Quality Control Manual PDF - ICON Aerospace, LLC

QUALITY CONTROL MANUAL ICON AEROSPACE, LLC QUALITY CONTROL MANUAL Federal Aviation Administration Repair Station Certificate Number: 68IR700B EASA Acceptance Number: EASA.145.6295 CONTROL NUMBER: 100 ASSIGNMENT: FAA Inspector Page Revision Number 1 12 Revision Date Original Issue Date Aug...

QUALITY CONTROL MANUAL ICON AEROSPACE, LLC QUALITY CONTROL MANUAL Federal Aviation Administration Repair Station Certificate Number: 68IR700B EASA Acceptance Number: EASA.145.6295 CONTROL NUMBER: 100 ASSIGNMENT: FAA Inspector Page Revision Number 1 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC MANUAL DISTRIBUTION LIST MANUAL NUMBER Master 100 101 102 103 ASSIGNED TO: TITLE OR ORGANIZATION Accountable Manager FAA Inspector Director of Operations Quality Assurance Manager Shop Accountable Manager Aviation Safety Inspector Director of Operations Quality Assurance Manager Icon Aerospace Page Revision Number 2 12 Revision Date Original Issue Date CONTACT INFORMATIO N 704-821-4266 704-319-7020 704-821-4266 704-821-4266 704-821-4266 Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC RECORD OF REVISIONS REVISION NUMBER Original 1 2 3 4 5 6 7 8 9 10 11 12 REVISION DATE 11/15/2009 01/24/2011 01/16/2012 May 05, 2013 Dec 15, 2014 Mar 28, 2015 Sep 02, 2017 Jan 15, 2019 Aug 15, 2019 Apr 12, 2021 Apr 01, 2022 May 01, 2023 Aug 11, 2023 INSERTION DATE 11/15/2009 01/24/2011 01/16/2012 May 05, 2013 Dec 15, 2014 Mar 28, 2015 Sep 02, 2017 Jan 15, 2019 Aug 15, 2019 Apr 12, 2021 Apr 01, 2022 May 01, 2023 Aug 11, 2023 PAGES BY ALL 1,3,4, & 22 1,3,4 & 7 ALL 1,2,3,4 & 22 1,2,3,4,5, & 6 1,2,3,4, & 7-21 ALL ALL ALL ALL ALL ALL AG AG AG AG AG AG AG AG AG AG NH NH Reason for revision: Revision to comply with RSM 1.3.6 – Updated segregation of parts Page Revision Number 3 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC LIST OF EFFECTIVE PAGES Title Cover Page Manual Distribution List Record of Revision List of Effective Pages Table of Contents Page Section 1: Quality Control System 1.1 Introduction and Basic Requirement for a Manual 1.2 Manual Distribution, Control and Revision Process 1.3 Quality Control Procedures 1.4 Equipment, Materials and Technical Data 1.5 Major Repairs and Major Alteration 1.6 Contracting Maintenance Functions 1.7 Corrective Action Procedures 1.8 Quality Monitoring System 1.9 Handling of Consumable Material that contain Hazardous Materials Page Revision Number 4 12 1 2 3 4 5 Revision Date Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 6 7 7 22 27 28 29 30 30 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Aug 11, 2023 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC TABLE OF CONTENTS Title Cover Page Manual Distribution List Record of Revision List of Effective Pages Table of Contents Page 1 2 3 4 5 Section 1: Quality Control System 1.1 Introduction and Basic Requirement for a Manual 1.2 Manual Distribution, Control and Revision Process 1.3 Quality Control Procedures 1.3.1 Receiving Inspection for Material 1.3.2 Preservation and Storage of Aviation Parts 1.3.3 Incoming Inspection of Articles for Maintenance or Alteration 1.3.4 Preliminary Inspection 1.3.5 Establishing/Maintaining Proficiency of Quality Personnel 1.3.6 Segregation and Handling of Parts 1.3.7 Handling & Documentation of Quarantine Items 1.3.8 Hidden Damage Inspection 1.3.9 Life Limited Scrap Parts 1.3.10 Shelf Life Limited Articles 1.3.11 Final Insp, Approval for Return To Service, Shipping & FOD 1.3.12 Process for Ensuring Continuity of Inspection Responsibility 1.3.13 In-Process Inspections & FOD 1.4 Equipment, Materials and Technical Data 1.4.1 General Requirements 1.4.2 Tool and Test Equipment Equivalency (TTE) 1.4.3 Calibration Policy and Procedures 1.4.4 Calibration Policy and Procedures (IN house) 1.5 Major Repairs and Major Alteration 1.6 Contracting Maintenance Functions 1.6.1 Contracted Maintenance Functions 1.6.2 Contracting Maintenance Functions 1.7 Corrective Action Procedures 1.8 Quality Monitoring System 1.8.1 Quality Monitoring System Preventive and Corrective Actions 1.9 Handling of Consumable Material that contain Hazardous Materials 6 7-8 8 8-9 9-10 11-13 13-14 15 15-16 16 17 18 18 19-20 21 21-22 23 23-24 24-26 27 28 28 29 29 29 30 31 31 31 Page Revision Number 5 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC SECTION 1: QUALITY CONTROL SYSTEM 1.1 Introduction and Basic Requirement for a Manual Icon Aerospace, LLC is dedicated to quality and always puts the customer first in all that we do. We are committed to improving our performance by using a quality management system that is continuously monitored and improved to ensure that all our services and products offer the highest standards of quality and reliability. This manual contains Icon Aerospace, LLC’s Quality Control policies and procedures. The basic purpose of the Quality Control (QC) system is to permit Icon Aerospace, LLC to properly approve work performed on an article for return to service. This section addresses the requirements found in 14 CFR 145.211 & 14 CFR 145.213. Icon Aerospace, LLC recognizes the need to focus its business on ensuring high quality performance throughout the organization. This commitment to quality is based on effective and consistent operational systems, which are continually monitored. The primary goal is the satisfaction of customer needs. This section describes the following in detail: • • • • • • • • Inspection procedures, including— o Incoming inspection, o Preliminary inspection, o In-process inspection, o Hidden damage inspection, o Final inspection and approval for return to service, Corrective action procedures, Continuity of inspection, Handling of rejected / condemned items, Purchase of parts, (ESD) Electrostatic Discharge reference ICON SOP ESD Shelf-life limited articles, Malfunction or Defect Report. All forms referred to in this manual are maintained along with instructions in a separate manual named REPAIR STATION FORMS MANUAL. (RSFM) located in section 6 of ICON RSM. It is the policy of Icon Aerospace, LLC that its management system will continue to provide an effective tool to satisfy the requirements of its customers, the Code of Federal Regulations, and all other legal and regulatory obligations. Page Revision Number 6 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC 1.2 Manual Distribution, Control, and Revision Process Paper Format This manual will be maintained current at all times. Icon Aerospace, LLC shall assign copies of its manual as required to ensure that all personnel have easy and ready access to it. The local Flight Standards District Office (FSDO) shall be assigned a copy of this manual. A complete list of the assigned copies of the manual can be found in this manual. To prevent access to information that is not maintained current, no employee may make a copy of the manual or pages from the manual, without clearly identifying them as uncontrolled copies. The Quality Assurance Manager is responsible for coordinating all revisions to this manual with the local Flight Standards District Office by forwarding hard a copy of the contemplated changes thirty (30) days prior to the issuance date for comment. Revisions will be recorded on the list of effective pages by the revision date and the revised material or text will be shaded gray until the next revision. If comments are received, they will be directed for proper disposition in accordance with the Code of Federal Regulations (CFRs). Distribution to the FAA will be by first class mail, return receipt requested, hand delivered or electronic mail unless otherwise directed in writing by the local Flight Standards District Office. Upon review by the FAA or after (30) days, whichever is shorter, the Quality Assurance Manager shall update the list of effective pages with the correct revision date and sign the revised List of to indicate approval before copying, distribution and insertion. The Master Manual shall be kept and maintained on file by the Quality Assurance Manager and contain the signed original documents. If at any time the FAA finds any portion of this manual unacceptable due to noncompliance with an enumerated CFR, the Repair Station shall initiate expedited manual change procedures. The FAA initiated change shall be accomplished within ten (10) working days of written notification of the non-compliance in accordance with the procedures in this manual. The Quality Assurance Manager is also responsible for coordinating and distributing the revised versions of this manual. Revisions will be distributed to all those assigned a controlled copy of the manual. The person named on the cover of the manual copy, or an individual delegated that authority will— • Revise the manual. • Make the appropriate entry in the Record of Revisions. • Insert the updated List of Effective Pages If the manual has been completely revised, the Quality Assurance Manager will ensure that old manuals shall be destroyed. Each Supervisor and Inspector working for Icon Aerospace, LLC will have a current copy of this manual and should thoroughly understand its contents. It will also be available to other repair station personnel. Page Revision Number 7 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC Electronic Format This manual will be maintained current at all times. This repair station’s system to ensure currency and consistency for all users of the manual is to maintain only one version of the manual electronically. The Quality Assurance Manager is responsible for ensuring that this electronic version of the manual is kept current and accurate. Any employee can access the manual through the company software system using the workstations in any office or work location. Access is read-only to prevent any inadvertent changes to the information. Only the Quality Assurance Manager can make changes. 1.3 Quality Control Procedures Generally, the Quality Assurance Manager will attempt to correct discrepancies noted or to resolve any issues with the manufacturer, distributor, or service provider. However, if the discrepancy involves activity believed to be a violation of the CFRs or if criminal activity is suspected, the Quality Assurance Manager is responsible to have the customer contacted and report the suspected unapproved part using the FAA Form 8120-11. FAA Form 8120-11 shall be completed in accordance with the instructions and guidance set forth in Advisory Circular 21-29 (as revised), entitled Detecting and Reporting Suspected Unapproved Parts. 1.3.1 Receiving Inspection for Materials The Quality Assurance Manager is responsible for receiving all incoming raw materials. Raw materials used by the repair station for maintenance, preventive maintenance, or alteration could include hardware, solder, flux, tear bands, etc., as well as standard parts including capacitors, resistors, transistors, diodes, etc. The Quality Assurance Manager receives all raw materials in the receiving “Inspection Area.” The inspection procedures for receiving raw materials are as follows: • • • • • All materials, parts and components are checked against purchase orders, manufacturers’ specifications, drawings, and dimensions, and other available documentation or information to confirm the authenticity of the materials. The Quality Assurance Manager will inspect the raw material for any Warning Static Sensitive labels so the material may be received in accordance with Electrostatic Discharge Procedures (ESD), reference ICON SOP ESD. The Quality Assurance Manager will inspect material for shelf-life markings or labels so the material may be processed in accordance with Shelf-Life Limited Article Procedures. New parts or components will be visually inspected to confirm the part and serial number, the part markings, and the general condition of the article. All parts/components must be accompanied by documents that clearly indicate an approved/acceptable source with traceability paperwork traced to the OEM. Or a Certificate of Conformance signed by an inspector of the vendor. The inspection will be performed by proper visual identification of the materials and their conformance to applicable technical standards verified by the Page Revision Number 8 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC comparison to manufacturer’s specifications, drawings, dimensions and other available documentation or information. The Quality Assurance Manager also ensures that all incoming raw materials are inspected visually to verify that each is appropriately preserved and free from defects and malfunctions. To ensure the preservation of each raw material, the Quality Assurance Manager will verify that the raw material is free from cracking, deterioration, corrosion, discoloration, leakage, dry lubed, unusual scents, having warped shape, having bent shape, scratches, etc. The Quality Assurance Manager is responsible for ensuring the material is to be stored in the stock room, unless otherwise suggested by the manufacturer. For further information regarding storage see Preservation and Storage of Aviation Parts. Any material, part or component failing to meet the incoming inspection review and deemed unacceptable will be brought to the Quality Assurance Manager. The Quality Assurance Manager will determine if the material is to be rejected and returned to the vendor. The material will be placed in a quarantine cage with a copy of the incoming paperwork and a computer generated (RMA) Returned Material Authorization document will be issued with the rejected article being sent to the vendor. The RMA is kept with the PO documenting the rejection. The Quality Assurance Manager will also forward a copy of the RMA to the Accountable Manager. • • • 1.3.2 Preservation and Storage of Aviation Parts The Quality Assurance Manager is responsible for articles stored in the repair station for installation on civil aviation articles, raw materials or awaiting customer disposition. The articles shall be stored and/or preserved in accordance with the manufacturer’s recommendations or other government or industry standard practices applicable to the article involved. The Quality Assurance Manager is responsible for the preservation and storage of all articles for the repair station. • • • The Quality Assurance Manager will ensure that preservation measures shall afford adequate protection from humidity, static charged atmospheres, extreme temperatures, dust, rough handling, and/or damage during processing or shipping. Once articles are received and accepted the Quality Assurance Manager will ensure that articles subject to long-term storage shall be placed in a separate location as designated by the Quality Assurance Manager. The preservation techniques shall be in accordance with the article manufacturer’s recommendations or other government, or industry practices designed to provide the maximum protection from physical damage or deterioration. Since it is not anticipated that the repair station shall be preserving or storing items on a longterm basis the described method shall be adequate. The Quality Assurance Manager also ensures that upon acceptance, a computer-generated Receiver Label will be issued and attached to each part. The Label consists of the repair station’s information, the part number, serial number (if applicable), description, original manufacturer’s expiration date (if applicable), shelf-life date (if applicable), condition, quantity, warehouse location, Page Revision Number 9 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.2 • • • • ICON AEROSPACE, LLC Preservation and Storage of Aviation Parts (cont) traceability, tag date (if applicable), PO number, inspectors name and date. This label is for identification of the parts while in the stockroom. All data entered on Receiver Label may be viewed from the company’s computer network. The Quality Assurance Manager will ensure that all articles will be stored in appropriate sealed bags, (ESD) Electrostatic shielding bags or containers, bins trays, or racks. All paperwork including trace and COC will be filed with the PO. reference ICON SOP ESD. Accepted parts will then be ready for storage in the inventory/stockroom, located in the storage room. Stock rotation will be performed to ensure the usage of previously stocked items within the storage bin. Upon stocking items into its appropriate storage bins, previously stocked items are to be transferred towards the front of the storage bin to ensure priority of usage over recently stocked items. Inventory/stock item data may be viewed from the company’s computer network system. Inventory/stock items may be reserved for particular jobs requiring parts needed to complete the work scope for that particular article. The Quality Assurance Manager will assign and reserve the aged inventory/stock items in the company’s computer network to comply with the stock rotation method. When the technician is ready for the installation of a part required, the technician requests o the part from the Technical Publications/Stores Manager. Technical Publications/Stores Manager will view parts listed on the Parts & Materials section of the Work Order, enter them into the computer and locate the parts location. Batch and shelf-life data (if applicable) will be printed on the label of the part. Once the part is located the Technical Publications/Stores Manager will withdraw the part from stock and deliver it to the appropriate technician. The technician and Quality Assurance Manager will both verify the airworthiness of the part prior to installation and after installation and completion of the work. The airworthiness of the part will be verified at final inspection. Parts and material are taken from the stockroom on an as needed basis. Information pertinent to the airworthiness of a particular part or material will be re-verified during the normal course of maintenance. Page Revision Number 10 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.3 ICON AEROSPACE, LLC Incoming Inspection of Articles for Maintenance or Alteration The Quality Assurance Manager is responsible for the receiving of all articles for maintenance or alteration. The Quality Assurance Manager receives all articles for maintenance or alteration in the receiving Inspection Area. The inspection procedures for receiving articles for maintenance or alteration are as follows: • Prior to performing any maintenance or alteration on civil aviation articles, the Quality Assurance Manager will assess the requirements of each customer order and verify that it has the capability to accomplish the work. • Verify that the work required is within the authority of this repair station as defined in its ratings and Operations Specifications. The Accountable Manager will verify that it has the appropriate housing, facilities, equipment, personnel, and technical instructions available to perform the requested work. • The Quality Assurance Manager will inspect the articles for maintenance or alteration for any “Warning Static Sensitive” labels so the material may be received in accordance with Electrostatic Discharge Procedures (ESD). reference ICON SOP ESD. • Articles for maintenance or alteration will be visually inspected by the Quality Assurance Manager to confirm the part and serial number, the part markings and the general condition of the article. Discrepancies will be noted on the Incoming Inspection part of the work order. All parts/components must be accompanied by the customer’s repair order. If unit arrives without Repair Order, the Quality Assurance Manager will request the Repair Order from the customer and generate a White identification tag and place the unit in the quarantine cage until the Repair Order Is received from the customer. • The Quality Assurance Manager will evaluate the customer requirements and clarify with the customer any questions about the scope and type of work to be performed. This includes the current, applicable parts of an air carrier maintenance program or manuals. • The Quality Assurance Manager will check all articles for maintenance or alteration against the customers repair order, manufacturer’s specifications, drawings, dimensions and other available documentation or information to confirm the authenticity of the materials. The Quality Assurance Manager will check paperwork to determine if any incoming article has been involved in an accident. If there is any question, The Quality Assurance Manager consults with the customer. If the article was involved in an accident or shows signs of mishandling the incoming inspection will be noted on the work order and a Hidden Damage Inspection will be performed as described in this manual. Page Revision Number 11 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.3 • • • • • • ICON AEROSPACE, LLC Incoming Inspection of Articles for Maintenance or Alteration (cont) The Quality Assurance Manager also ensures that all incoming articles for maintenance or alteration are inspected visually to verify that each is appropriately preserved during shipment or handling and free from defects and malfunctions. To ensure the preservation of each article for maintenance or alteration, the Quality Assurance Manager will verify that the article is free from cracking, deterioration, corrosion, discoloration, leakage, dry lubed, unusual scents, having warped shaped, having bent shape, scratches, etc. generate Green Repairable Tag for the article. As applicable, the tag should indicate the work order number, the customer’s name, article name, article number, article serial number, work requested, Inspectors name and date. Part Identification Tag may be used in place of the identification tag. If the article for maintenance or alteration is accepted, the Quality Assurance Manager will issue a computer generated a FORM IAF-3117 (WO) Work Order Form. Each Work Order Form will be a consecutively numbered document, and the number will be used as reference for all maintenance, alteration or inspections performed on the received article. The Work Order Form will contain a work order number, vendor information, repair order number, shipping method, terms of payment, quantity sent, part number, serial number, part description, alternate part number (if applicable), status/work requested, manufacturer, trace to information, tag date, report by customer information, preliminary inspection information, progressive inspection information, hidden damage inspection information, corrective action information, description of parts required, part number of part required, quantity of parts required, and manual information and location. The Quality Assurance Manager will ensure that one copy will be attached to the article for maintenance or alteration and the other will be attached to the customer’s repair order and filed in temporary storage until the final release of the article for maintenance or alteration. A Work Order Form may be used in place of an identification tag. All data entered on the Work Order Form may be viewed from the company’s computer network. The Quality Assurance Manager will verify required parts and materials are available for the work scope requested. The Quality Assurance Manager will verify that all required technical data is available and current. Location, revision status, and current date of technical data will be automatically documented on the Work Order Form upon receiving the article for maintenance or alteration. (Revision status, current date of technical data is also available in FORM IAF-3110 (TPSS) Technical Publication Status Forms in every manual). The Director of Operations will assign personnel for work after verifying qualifications and training records. Page Revision Number 12 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.3 • ICON AEROSPACE, LLC Incoming Inspection of Articles for Maintenance or Alteration (cont) The Quality Assurance Manager will determine if the articles for maintenance or alteration are acceptable or are to be rejected. The Quality Assurance Manager will revise the list of discrepancies noted on the Work Order Form and forward them to the customer. The customer will have an option to either request the item be issued a Red Rejected Tag to be attached to the completed FORM IAF-3116 (TDR) Teardown Report (Teardown Report is the finalized version of the Work Order Form filled in by computer not handwritten) and returned or the customer may authorize the Quality Assurance Manager to issue a Red Rejected Tag and identify the item as BER (beyond economical repair). The Quality Assurance Manager will determine if the item is to be processed to the quarantine area or to proceed with the disposition of the rejected / condemned / BER item in the repair station. Procedures for handling and documenting of quarantined items will be performed in accordance with Handling & Documentation of Quarantine Items located in this manual. Procedures for handling and documenting rejected / condemned / BER items will be performed in accordance with Handling Rejected / Condemned / BER Items located in this manual. • 1.3.4 Preliminary Inspection Technicians and Inspectors are responsible for accomplishing preliminary inspections for all articles undergoing maintenance, preventive maintenance and alteration by this repair station and will be performed in accordance with the customer’s instructions and the CFRs. The Inspector conducts all preliminary inspections for all articles for maintenance or alteration in the appropriate testing area for that particular item. The preliminary inspection procedures for articles for maintenance or alteration are as follows: • • • • • The Inspector will verify the company’s Operation Specifications to ensure the repair station is properly rated to perform the maintenance required. The Inspector will verify that all required technical data is available and current. Location, revision status, and current date of technical data will be automatically documented on the FORM IAF-3117 (WO) Work Order Form upon receiving the article for maintenance or alteration. (Revision status, current date of technical data is also available in FORM IAF-3110 (TPSS) Technical Publication Status Forms in every manual). Civil aviation articles accepted and received by this repair station for maintenance or alteration will be given an appropriate preliminary inspection check and test to determine their state of preservation and apparent defects as requested by the customer. The Inspector will verify the unit complies with any (SBs) Service Bulletins or (ADs) Airworthy Directives. The Inspector shall record the compliance of any SBs or ADs in the FORM IAF-3117 (WO) Work Order Form. The technicians or Inspectors shall proceed with the preliminary inspection of each unit during the disassembly process. Page Revision Number 13 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.4 • • • • • • • • • • ICON AEROSPACE, LLC Preliminary Inspection (cont) The preliminary inspection shall include verification, as applicable, of reported conditions, obvious damage, overall part condition, and the possibility that a specific hidden damage inspection will be required. The technician or Inspector will record the results on a Work Order Form provided by this repair station, which will remain with the unit undergoing maintenance until it is approved for return to service. The Work Order Form may also be attached to a disassembly bin or tray as the unit undergoes maintenance until it is approved for return to service. If the preliminary inspection reveals a discrepancy, the Quality Assurance Manager will be notified, and a detailed description of the discrepancy will be recorded in the appropriate section of the Work Order Form to assist the technician in the disassembly and troubleshooting process. The discrepancy noted during this inspection will need to be addressed during the corrective actions taken during the maintenance. The recorded discrepancy found during the preliminary inspection must show a method of correction in accordance with the manufacturer’s spec’s, SBs, ADs, or other acceptable data. Discrepancies found that are outside of the contracted works scope are to be resolved in accordance with the Contracted Maintenance Program manual. During the initial disassembly, cleaning, and inspection process, the Chief Inspector will verify that the current status of all life-limited parts is appropriately documented by the owner/operator. The status documents of life-limited parts are attached to articles sent to the repair station. Any article sent for inspection or repair without a life-limited status document will be reported to the Inspector, unless the article is being sent for a fresh overhaul. The Inspector shall contact the customer and request for life-limited status on the article (if applicable). If the customer’s work scope is limited in nature, the Chief Inspector will determine whether the requested maintenance, preventive maintenance or alteration can be accomplished within the applicable data despite any other damage or discrepancies noted. Once the unit has undergone the preliminary inspection and test, the unit will be understood as being acceptable. If the articles for maintenance or alteration are not acceptable, The Chief Inspector will be notified. The chief Inspector will determine if the articles for maintenance or alteration are to be rejected. The Quality Assurance Manager will revise the list of discrepancies noted on the Work Order Form and forward them to the customer. The customer will have an option to either request the item be issued a Red Rejected Tag attached to the completed FORM IAF-3116 (TDR) Teardown Report (Teardown Report is the finalized version of the Work Order Form filled in by computer not handwritten) and returned or the customer may authorize the Quality Assurance Manager to issue a Red Rejected Tag and identify the item as BER (beyond economical repair). The Quality Assurance Manager will determine if the item is to be processed to the quarantine area or to proceed with the disposition of the Rejected / Condemned / BER / Scrap item in the repair station. Procedures for handling and documenting of quarantined items will be performed in accordance with Handling & Documentation of Quarantine Items located in this manual. Page Revision Number 14 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.5 ICON AEROSPACE, LLC Establishing and Maintaining Proficiency of Quality Personnel The Accountable Manager is responsible for establishing qualifications for the Inspection personnel. Inspection personnel shall have a minimum of 18 months of experience (including previous work history) in order to perform the quality tasks assigned and be able to read, write, and understand English. The Accountable Manager is also responsible for maintaining proficiency. Inspection personnel will maintain proficiency through on-the-job and classroom training. All inspection personnel are listed on the Repair Station Roster. Inspection personnel with authority for return to service (RTS) shall meet the following requirements: a. Be certificated under CFR Part 65 Repairman Certificate. b. Have a minimum of 18 months of training and/or experience (including previous work history) with the methods, techniques, practices, equipment, and tools used on each product for which RTS authority will be approved. c. Has worked with an approved RTS Inspector on the requirements for RTS of the product as documented within the training records. d. Has thorough knowledge of the Service Bulletins, Modifications, and FAA A.D.'s that apply to the product and additionally, thorough knowledge of CFR Part 43 and Part 145 regulations and the repair station's RSM and QCM. e. Must understand, read, and write English. All Quality personnel will review all newly released documentation (CMM's, S/B's, A.D.'s) to ensure proficiency with the product(s) being maintained by the repair station. 1.3.6 Segregation and Handling of Parts Technicians and Inspectors are responsible for the segregation and handling of units in the repair station during inspection, disassembly, cleaning, assembly, testing, and final inspection and approval for return to service. Technicians and Inspectors may delegate all segregation and handling of parts duties to any qualified assistant as necessary however, such delegation does not relieve the Inspector or Technician of overall responsibilities. • • • Inspectors or technicians will use suitable trays, racks, stands and containers in the shop areas to ensure proper segregation and maximum protection of all parts during the maintenance and/or alteration process, parts will be segregated from environmentally hazardous or sensitive operations such as painting, cleaning, welding, avionics work, electronic work, and machining as per standard practices and the repair station floorplan and reference the ESD SOP. Inspectors or technicians will ensure that all parts are handled according to the manufacturer’s recommendations to ensure that articles or parts are not damaged in transit from one area of the repair station to another. When complete units are disassembled, the Inspector will verify the computergenerated FORM IAF-3117 (WO) Work Order Form is attached such that components are appropriately identified and segregated on carts or in containers Page Revision Number 15 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC to ensure that all individual parts or units of the same assembly are identified to that assembly. 1.3.6 • Segregation and Handling of Parts (cont) Inspectors or technicians will ensure that all inspections including Articles for Maintenance or Alteration, Preliminary, Hidden Damage, and Final Inspection for Approval to Return to Service that require precautions for handling (ESD) Electrostatic sensitive devices will be conducted in a (ESD) Electrostatic safeguard work area. For procedures regarding ESD, see (ESD) Electrostatic Discharge Procedures reference ICON SOP ESD 1.3.7 Handling & Documentation of Quarantine Items The Quality Assurance Manager is responsible for the handling and documentation of quarantine items for the repair station. The Quality Assurance Manager may delegate all handling and documentation of quarantine item duties to any qualified assistant as necessary; however, such delegation does not relieve the Quality Assurance Manager of the overall responsibilities. The procedures for the handling and documentation of quarantine items for the repair station are as follows: • Any material, part or component failing to meet any inspection review will be reported to the Quality Assurance Manager and he shall determine if the part is to be segregated to a quarantine area, red tagged and documented in the teardown with a list of discrepancies. If any parts purchased from a supplier are rejected, parts will be returned to the supplier. • The Quality Assurance Manager will forward the teardown with a list of discrepancies to the customer. The customer may authorize the Quality Assurance Manager to determine the final disposition of the quarantined item or to return the item to the customer. • The Quality Assurance Manager may identify quarantined items as rejected/BER Parts/Components which shall be rendered useless so as to prevent a means to re-introduce these items into the market or to be segregated and stored in the quarantined area. (The authorization of the owner of the item is the only approval acceptable to proceed in identifying an item as BER, beyond economical repair) • Items segregated to the quarantine area will be identified with a Red Rejected tag and documented on the work order which is kept on file for three years. • The Quality Assurance Manager or other delegated personnel will inspect and segregate the item from the usual workflow ensuring the red tag, and a copy of the work order documenting the discrepancies are attached upon receiving the item to the quarantine area. • The quarantined Red Rejected tag item will be stored in a locked Quarantine Area by the Quality Assurance Manager for 30 days or until the customer request the unit to be returned. If the customer does not request within 30 days the unit will be destroyed (SCRAPED) and documented on FORM IAF-316 (CPR) Condemned Parts Record. The key is located in the office of the Quality Assurance Manager. Page Revision Number 16 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.8 ICON AEROSPACE, LLC Hidden Damage Inspection A hidden damage inspection is required on all parts that have been involved in an aircraft accident. The inspection includes a search for any damage that could result from an accident, such as fire or heat damage. The Chief Inspector is responsible for all hidden damage inspections of all parts that have been involved in an aircraft accident. The Chief Inspector may delegate all hidden damage inspection duties to any qualified assistant as necessary, however, such delegation does not relieve the Chief Inspector of overall responsibilities. The hidden damage inspection procedures for articles for maintenance or alteration are as follows: • • • • • • • Before this repair station starts work, all units and components known to have been involved in an accident will be given a thorough inspection for possible hidden damage by the Chief Inspector. Hidden damage inspections may also be generated by noted discrepancies during preliminary or in-process inspections. The Quality Assurance Manager is responsible for communicating with the customer regarding any hidden damage noted. If the hidden damage inspection reveals a discrepancy, the Chief Inspector will be notified, and a detailed description of the discrepancy will be recorded in the appropriate section of form IAF-3117 (WO) Work Order Form. The discrepancy noted during this hidden damage inspection will be addressed during the corrective actions taken during the maintenance. The recorded discrepancy found during the hidden damage inspection must show a method of correction in accordance with the manufacturer specifications. When a hidden damage inspection is required, the Chief Inspector will perform the inspection in accordance with the specific instructions provided by the applicable manufacturer of the article. The inspection will include areas adjacent to or likely to have been affected by the obviously damaged unit or component. The Chief Inspector will then forward the hidden damage inspection findings to the Quality Assurance Manager. The Quality Assurance Manager will revise the list of discrepancies noted on the Work Order Form and forward them to the customer. The customer will have an option to either request for the item to be issued a Red Rejected Tag attached to the completed FORM IAF-3116 (TDR) Teardown Report (Teardown Report is the finalized version of the Work Order Form filled in by computer not handwritten) and returned or the customer may authorize the Quality Assurance Manager to issue a Red Rejected Tag and identify the item as BER (beyond economical repair). The Quality Assurance Manager will determine if the item is to be routed to the quarantine area or to proceed with the disposition of the rejected / condemned / BER item in the repair station. Procedures for handling and documenting of quarantined items will be performed in accordance with Handling & Documentation of Quarantine Items located in this manual. Procedures for handling and documenting rejected / condemned / BER items will be performed in accordance with Handling Rejected / Condemned / BER Items located in this manual. Page Revision Number 17 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL 1.3.9 ICON AEROSPACE, LLC Life Limited Scrap Parts Components, piece parts raw materials, defective parts removed from units, etc deemed rejected or condemned will be destroyed and disposed of by the Quality Assurance Manager and or the Director of Operations. 1.3.10 Shelf-Life Limited Articles The Quality Assurance Manager along with the Director of Operations are responsible for all shelf-life limited articles, including raw materials, standard parts, components, lubricants, and paint or cleaning solutions. The Quality Assurance Manager on a monthly basis will verify consumables for expiration dates and dispose of expired items. The Quality Assurance Manager may delegate duties for all shelf-life limited related articles to any qualified assistant as necessary however, such delegation does not relieve the Quality Assurance Manager of overall responsibilities. All inspections including Raw Materials and Articles for Maintenance or Alteration that require shelf-life limited processing will be conducted in the receiving Inspection Area by the Quality Assurance Manager or delegated assistant. The shelf-life limited inspection procedures for Raw Material and Articles for Maintenance or Alteration are as follows: • • • • • • • The Quality Assurance Manager will inspect the shelf-life limited article for any Warning Static Sensitive labels so the article may be received in accordance with Electrostatic Discharge Procedures. The Quality Assurance Manager will identify shelf-life limited parts by the original manufacturer’s expiration date marked on the part, material, and/or container, along with the purchase date, purchase order number and any attaching documentation which will be filed once accepted, in the Records Storage room. The data regarding shelf-life dates, cure dates, and expiration dates will be incorporated, recorded, and registered in a computer-generated Receiver Label. The computer stores a record of the expiration date of the shelf-life item and a monthly report is generated. Items shown on the report as expired will be removed from stock and destroyed by the Quality Assurance Manager. The Receiver Label consists of the repair station’s information, the part number, serial number (if applicable), description, original manufacturers expiration date (if applicable), shelf-life date (if applicable), condition, quantity, warehouse location, trace to information, tag date (if applicable), receiver number, inspectors name, and date. All data entered on Receiver Label may be viewed from the company’s computer network. Only once accepted and the data is registered may the Raw Material or Articles for Maintenance or Alteration proceed to their required inspection procedure methods. See Receiving Inspection Procedures for Raw Materials and Incoming Inspection Procedures for Articles for Maintenance or Alteration for further inspection procedures. If the shelf-life limited article or data attached is not acceptable the Quality Assurance Manager will be notified. The Quality Assurance Manager will determine if the shelf-life limited article and data are acceptable or if it is to be rejected and returned to the vendor. A computer-generated Returned Material Authorization (RMA) document will be issued with the rejected article returned to the vendor. The Quality Assurance Manager will also forward a copy of the RMA to the Accountable Manager. Page Revision Number 18 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC 1.3.11 Final Inspection, Approval for Return to Service and Shipping Inspectors and Supervisors with RTS authority listed on the roster, are qualified and certificated under 14 CFR part 65 and are thoroughly familiar with the applicable regulations and inspection methods, techniques, practices, aids, equipment, and tools used to determine airworthiness of the article. Inspectors, listed on the roster, have access to all current technical data and understand, read, and write English. Inspectors are responsible for accomplishing final inspections, and approvals for return to service for all articles undergoing maintenance, preventive maintenance, and alteration by this repair station. All articles for final inspection will be visually inspected by the Inspector to confirm the part and serial number, the part markings, and the general condition of the article. The customer will receive the original FAA Form 8130–3 along with a signed copy of the work order package documents, may also be entitled as Teardown Report. Before generating FAA Form 8130–3, the inspector shall inspect the article and audit the work order package to determine whether— • • • • • • • • • The work was accomplished in accordance with the work scope requested by the customer. Each task has been accomplished or determined to be non-applicable to the work scope requested and the technician’s signature or initials indicate that the task has been accomplished on the appropriate work order package document. Each inspection required by the work order package has been satisfactorily completed, recorded on the applicable document, and verified with each technician to ensure that all activities related to final inspection are performed. To include FOD inspection at final inspection to assure there is no debris left behind. The final test and parts replaced operate in accordance with maintenance manuals, Service Bulletins (SBs), service letters, Airworthiness Directives (ADs), and/or other data acceptable to or approved by the FAA. The final description of maintenance manuals, Service Bulletins (SBs), service letters, Airworthiness Directives (ADs), and/or other data acceptable to or approved by the FAA used during the work scope requested is documented and entered to the work order package. The articles for maintenance or alteration require any “Warning Static Sensitive” labels so the material may be labeled and handled in accordance with (ESD) Electrostatic Sensitive Caution. The Inspector will ensure all appropriate labels are attached reference ICON SOP ESD All discrepancies have been addressed and appropriately resolved in accordance with accepted corrective actions. If the article is not satisfactory, or that a maintenance step or function has been performed out of sequence or accomplished incorrectly, the work will be repeated and inspected to ensure proper completion. Any rework will be performed in accordance with approved or acceptable technical data. After the final inspection is complete, and to ensure appropriate description of the work performed it shall be entered in FAA Form 8130–3 (02-14) and the authorized inspector listed in the repair station roster to approve articles for return to service for the repair station shall sign the form. The FAA Form 8130-3 shall clearly state in Block 12 the general scope of work performed and reference the principal documents used to perform the work. Page Revision Number 19 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC 1.3.11 Final Inspection, Approval for Return to Service and Shipping (cont) NOTICE: An Airworthiness Directive may apply to the article(s) described herein. The installer is responsible for ensuring complete compliance with any applicable Airworthiness Directives. • • • • • • If the Inspector determines the article is not satisfactory or that a maintenance step or function has been performed out of sequence or accomplished incorrectly during any of the various stages of maintenance, the work will be repeated and inspected to ensure proper completion. Any rework will be performed in accordance with approved or acceptable technical data. If the final inspection reveals a discrepancy, the Chief Inspector will be notified, and a detailed description of the discrepancy will be recorded on any additional pages required to be attached to the Work Order Form. The article for final inspection will be considered not satisfactory and rejected. The Chief Inspector will then forward the final inspection findings to the Quality Assurance Manager. The Quality Assurance Manager will revise the list of discrepancies noted on the Work Order Form and forward them to the customer. The customer will have an option to either request for the item to be issued a Red Rejected Tag attached to the completed FORM IAF-3116 (TDR) Teardown Report (Teardown Report is the finalized version of the Work Order Form filled in by computer not hand written) and returned or the customer may authorize the Quality Assurance Manager to issue a Red Rejected Tag and identify the item as BER (beyond economical repair). The Quality Assurance Manager will determine if the item is to be processed to the quarantine area or to proceed with the disposition of the rejected / condemned / BER item in the repair station. Procedures for handling and documenting of quarantined items will be performed in accordance with Handling & Documentation of Quarantine Items located in this manual. Procedures for handling and documenting rejected / condemned / BER items will be performed in accordance with Handling Rejected / Condemned / BER Items located in this manual. Once the 8130 has been issued the unit is prepared for shipping. The completed unit is taken to a holding area in shipping where the Quality Assurance Manager performs a visual inspection for any defects and imperfections with paint, safety wire, or damage all preservation caps for connectors or plugs are installed. The unit is then matched to the final paperwork and part number and serial numbers are verified pictures are taken of every angle of the unit for records. The Quality Assurance Manager assures that the unit is properly prepared for shipping. Each unit is packaged as per reference to unit CMM and in a resealable bag that includes desiccant and a label that has all required information of the unit. If required a static shield bag is used for ESD items. Once all is completed it is passed to the shipping clerk where the unit is packaged. ICON does not reuse old boxes only new boxes are used or if the unit was received in an ATA container the unit is matched to the original container. All units are wrapped in bubble wrap then the unit is foam packed. Boxes are stapled on the bottom and taped on the top. The package will include all applicable certs and shipping documents. Page Revision Number 20 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC 1.3.12 Process for Ensuring Continuity of Inspection Responsibility Inspections are a continuous process from receiving inspection through the various stages of repair or alteration until the final inspection prior to approval of the work for return to service. The in-process inspections will be performed in accordance with the manufacturer's recommendations or in accordance with the customer's program, as appropriate. In addition, as work progresses on a specific item, inspections will be made as necessary so that final inspection to determine airworthiness will not require disassembly. • • • • It will be the responsibility of the Inspector and or Supervisor approving the work on the article for return to service to determine through a review of the documentation, or through observation or inspection that all required inspections have been completed. The Inspector will be responsible for ensuring that no article will have any additional work performed on it following an in-process inspection until all discrepancies noted during the inspection have been corrected. When the customer requests a specifically limited work scope, and the preliminary or inprocess inspection indicates discrepancies which do not affect the completion of the limited work scope, the final inspection and approval for return to service will be limited to the particular work performed. The Inspector will be responsible to ensure continuity of inspection, no maintenance or alteration may be accomplished following any item needing an in-process inspection until the inspection has been accomplished and the results found acceptable as evidenced by the inspector’s initials or signature. The Inspectors will ensure the repair station will perform work steps in sequence. If work out of sequence is contemplated, an appropriate review will be made to ensure that the airworthiness of the article will not be affected. 1.3.13 In-Process Inspection Inspectors, listed on the roster, are responsible for accomplishing in-process inspections for all articles undergoing maintenance, preventive maintenance, and alteration by this repair station. The Inspector may delegate all in-process duties to any qualified supervisor as necessary; however, such delegation does not relieve the Inspector of overall responsibilities. The in-process inspection (may also be entitled as “progressive inspection”) procedures for articles for maintenance or alteration are as follows: • • • Inspectors are responsible for ensuring that in-process inspections are performed properly, and that the inspection results are acceptable. The Inspector will ensure that the requirement for and frequencies of the inprocess inspections shall be determined in accordance with the applicable manufacturer’s Instructions for Continued Airworthiness (e.g., maintenance, repair, and overhaul manuals), Service Bulletins (SBs), service letters, Airworthiness Directives (ADs), and/or other data acceptable to or approved by the FAA. Perform in process FOD inspection to assure there is no debris present. Page Revision Number 21 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC 1.3.13 In-Process Inspection (cont) • The Inspector will conduct an in-process inspection during various stages of disassembly, repair, and reassembly of an article. These inspections are to be conducted in accordance with maintenance manuals, Service Bulletins (SBs), service letters, Airworthiness Directives (ADs), and/or other data acceptable to or approved by the FAA. • The in-process inspection, conducted by the Inspector, includes a visual and dimensional test. The Inspector will determine if the in-process inspection will require a functional test and/or precision test equipment. The Inspector will also determine if the article will require any special or non-destructive testing. • The Inspector will then determine if the article will require shipment to another facility for contracted maintenance. Procedures for contracted maintenance may be found in a manual entitled: “Contracted Maintenance Program”. • When a record of an inspection by dimension or test is required by the applicable technical data, the results will be recorded in the in-process inspection section of the computer-generated document FORM IAF-3117 (WO) Work Order Form. • If the Inspector determines the article is satisfactory and passes all functional or dimensional tests in accordance with the manufacturer’s Instructions for Continued Airworthiness, the article is considered acceptable. The article will be approved for final inspection. • If the Inspector determines the article is not satisfactory or that a maintenance step or function has been performed out of sequence or accomplished incorrectly during any of the various stages of the in-process inspection, the work will be repeated and inspected to ensure proper completion. Any rework will be performed in accordance with approved or acceptable technical data. • The Inspector will ensure any defects or discrepancies noted during this inprocess inspection will be addressed by the corrective actions taken. The recorded discrepancy found during the in-process inspection must show a method of correction in accordance with the manufacturer specifications. • If the in-process inspection reveals a discrepancy, the Chief Inspector will be notified, and a detailed description of the discrepancy will be recorded in the appropriate section of the Work Order Form. • The Chief Inspector will then forward the hidden damage inspection findings to the Quality Assurance Manager. • The Quality Assurance Manager will revise the list of discrepancies noted on the Work Order Form and forward them to the customer. The customer will have an option to either request for the item to be issued a Red Rejected Tag attached to the completed FORM IAF-3116 (TDR) Teardown Report (Teardown Report is the finalized version of the Work Order Form filled in by computer not handwritten) and returned or the customer may authorize the Quality Assurance Manager to issue a “red tag” and identify the item as BER (Beyond Economical Repair). The Quality Assurance Manager will determine if the item is to be processed to the quarantine area or to proceed with the disposition of the rejected / condemned / BER item in the repair station. Procedures for handling and documenting of quarantined items will be performed in accordance with Handling & Documentation of Quarantine Items located in this manual. Procedures for handling and documenting rejected / condemned / BER items will be performed in accordance with Handling Rejected / Condemned / BER Items located in this manual. Page Revision Number 22 12 Revision Date Original Issue Date Aug 11, 2023 November 15, 2009 QUALITY CONTROL MANUAL ICON AEROSPACE, LLC 1.4 Equipment, Materials and Technical Data 1.4.1 General Requirements All equipment, materials, and technical data needed for the work that Icon Aerospace, LLC performs will be available where the work is accomplished and be under Icon Aerospace, LLC’s control when the work is being performed. The equipment used to make airworthiness determinations will be calibrated according to the procedures described below. The following materials and technical data pertaining to the performance of any work under Icon Aerospace, LLC’s Certificate will be maintained current and accessible in printed or digital format accessible from computer. All new revisions will be maintained digitally, and printed data will be phased out eventually. • • • • • • • • Airworthiness Directives (Maintained printed or digital) Instructions for Continued Airworthiness (Maintained printed or digital) Maintenance manuals (Maintained printed or digital) Overhaul manuals (Maintained printed or digital) Standard practice manuals and Service bulletins (Maintained printed or digital) Whenever a new article is introduced for maintenance, preventive maintenance or alteration, or a manufacturer updates its manual the Technical Publications Manager will ensure the currency of the technical information required to perform the work it will be replaced with the new revision and documented on FORM IAF3110 (TPSS) Technical publication Status Sheet. This form is kept on the first page of the CMM or in digital format. Data for Items which are no longer supported by manufactures, and or are not listed on publications index will be considere