Sofema Aviation Services (SAS) considers key content to be found within the GACAR Part 145 QCM
Introduction
The Quality Control Manual (QCM) as per GACAR Part 145 is a key element that a certificated repair station must establish and maintain. According to § 145.91(c), the QCM must include the following essential elements:
Description of the Quality Control System
Procedures for Inspecting Incoming Raw Materials to Ensure Acceptable Quality
Considerations:
Establish a system for receiving and inspecting all materials, ensuring they meet manufacturer specifications or standards. Assign specific personnel responsible for inspections with access to relevant documentation and specifications. Implement a process for logging inspection results and marking accepted materials for easy identification. Define criteria for rejecting materials and the process for managing rejected materials (e.g., quarantining, return to vendor). Develop a traceability system to track materials from receiving to final use.
Identification, Removal, and Reporting of Suspected Unapproved Parts
Considerations:
Create protocols to identify parts that lack proper documentation or that do not conform to certification standards. Train staff on how to recognize and label suspected unapproved parts (SUP). Implement clear procedures for reporting SUPs to management and regulatory authorities, including notifying the GACA. Set up quarantine areas for suspected parts to prevent their use while investigations are conducted. Develop a record-keeping system for all suspected, removed, or reported unapproved parts.
Procedures for Performing Preliminary Inspections on All Articles Maintained
Considerations:
Designate specific personnel or departments responsible for preliminary inspections of each article. Define inspection criteria for different articles, including visual and technical inspections using relevant equipment. Develop checklists for standard preliminary inspections, ensuring consistency across all inspections. Ensure that inspection results are logged in the maintenance system and tied to the specific article’s history. Establish a feedback loop for revising preliminary inspection protocols based on identified trends or deficiencies.
Inspections for Hidden Damage on Articles Involved in Accidents Before Maintenance
Considerations:
Develop specific protocols for inspecting articles that have been involved in accidents or subjected to unusual stress. Train inspectors in techniques for detecting hidden damage, including the use of specialized tools (e.g., borescopes, ultrasonic testers). Require mandatory documentation of the inspection findings, with specific focus on areas prone to hidden damage. Establish protocols for escalating findings to engineering or other experts if damage is suspected but not confirmed. Include these inspections in the article’s record to ensure traceability of findings and actions.
Processes for Establishing and Maintaining Proficiency of Inspection Personnel
Considerations:
Develop a training matrix that outlines the required qualifications, certifications, and competencies for all inspection personnel. Create a recurrent training program that includes both theoretical knowledge and hands-on training, with intervals based on the personnel’s role. Schedule periodic proficiency checks, such as practical exams or observed inspections, to assess ongoing competency. Keep detailed training records for each inspector, documenting initial qualifications and recurrent training. Include human factors training to ensure inspectors understand the impact of coordination and communication on inspection effectiveness.
Procedures for Maintaining Current Technical Data for Maintenance Activities
Considerations:
Establish a process for acquiring, storing, and distributing the latest technical data, such as service bulletins, airworthiness directives, and maintenance manuals. Develop a central repository or database that is accessible to all maintenance personnel, ensuring they always use the latest data. Assign personnel responsible for maintaining the repository, including updating and archiving obsolete data. Implement a notification system that alerts maintenance staff when new or revised technical data becomes available. Ensure that technical data is integrated into work orders and inspection reports, guaranteeing that the correct standards are applied.
Methods for Qualifying and Surveilling Non Certificated Personnel Performing Maintenance for the Repair Station
Considerations:
Define qualification standards for non-certificated personnel performing maintenance functions, including experience and specific task-based qualifications. Create a process for initial approval of non-certificated personnel, including an assessment of their technical knowledge and practical skills. Establish ongoing surveillance procedures, such as periodic audits or direct supervision, to ensure non-certificated personnel are following approved procedures. Document the performance of non-certificated personnel and address deficiencies through corrective action or additional training. Ensure that non-certificated personnel receive regular feedback and updates on procedural changes.
Final Inspection and Procedures for Return to Service of Maintained Articles
Considerations:
Develop clear criteria for final inspections, ensuring all maintenance or alterations meet regulatory and manufacturer standards. Ensure only authorized personnel, who meet the necessary qualifications, are permitted to sign off on final inspections and approve articles for return to service. Utilize detailed checklists that cover all aspects of the maintenance process, ensuring nothing is overlooked during the final inspection. Record the final inspection results and approval for return to service in both the article’s maintenance log and in electronic records. Establish a system for addressing any last-minute discrepancies discovered during final inspections, with procedures for re-inspection if needed.
Calibration of Measuring and Test Equipment, Including Interval Definitions
Considerations:
Create a master schedule for the calibration of all measuring and test equipment, based on manufacturer recommendations and regulatory requirements. Assign a calibration manager or team responsible for overseeing and documenting all calibrations. Maintain detailed records for each piece of equipment, including calibration dates, results, and any adjustments made. Implement procedures for identifying and removing equipment from service if it fails calibration or is overdue for calibration. Store equipment calibration certificates and ensure they are readily accessible for audits and inspections.
Procedures for Corrective Actions on Deficiencies Identified During Inspections
Considerations:
Establish a corrective action system that categorizes deficiencies by severity and outlines appropriate responses. Train personnel on how to document deficiencies, including root cause analysis and suggested corrective actions. Implement a follow-up process to verify that corrective actions have been taken and are effective. Create a feedback loop between inspection teams and management, ensuring that recurring deficiencies are addressed through systemic changes. Document all corrective actions taken and maintain records for a specified period, ensuring they are available for audits.
Manufacturer’s Inspection Standards:
The QCM should reference applicable manufacturer’s inspection standards for specific articles, including technical data specified by the manufacturer.
Considerations:
Identify relevant manufacturer standards by reviewing technical documentation for each article, including service bulletins, overhaul manuals, standard practice manuals, airworthiness directives, and repair instructions. Establish a process for identifying and maintaining relevant manufacturer’s standards for specific articles and tasks. Assign responsibility for monitoring and updating the repository of these standards. Maintain a central, secure repository for technical data that is easily accessible to personnel. Ensure accessibility and usability for inspection personnel through training and dedicated workstations. Integrate manufacturer standards into inspection checklists and training programs. Audit compliance with manufacturer standards through internal reviews and regulatory audits.
Sample Inspection and Maintenance Forms:
The QCM must include samples of inspection and maintenance forms or a reference to a separate forms manual that provides instructions for completing such forms.
Revisions and Notifications:
The QCM should include procedures for revising the manual and notifying the GACA of any revisions, specifying the frequency of such notifications.
These elements ensure that the repair station’s quality control system maintains the airworthiness of articles and complies fully with GACAR regulations. The QCM must be regularly updated and adhered to by all personnel involved in maintenance, ensuring a high standard of safety and regulatory compliance.
Next Steps
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Sofema Aviation Services provides regulatory training compliant with GACAR Parts 43 and 145. Please see the following link or email team@sassofia.com:
Kingdom of Saudi Arabia GACAR Part 145 & GACAR Part 43 for Repair Stations – Initial (3 Days)
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Aviation Quality Assurance, Inspection Procedures, GACAR Part 145, Aviation Safety Management, SAS blogs, Aircraft Repair Stations, airworthiness compliance, GACA regulations, Quality Control Manual (QCM), Aviation Maintenance Compliance, Regulatory Compliance in Aviation, Aircraft Maintenance Training, Calibration and Testing Standards, Aviation Inspection Standards, Aviation Corrective Actions
