarily fit an aircraft component without the
appropriate release certificate for a maximum of 30 flight
hours or until the aircraft first returns to the main line
station or main maintenance base, whichever is the
sooner, subject to the aircraft operator agreement and
said component having a suitable serviceable tag but
otherwise in compliance with other operational and CAR-
145 requirements. Such aircraft components must be
removed by the specified time unless an appropriate
release certificate has been obtained in the mean time.
Maintenance Organisation Exposition
MOE
• The purpose of the Maintenance
Organization Exposition (MOE) is to set
forth procedures, means and methods of
the organization.
• Compliance with its contents will assure
compliance with the CAR-145
requirements, which is a pre-requisite for
obtaining and retaining an approved
maintenance organization certificate.
Maintenance Organisation Exposition
MOE
• The Maintenance Organisation Exposition
and any subsequent amendments must be
approved by the DGCA.
• The CAR-145 approved maintenance
organisation must provide a Maintenance
Organisation Exposition for use by the
CAR-145 approved maintenance
organisation, containing the following
information;
Maintenance Organisation Exposition

• (1) A statement signed by the accountable manager confirming that the


maintenance organization exposition and any referenced associated
manuals defines the organization's compliance with CAR-145 and will be
complied with at all times.
• (2) The organization's safety and quality policy.
• (3) The title(s) and name(s) of the senior person(s) accepted by DGCA
• (4) The duties and responsibilities of the senior person(s) specified in
subparagraph including matters on which they may deal directly with DGCA
on behalf of the CAR-145 approved maintenance organisation.
• (5) An organisation chart showing associated chains of responsibility of the
senior person(s)
• (6) A list of certifying staff.
• (7) A general description of manpower resources.
• (8) A general description of the facilities located at each address specified in
the CAR-145 approved maintenance organisation’s approval certificate.
Maintenance Organization Exposition

• (9) A specimen of the CAR-145 approved maintenance organisation’s scope


of work relevant to the extent of the approval.
• (10) The notification procedure of CAR-145.85 for the CAR-145 approved
maintenance organisation changes.
• (11) The maintenance organisation exposition amendment procedure.
• NOTE Sub-paragraphs (1) to (11) inclusive constitute the management part
of the maintenance organisation exposition.
• (12) The CAR-145 approved maintenance organisation’s procedures and
quality system.
• (13) A list of operators, if appropriate, to which the CAR-145 approved
maintenance organisation provides an aircraft maintenance service.
• (14) A list of organisations, if appropriate, as specified in CAR-145.75(b).
• (15) A list of line stations, if appropriate, as specified in CAR-145.75(d).
• (16) A list of contracted CAR-145 approved maintenance organisations, if
appropriate.
Maintenance Organization Exposition

• CAR-145.70(a) (1) to (11) constitutes the `management


part of the MOE and therefore could be produced as one
document and made available to the CAR-145.30(a)
person(s) who should be reasonably familiar with its
contents.
• CAR-145.70(a)(6) list of certifying staff may be produced
as a separate document.
• CAR-145.70(a)(12) constitutes the working procedures
of the organisation and therefore as stated in the
requirement may be produced as any number of
separate procedures manuals. It should be remembered
that these documents should be cross referenced from
the management MOE.
• Personnel are expected to be familiar with those parts of
the manuals that are relevant to the maintenance work
they carry out.
Maintenance Organization Exposition

• In reality therefore the MOE has to cover five parts;


• a. The management MOE covering the parts specified
earlier.
• b. The maintenance procedures covering all aspects of
how aircraft components are accepted.
• c. The quality system procedures including the methods
of qualifying mechanics, inspection, certifying staff and
quality audit personnel.
• d. Contracted operator procedures and paperwork.
• e. Safety Management System.
Privileges of the Approved Maintenance Organisation

• (a) Maintain any aircraft or aircraft component


for which it is approved at the locations identified
in the approval certificate and/or in the CAR-145
approved organization exposition.
• (b) Arrange the maintenance of any aircraft or
aircraft component within the limitations of CAR-
145.1(e) for which it is approved at another
organization that is working under the quality
system of the CAR-145 approved maintenance
organization.
Privileges of the Approved Maintenance Organization

• (c) Maintain any aircraft or any aircraft component for


which it is approved at any location subject to the need
for such maintenance arising from the unserviceability of
the aircraft or from the necessity of supporting
occasional line maintenance subject to the conditions
specified in a procedure acceptable to DGCA and
included in the CAR-145 approved maintenance
organization exposition.
• (d) Maintain any aircraft or aircraft component for which
it is approved at a location identified as a line station
capable of supporting minor maintenance and only if the
CAR-145 approved maintenance organization exposition
permits such activity and lists such locations.
Limitations on the Approved
Maintenance Organization

• The CAR-145 approved maintenance


organization may only maintain an aircraft
or aircraft component for which it is
approved when all necessary facilities,
equipment, tooling, material, maintenance
data and certifying staff are available.
Changes to the Approved Maintenance Organization

• The CAR-145 approved maintenance organization must notify


DGCA of any proposal to carry out any of the following changes
before such changes take place to enable DGCA to determine
continued compliance with this CAR 145 and to amend, if
necessary, the approval certificate, except that in the case of
proposed changes in personnel not known to the management
beforehand, these changes must be notified at the earliest
opportunity.
• (1) The name of the organization.
• (2) The location of the organization.
• (3) Additional locations of the organization
• (4) The accountable manager
• (5) Any of the senior persons specified
• (6) The facilities, equipment, tools, material, procedures, work scope
and certifying staff that could affect the approval.
• DGCA may prescribe the conditions under which the CAR-145
approved maintenance organization may operate during such
changes unless DGCA determines that the approval should be
suspended.
Revocation, Suspension, Limitation or refusal to
Renew the CAR 145
Approval Certificate

• DGCA may, on reasonable grounds after due enquiry,


revoke, suspend, limit or refuse to renew the CAR-145
approval certificate if the DGCA is not satisfied that the
holder of the approval certificate continues to meet the
requirements of CAR-145
• before revoking, suspending, limiting or refusing to
renew a CAR-145 approval certificate, the DGCA must
give at least 28 days notice to the holder in writing of its
intention to do so and the reasons for its proposal.
• Also, DGCA must offer the holder an opportunity to make
representations for consideration.
Continued Validity of
CAR-145 Approval
• (a) The CAR-145 approved maintenance
organization remaining in compliance with CAR-
145 and;
• (b) DGCA being granted access to the CAR-145
approved organization to determine continued
compliance with this CAR-145 and;
• (c) The payment of any charges prescribed by
DGCA. (Failure to pay such charges entitles
DGCA to suspend, but does not automatically
render the approval invalid.)
• Note: The validity of approval / renewal of
approval shall not exceed 12 months.
Production Planning

• Depending upon the amount and


complexity of work generally performed by
the maintenance organization, the
planning system may range from a very
simple procedure to a complex
organizational set up including a dedicated
planning function in support of the
production function.
Production Planning

• For the purpose of CAR-145, the production


planning function included two complementary
elements;
• ·Scheduling the work ahead, to ensure that it will
not adversely interfere with other work as
regards to the availability of all necessary
personnel, tools, equipment, material,
maintenance data and facilities.
• ·During such work, organizing maintenance
teams and shifts and provide all necessary
support to ensure the completion of
maintenance without undue time pressure.
Production Planning

• When establishing the production planning procedure,


consideration should be given to the following;
· Logistics
· Inventory control
· Square meters of accommodation
· Man-hours estimation
· Man-hours availability
· Preparation of work
· Hangar availability
· Environmental conditions (access, lighting standards and cleanliness)
· Co-ordination with internal/external suppliers etc
· Scheduling of safety critical tasks during period when staff are likely
to be most alert
CAR-145
• The primary objective of the changeover
information is to ensure effective communication
at the point of handing over the continuation or
completion of maintenance actions. Effective
task and shift handover depends upon three
basic elements;
• · The outgoing person’s ability to understand
and communicate the important elements of the
job or task being passed over to the incoming
person.
CAR-145
• The incoming person’s ability to understand and
assimilate the information being provided by the
outgoing person.
• · A formalized process for exchanging
information between outgoing and incoming
persons and a planned shift overlap and a place
for such exchanges to take place.
• The referenced procedure should be specified in
the Maintenance Organization Exposition
Maintenance Records

• Properly executed and retained records provide owners,


operators and maintenance personnel with information
essential in controlling unscheduled and scheduled
maintenance, and trouble shooting to eliminate the need for re-
inspection and rework to establish airworthiness. As a
minimum records necessary to prove all requirements have
been met for issuance of the certificate of release to service
including
• sub-contractor’s release to service documents should be
retained. The prime objective is to have secure and easily
retrievable records with comprehensive and legible contents.
• The aircraft record should contain basic details of all serialized
aircraft components and all other significant aircraft
components installed, to ensure traceability to such installed
components documentation and associated CAR-145
maintenance data.
Maintenance Records

• Reconstruction of lost or destroyed records can be done


by reference to other records which reflect the time in
service, research of records maintained by repair
facilities and reference to records maintained by
individual mechanics etc.
• When these things have been done and the record is still
incomplete, the owner/operator may make a statement in
the new record describing the loss and establishing the
time in service based on the research and best estimate
of time in service. The reconstructed records should be
submitted to DGCA for acceptance.
• NOTE: Additional maintenance may be required.
Maintenance Records

• The maintenance record can either be a paper or


computer system or any combination of both.
• Paper systems should use robust material which can
withstand normal handling and filing. The record should
remain legible throughout the required period.
• Computer systems may be used to control maintenance
and/or record details of maintenance work carried out.
Computer systems used for maintenance should have at
• least one backup system which should be updated at
least every 24 hours of any maintenance. Each terminal
is required to contain program safeguards against the
ability for unauthorized personnel to alter the database.
Occurrence Reporting

• The aim of occurrence reporting is to identify the factors


1.
contributing to incidents and to make the system resistant to similar
errors.
• 2. Any occurrence reporting system should enable and encourage
free and frank reporting of any (potentially) safety related
occurrence. This will be facilitated by the establishment of a just
culture. An organization should ensure that personnel are not
inappropriately punished for reporting or cooperating with
occurrence investigations.
• 3. The internal reporting process should be a closed loop, ensuring
that actions are taken to address safety hazards.
• 4. Feedback to reportees, both on an individual and more general
basis, is important to ensure their continued support for the scheme.
Maintenance Procedures and Quality System

• The safety and quality policy should as a minimum


include a statement committing the organization to;
• Recognize safety as a prime consideration at all times
· Adopt safety management system in the organization
· Apply human factor principles· Encourage personnel to
report maintenance related errors/incidents
· Recognize that compliance with procedures, quality
standards, safety standards and regulations is the duty
of all personnel.
· Recognize the need for all personnel to cooperate with
the quality auditors.
Maintenance procedures and Quality System

1. The prime objectives of the quality system is to enable the CAR-


145 approved maintenance organization to ensure that it can
deliver a safe product and that the CAR-145 approved
maintenance organization remains in compliance with the
requirements.
2. An essential element of the quality system is the independent
audit.
3. The independent audit is an objective process of routine sample
checks of all aspects of the CAR-145 approved maintenance
organization's ability to carry out all maintenance to the required
standards and includes some product sampling as this is the end
result of the maintenance process.
4. The independent audit should ensure that all aspects of CAR-145
compliance are checked every 12 months and may be carried out
as a complete single exercise or sub-divided over the 12 month
period in accordance with a scheduled plan.
Maintenance procedures and Quality System

• Where the CAR-145 approved maintenance organization has line


stations the quality system should describe how these are integrated
into the system and include a plan to audit each line station at a
frequency consistent with the extent of flight activity at the particular
line station. the maximum period between audits of a particular line
station should not exceed 24 months.
• DGCA may agree to increase any of the audit time periods specified
by up to 100% provided that there are no safety related findings and
subject to being satisfied that the CAR-145 approved maintenance
organization has a good record of rectifying findings in a timely
manner.
• A report should be raised each time an audit is carried out
describing what was checked and the resulting findings against
applicable requirements, procedures and products.
• The independence of the audit should be established by always
ensuring that audits are carried out by personnel not responsible for
the function, procedure or products being checked.
Maintenance procedures and Quality System

• An essential element of the quality system is the quality


feedback system.
• The quality feedback system may not be contracted to
outside persons. The principal function of the quality
feedback system is to ensure that all findings resulting
from the independent quality audits of the organization
are properly investigated and corrected in a timely
manner and to enable the accountable manager to be
kept informed of any safety issues and the extent of
compliance with CAR-145.
• The independent Quality Audit should be sent to the
relevant department(s) for corrective action giving target
rectification dates.
• The relevant departments are required to rectify findings
and inform the quality department or nominated quality
auditor of such rectification.