ICON AEROSPACE, LLC REPAIR STATION MANUAL PDF
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2009
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Summary
This document is a repair station manual for ICON Aerospace, LLC. It details procedures, regulations, and specifications for performing maintenance on civil aviation articles. The manual was last updated in 2009.
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REPAIR STATION MANUAL ICON AEROSPACE, LLC REPAIR STATION MANUAL Federal Aviation Administration Repair Station Certificate Number: 68IR700B EASA Acceptance Number: EASA.145.6295 CONTROL NUMBER: ASSIGNMENT: Page Revision Number 100 FAA Inspector 1 12 Revision Date Original Issue Date Jul 17,...
REPAIR STATION MANUAL ICON AEROSPACE, LLC REPAIR STATION MANUAL Federal Aviation Administration Repair Station Certificate Number: 68IR700B EASA Acceptance Number: EASA.145.6295 CONTROL NUMBER: ASSIGNMENT: Page Revision Number 100 FAA Inspector 1 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Table of Contents GENERAL AND ADMINISTRATIVE PROCEDURES ................................. 8 Introduction ................................................................................................................ 8 Manual Distribution, Control, and Revision Process ................................................ 8 Paper Format ............................................................................................................... 8 Paper Format (Cont) ................................................................................................... 9 Electronic Format........................................................................................................ 9 Definitions.................................................................................................................. 9 Accountable Manager ............................................................................................... 10 Article ....................................................................................................................... 10 Directly in charge ...................................................................................................... 10 Line Maintenance...................................................................................................... 10 General Requirements .............................................................................................. 10 FAA Inspections ...................................................................................................... 10 Hazardous Materials ................................................................................................ 11 CERTIFICATE AND OPERATIONS SPECIFICATIONS ........................... 12 Application Process ................................................................................................. 12 Certificate Requirement, Change or Transfer and Duration .................................... 12 Requirement .............................................................................................................. 12 Change or Transfer ................................................................................................... 12 Duration .................................................................................................................... 12 Certificate Limitations and Privileges ..................................................................... 12 Availability of Certificate ........................................................................................ 13 ORGANIZATION ........................................................................................... 14 General ..................................................................................................................... 14 Organizational Structure .......................................................................................... 14 Key Personnel — Duties and Responsibilities ........................................................ 15 Accountable Manager ............................................................................................... 15 Accountable Manager (Cont) .................................................................................... 16 Chief Inspector .......................................................................................................... 16 Quality Assurance Manager ...................................................................................... 17 Quality Assurance Manager (Cont) .......................................................................... 18 Director of Operations .............................................................................................. 18 Director of Operations (Cont) ................................................................................... 19 Inspector .................................................................................................................... 20 Technician ................................................................................................................. 20 Technical Publications/Stores Manager .................................................................... 21 PERSONNEL .................................................................................................. 22 Employee Certificates .............................................................................................. 22 Employee Qualifications .......................................................................................... 22 Accountable Manager ............................................................................................... 23 Quality Assurance Manager ...................................................................................... 23 Director of Operations .............................................................................................. 24 Chief Inspector/Inspectors ........................................................................................ 24 Technician ................................................................................................................. 25 Rosters and Roster Records ..................................................................................... 26 Page Revision Number 2 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Roster Records .......................................................................................................... 26 Repair Station Roster ................................................................................................ 26 Repair Station Roster Inspection Personnel .............................................................. 27 Repair Station Roster Employee Summary .............................................................. 28 FACILITIES .................................................................................................... 29 Physical Description ................................................................................................ 29 Description of Operation........................................................................................... 29 Facility Layout ......................................................................................................... 30 Facility Layout .......................................................................................................... 31 Facility Layout .......................................................................................................... 32 Procedures for Location, Housing or Facility Changes ........................................... 33 Procedures for Accomplishing Work Outside of Fixed Location ........................... 33 Procedures for Contract Maintenance, Maintaining and Revising .......................... 33 Equipment, Materials and Technical Data ............................................................... 33 TRAINING ...................................................................................................... 34 General Program Description .................................................................................. 34 Procedures for Revising the Training Program ....................................................... 35 PROCEDURES FOR WORK PERFORMED FOR CERTAIN OPERATORS (SUBJECT TO PARTS 121, 125, 129 OR 135) ............................................................ 36 Standard Performance Requirements ....................................................................... 36 Line Maintenance..................................................................................................... 36 RECORDS AND REPORT ............................................................................. 37 General Policy .......................................................................................................... 37 Recordkeeping System............................................................................................. 37 Recordkeeping System (Cont) ................................................................................. 38 Reports of Defects or Un-airworthy Conditions ...................................................... 38 Responsibility ........................................................................................................... 38 Detecting and Reporting Suspected Unapproved Parts ........................................... 38 CAPABILITY LIST ESTABLISHMENT AND REVISION PROCESS ....... 39 Establishment and Revision ..................................................................................... 39 MANUAL DISTRIBUTION Page Revision Number 3 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC MANUAL ASSIGNED NUMBER TO: Master ACCOUNTABLE MANAGER 100 101 102 103 FAA INSPECTOR DIRECTOR OF OPERATIONS QUALITY ASSURANCE MANAGER SHOP Page Revision Number 4 12 TITLE OR ORGANIZATION Accountable Manager CONTACT INFORMATION 704-821-4266 Aviation Safety Inspector Director of Operations Quality Assurance Manager 704-319-7020 704-821-4266 704-821-4266 Icon Aerospace 704-821-4266 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC RECORD OF REVISION REVISION NUMBER Original 1 2 3 4 5 6 7 8 9 10 11 12 REVISION DATE NOV 15, 2009 JAN 24, 2011 JUN 01, 2011 OCT 12, 2011 JAN 16, 2012 MAY 21, 2012 June 17, 2013 OCT 17, 2013 DEC 15, 2014 JAN 15, 2019 AUG 15, 2019 MAY 01, 2023 JUL 17, 2023 INSERTION DATE NOV 15, 2009 JAN 24, 2011 JUN 01, 2011 OCT 12, 2011 JAN 16, 2012 MAY 21, 2012 June 17, 2013 OCT 17, 2013 DEC 15, 2014 JAN 15, 2019 AUG 15, 2019 MAY 01, 2023 JUL 17, 2023 PAGES ALL 23,24, & 25 23,24, & 25 23,24, & 25 1,5,6,7,8 & 30 1,5,6,7,23,24, & 25 ALL 1,3,5,6,25,26 & 27 1,2,3,4,5,6,7 ALL ALL ALL ALL BY AG AG AG AG AG AG AG AG AG AG AG NH NH Reason for update: • Section 3.2 Updated Organizational Chart Signature ______________________ Page Revision Number 5 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC LIST OF EFFECTIVE PAGES Title Cover Page Table of Contents Manual Distribution Record of Revision List of Effective Pages Section 1: General and Administrative Procedures 1.1 Introduction 1.2 Manual Distribution Control & Revision Process 1.3 Definition 1.4 General Requirements 1.5 FAA Inspections 1.6 Hazardous Materials Section 2: Certificate and Operations Specifications 2.1 Application Process 2.2 Certificate Requirement, Change or Transfer and Duration 2.3 Certificate Limitations and Privileges 2.4 Availability of Certificate Section 3: Organization 3.1 General 3.2 Organizational Structure 3.3 Key Personnel-Duties and Responsibilities Section 4: Personnel 4.1 Employee Certificates 4.2 Employee Qualifications 4.3 Rosters and Roster Records Section 5: Facilities 5.1 Physical Description 5.2 Facility Layout 5.3 Procedures for Location, Housing or Facility Changes 5.4 Procedures for Accomplishing Work Outside of Fixed Location 5.6 Equipment, Materials and Technical Data Page Revision Number 6 12 Page 1 2-3 4 5 6-7 Revision Date MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 8 8-9 9-10 10 10 11 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 12 12 MAY 01, 2023 MAY 01, 2023 12 13 MAY 01, 2023 MAY 01, 2023 14 14 15-21 MAY 01, 2023 JUL 17, 2023 MAY 01, 2023 22 22-25 26-28 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 29 30-32 33 33 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 33 MAY 01, 2023 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC LIST OF EFFECTIVE PAGES (cont) Title Section 6: Training 6.1 General Program Description 6.2 Procedures for Revising the Training Program Page Revision Date 34 35 MAY 01, 2023 MAY 01, 2023 Section 7: Procedures for Work Performed for Certain Operators (Subject to Parts 121, 129 or 135) 7.1 Standard Performance Requirements 7.2 Line Maintenance 36 36 MAY 01, 2023 MAY 01, 2023 Section 8: Records and Report 8.1 General Policy 8.2 Recordkeeping System 8.3 Reports of Defects or Un-airworthy Conditions 8.4 Detecting & Reporting Suspected Unapproved Parts 37 37-38 38 38 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 MAY 01, 2023 Section 9: Capability List Establishment and Revision Process 9.1 Establishment and Revision 39 Page Revision Number 7 12 Revision Date Original Issue Date MAY 01, 2023 Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC GENERAL AND ADMINISTRATIVE PROCEDURES Introduction The Repair Station Manual has been prepared in accordance with the current Code of Federal Regulation (CFR) and the policies of Icon Aerospace, LLC The information contained in this manual explains the systems used by Icon Aerospace, LLC when performing maintenance, preventative maintenance or alteration on civil aviation articles. When more detail is required to accomplish or record a particular operation, those details are contained in the applicable manufacturer’s instruction for continued airworthiness (e.g. maintenance, overhaul and repair manuals), service bulletins, service information letters, Airworthiness Directives, and/or other data acceptable to or approved by the Federal Aviation Administration (FAA). The general repair, overhaul or alterations of products will be performed in accordance with the current CFR’s, manufacturer’s data, drawings, specifications and bulletins or other technical data approved for the particular ratings, limited ratings or specialized ratings held by Icon Aerospace, LLC (See copies of certificates of ratings held). Icon Aerospace, LLC will not maintain or alter any item for which it is not rated and will not maintain or alter any article for which it is rated if it requires technical data, equipment, materials, facilities or trained personnel that are not available (Ref: 14 CFR 145.53). The Technical Library and the Repair Station Manual, required for operation of this Repair Station, will be maintained in a current status at all times. The Repair Station Manual is made up of the following manuals, Quality Control Manual, Training Manual, Forms Manual, and Contracted Maintenance Program 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 Page Revision Number 8 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Paper Format (Cont) 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 non-compliance 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. 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. Definitions The following definitions apply to all related information in the manual. The definitions are consistent with those found in 14 CFR Part 145.3. Page Revision Number 9 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Accountable Manager The person designated by the certificated Repair Station who is responsible for and has the authority over all Repair Station operations that are conducted under Part 145, Including ensuring that Repair Station personnel follow the regulations and serving as the primary contact with the FAA. Article An aircraft, airframe, aircraft engine, propeller, appliance, or component part. Directly in charge Having the responsibility for the work of a certificated Repair Station that performs maintenance, preventative maintenance, alterations, or other functions affecting aircraft airworthiness. A person directly in charge does not need to physically observe and direct each worker constantly but must be available for consultation on matters requiring instruction or decision from the higher authority. Line Maintenance (1) Any unscheduled maintenance resulting from unforeseen events; or (2) Scheduled checks that contain servicing and/or inspections that do not require specialized training, equipment or facilities. General Requirements To operate as a certificated Repair Station, this Repair Station must have a valid Repair Station Certificate issued in accordance with Part 145. The Repair Station certification includes the Air Agency Certificate, ratings and operations specifications. No operations will be conducted in violation of that certificate. The certificate will be made available for review upon request. In addition to having an appropriate certificate and ratings, prior to performing maintenance, preventive maintenance or alteration on a civil aviation article, this Repair Station must have available any required special technical data, equipment, personnel and facilities. FAA Inspections This repair station will allow the FAA to inspect our facility, inspection systems, records and procedures to determine compliance with CFRs at any reasonable time. The repair station will not contract any work to any non-certificated repair station or person. Page Revision Number 10 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Hazardous Materials Employees or contractors of ICON Aerospace, LLC will not perform work on or handle any hazardous materials with the exception of consumables such as aerosol paints etc. No employee or contractor of Icon Aerospace, LLC will prepare or offer any hazardous materials for shipment. All chemical products used by the repair station will be handled and stored in accordance with the manufacturer’s recommendations and outline as in the Material Safety Data Sheets for each hazardous chemical used by the repair station. These records will be maintained by the Technical Publications/Stores Manager. If an operator request for material not to be handled or shipped ICON Aerospace LLC will comply and acknowledge. Page Revision Number 11 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC CERTIFICATE AND OPERATIONS SPECIFICATIONS Application Process This manual provides all the information required by the regulations as broadly identified in the application process. Specifically, it contains – • Repair Station Manual • Organization chart, and • Description of the Repair Station facilities within the United States. Certificate Requirement, Change or Transfer and Duration Requirement A Repair Station Certificate issued by the FAA is required before accomplishing any work as a Repair Station. Icon Aerospace, LLC will not perform any Repair Station work in violation of its certificate. Change or Transfer If changes to add or amend a rating or change of location for repair station are required, Icon Aerospace, LLC will apply in writing to the FAA. If Icon Aerospace LLC sells or transfers its assets, the new owner must apply for an amended Repair Station Certificate. (145.57(b)) Duration Certificate will remain in effect until it is surrendered by ICON AEROSPACE, LLC, expires, suspended, or revoked by the FAA. The certificate must then be returned to the FAA/CHDO. Certificate Limitations and Privileges Icon Aerospace, LLC may maintain and alter any of the articles covered by its ratings and approve for return to service those articles. Icon Aerospace, LLC will not maintain or alter articles that require special tools, technical data, equipment, or facilities that are not available to it and articles not covered by its ratings. Icon Aerospace, LLC will not approve for return to service any article unless the maintenance, preventive maintenance, or alteration was performed in accordance with applicable approved technical data or data acceptable by the FAA. Page Revision Number 12 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Availability of Certificate The repair station certificate is displayed within the main entrance of the facility or conference room and shall be made available to the public and the FAA for inspection upon request. This request shall be fulfilled by the Quality Assurance Manager. Page Revision Number 13 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC ORGANIZATION General Employees are hired to perform work on civil aviation articles based on their knowledge and experience. An employee’s initial qualifications are determined by employment history, training, certification, knowledge, experience, and practical tests. Job assignments, including the performance of maintenance, inspection, or supervision, are based on the employee’s qualifications. All employees performing maintenance or other safety related functions for an air carrier or commercial operator certificated under 14 CFR Part 121 or Part 135 are included in an FAA – approved Anti-Drug/Alcohol Misuse Prevention Program. Organizational Structure This Repair Station’s organization is as shown in the following chart. The chart includes each management position with authority to act on behalf of the Repair Station. Details of personnel and title held are maintained in the Repair Station Roster Section. Page Revision Number 14 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Key Personnel — Duties and Responsibilities The duties and responsibilities of the individuals that fulfill managerial, supervisory, inspection and maintenance positions in this Repair Station are assigned by the Accountable Manager and are set forth in this section of the manual. These persons will be listed on the Repair Station roster. The actual Repair Station roster is contained in a separate document entitled “REPAIR STATION ROSTER” kept and maintained by the Quality Assurance Manager. Additionally, the qualifications for each position are set forth in this manual. The training requirements for each position responsible for performing maintenance, preventive maintenance or alterations will be set forth in a separate section/manual that is specifically approved by the FAA which is titled TM (TRAINING MANUAL). Accountable Manager The Accountable Manager is directly in charge of the maintenance functions of the Repair Station. In addition to the complete administration of the Repair Station, this position will ensure that the Repair Station continues to comply with applicable local, State, and Federal requirements. With respect to the CFRs and the European Aviation Safety Agency (EASA), the Accountable Manager shall ensure the Repair Station continues to meet the requirements for providing adequate housing, facilities, equipment, and personnel appropriate to the ratings of the Repair Station. In addition, the Accountable Manager shall ensure the financial resources are available to adjust to any changes in workload or to adjust the workload to the resources available. In addition to the overall duties and responsibilities listed above, the Accountable Manager has the following specific responsibilities: 1. Responsible for the overall operation of the Repair Station. 2. Responsible for establishing qualifications for the Inspection personnel. 3. Responsible for maintaining proficiency within the Inspection personnel. 4. Plan, direct, layout and coordinate the activities of all departments. 5. Provide recommendations of Repair Station requirements to best service Icon Aerospace, LLC’s customers efficiently and as economically as possible. 6. Ensure adequate fire-fighting equipment is available at the Repair Station. 7. Ensure adequate safety precautions are observed by Repair Station personnel. 8. Ensure each person authorized to approve an article for return to service under the repair station certificate and operations specifications is certificated under part 65. 9. Establish the criteria for hiring personnel for positions responsible for maintaining, supervising, or inspecting maintenance or alterations of civil aviation articles. 10. Establish the requirements for initial and recurrent training for all personnel involved in the maintenance, preventive maintenance, and/or alteration of civil aviation articles. 11. Is in charge of the Corrective Action Program and determines the appropriate actions to be taken when deficiencies are discovered or reported. 12. Act as the liaison with all customers. 13. Act as the liaison with all Federal officials. Page Revision Number 15 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Accountable Manager (Cont) 14. Sign the revised list of effective pages of this manual. 15. Act as a backup for key personnel whenever necessary. The Accountable Manager may delegate their duties to any supervisor; however, such delegation does not relieve them of the overall responsibility. Chief Inspector The Chief Inspector reports to the Accountable Manager and is responsible for the operations of the Inspection Department. It will be the Chief Inspector’s responsibility to— 1. Maintain the Repair Station roster for the Repair Station by ensuring that changes in personnel or job duties are reflected on the roster within five (5) business days as required by this manual. 2. Train, direct, supervise, and assist all personnel performing work under the Repair Station certificate as directed by the Accountable Manager. 3. Determine that, if the customer’s work scope is limited in nature, the requested maintenance, preventive maintenance or alteration can be accomplished with the applicable data despite any other damage or discrepancies noted. 4. Initiate the application for an employee to become a repairman certificated under 14 CFR Part 65. 5. Ensure that determinations concerning major alterations/repairs are accomplished as delineated in this manual. 6. Ensure all incoming articles, hidden damage, preliminary, in-process and final inspections are performed in accordance with the procedures set forth in this manual. 7. Submit reports of serious defects or recurring un-airworthy conditions in accordance with the procedures described in this manual. 8. Act as a backup for key personnel whenever necessary. 9. Is authorized to approve an article for return to service under the repair station certificate and operations specifications is certificated under part 65. The Chief Inspector may delegate their duties to any supervisor; however, such delegation does not relieve them of the overall responsibility. Page Revision Number 16 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Quality Assurance Manager The Quality Assurance Manager reports to the Accountable Manager and is responsible for the operations of the Quality Assurance Department. It will be the Quality Assurance Manager’s responsibility to— 1. Coordinate and distribute revisions to this manual. (For Repair Station using the electronic version of this manual: Ensure that the manual is kept current and accurate.) 2. Ensure that all revisions to this manual are coordinated with the FAA. 3. Sign the revised list of effective pages of this manual. 4. Coordinate FAA inspections as delineated in this manual. 5. Respond to any request for inspection of this Repair Station’s certificate. 6. Determine the final disposition of articles failing to meet the incoming inspection review. 7. Determine equivalency of tools as described in the QCM manual and equipment used by the Repair Station (other than that recommended by manufacturers) and document that determination. 8. Ensure appropriate calibrations and checks are made on the tools and equipment used by the Repair Station. 9. Ensure records of all calibrations and checks are kept current, and the calibrations are performed in accordance with the standards and procedures described in this manual. 10. Audit all maintenance function contractors before use and maintain the results of those audits. 11. Establish and maintain the Repair Station employment and training records. 12. Continuously review the Repair Station’s training program to ensure all the Repair Station’s training needs are met. (If applicable.) 13. Perform the Repair Station’s “self-evaluation” to determine whether it has the housing, facilities, equipment, material, data, and trained personnel to add an article to its Capability and revise. 14. Perform the incoming review to identify, control, segregate, and maintain all materials including raw materials, parts, and shelf-life items according to the manufacturer requirements or standard industry practices. 15. Ensure work performed by outside sources and incorporated in articles undergoing maintenance, preventive maintenance, or alteration in this Repair Station was properly performed and documented. Page Revision Number 17 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Quality Assurance Manager (Cont) 16. Ensure the preservation of all articles or parts, while carried in inventory, including parts that are subject to deterioration and self-life specifications. 17. Execute specified shelf-life requirements. 18. Ensure the preservation and storage of all materials, parts, and supplies in a condition enabling them to be installed or used on civil aviation articles. 19. Control and distribute the inventory. 20. Distribute any technical information, documents or data received through the stock room. 21. Ensure that parts that have been designated as scrap are appropriately disposed of. 22. Responsible for scrap parts program. 23. Responsible for maintaining the training program. 24. Act as a backup for key personnel whenever necessary 25. Act as the liaison with all customers 26. Act as the liaison with all Federal officials. The Quality Assurance Manager may delegate their duties to any supervisor; however, such delegation does not relieve them of the overall responsibility. President and Director of Operations The President and Director of Operations report to the Accountable Manager and are responsible for the operations of the Maintenance Department. It will be the President and/or Director of Operations responsibility to— 1. Ensure all personnel are trained in the appropriate safety practices and procedures, including proper use and location of firefighting equipment. 2. Periodically check the fire and safety equipment to ensure serviceability and adequacy. 3. Ensure technicians have the appropriate technical data available during the performance of maintenance, preventive maintenance, and alteration activities. 4. Ensure that Part 121, 125, 129 and 135 customer requirements are obtained, made available and followed by inspection personnel. Page Revision Number 18 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC President and Director of Operations (Cont) 5. Ascertain qualifications of all technical employees prior to work assignment through tests and evaluation of their previous experience. 6. Train, assist and supervise technicians in proper work procedures and practices. 7. Ensure the shop equipment and tools are maintained in good working order. 8. Ensure the shop premises are maintained in a clean and orderly manner. 9. Ensure that all maintenance or alteration processes are appropriately completed and documented on the maintenance forms as set forth in this manual. 10. Determine whether a hidden damage inspection should be performed, what should be done and properly perform maintenance. 11. Initiate requisitions for stock as required for the work being performed. 12. Maintain in current condition the pertinent CFRs and Airworthiness Directives relative to the work performed by the Repair Station. 13. Assigns work and ensures that non-certificated employees performing maintenance functions are assigned tasks that coincide with their training, knowledge, and experience. 14. Ensure the availability and currency of the technical information required to perform work whenever a new article is introduced for maintenance, preventive maintenance, or alteration. 15. Responsible for tool and test equipment program (Quality Assurance Manager Serves as backup for this program). 16. Determine that all manufacturers’ instructions for continued airworthiness (e.g., maintenance, overhaul, and repair manuals), service bulletins, service letters, government and industry standards, and other data acceptable to or approved by the FAA relative to the civil aviation articles maintained or altered by the Repair Station are in current status and available to maintenance and inspection personnel. 17. Act as a backup for key personnel whenever necessary. 18. Is authorized to approve an article for return to service under the repair station certificate and operations specifications is certificated under part 65. 19. Act as the liaison with all customers. 20. Act as the liaison with all Federal officials. The President and/or Director of Operations may delegate their duties to any supervisor; however, such delegation does not relieve them of the overall responsibility. Page Revision Number 19 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Inspector Personnel performing inspection functions report to the Chief Inspector and are responsible for performing duties as directed and assigned. Inspector(s) are responsible for performing preliminary, hidden-damage, in-process and final inspections on civil aviation articles in accordance with the current technical data provided in the manufacturer’s instructions for continued airworthiness, service bulletins, service letters, Airworthiness Directives, government and industry standard practices, and other data acceptable to or approved by the FAA. Inspector(s) are specifically responsible for1. Ensuring that they are thoroughly familiar with the inspection methods, techniques, aids, tools, and equipment used within their assigned area of responsibility. 2. Maintaining proficiency in using the inspection aids in their assigned area of responsibility. 3. Ensuring that the inspection tools and equipment, including inspection aids, used to perform inspections are in proper working order and the proper calibration information is affixed. 4. Understanding the current specifications involving inspection tolerances, limitations, and procedures established by the manufacturer of the article(s) being inspected. 5. Ensure all inspections are properly performed and recorded, and all records are properly executed before final approval for return to service of articles maintained or altered by this Repair Station. Technician Personnel assigned maintenance functions duties shall report to the Director of Operations and are specifically responsible for1. Properly executing the duties assigned. 2. Performing maintenance and alteration tasks on civil aviation articles in accordance with the current technical data provided in the manufacturers’ Instructions for Continued Airworthiness, Services Bulletins, service letters, Airworthiness Directives, government and industry standard practices, and other data acceptable to or approved by the FAA. 3. Ensuring that they are thoroughly familiar with all tools and equipment, including inspection aids, used within their assigned area of responsibility. 4. Properly record the work performed on the appropriate maintenance record. Page Revision Number 20 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Technical Publications/Stores Manager The Technical Publications/Stores Manager reports to the Quality Assurance Manager and is responsible for the acquisition and maintenance of all this Repair Station’s technical data. It will be the Technical Publications/Stores Manager’s responsibility to – 1. Provide technical data and assistance as required to the shop and technicians. Utilize the assistance of the Quality Assurance Manager and Director of Operations as required. 2. Procure and maintain all technical data on all units repaired or overhauled by the Repair Station. This material will consist of the manufacturer’s overhaul manual, service bulletins related to the Code of Federal Regulations, etc. 3. Responsible for technical data program (Quality Assurance Manager serves as backup for this program). 4. Ascertain that required technical data is available for units accepted for work and being processed through the shop. 5. Responsible for shelf-life program (Quality Assurance Manager serves as backup for this program) 6. Execute specified shelf-life requirements. 7. In conjunction with the Quality Control Manager, ensure that all parts entering Icon Aerospace, LLC comply with FAA regulations and are properly handled and stored. 8. Initiate purchase orders for stock as required. 9. Ensure the preservation of all articles or parts, while carried in inventory, including parts that are subject to deterioration and shelf-life specifications. 10. Ensure the preservation and storage of all materials, parts and supplies in a condition enabling them to be installed or used on civil aviation articles. 11. Control and distribute the inventory. 12. Distribute any technical information, documents or data received through the stock room. The Technical Publications/Stores Manager may delegate duties to any qualified personnel; however, delegation of duties does not relieve the Technical Publications/Stores Manager of his overall responsibilities. Page Revision Number 21 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC PERSONNEL Employee Certificates Whenever this Repair Station determines that an individual certificate is required for the performance of duties, the Chief Inspector may initiate the application for that employee to become a repairman certificated under 14 CFR Part 65. All supervisory personnel directly in charge of maintenance functions will be certificated under 14 CFR Part 65. Moreover, the Repair Station will collect the certificate of any repairman when they are no longer employed by the company. However, it should be noted that a repairman certificate is only valid for the work performed within the scope of assigned duties at this Repair Station. Employee Qualifications Employees, to include non-certificated employees, are hired to perform maintenance on civil aviation articles upon their knowledge and experience. The employee’s initial qualifications are determined by employment history, training, certification, knowledge, experience and/or practical tests. Job assignments, including the performance of maintenance, inspections, or supervision, are based upon the employee’s initial qualifications. Additionally, the employee qualifications listed in this manual will be the basis for determining the initial and recurrent training requirements. Supervisory personnel qualifications and title are documented in the Repair Station Roster Manual. All employees performing maintenance or other safety-related functions for an air carrier or commercial operator certificated under 14 CFR Part 121 or 135 are included in an FAA – approved “Anti-Drug/Alcohol Misuse Prevention Program.” Page Revision Number 22 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Accountable Manager The Accountable Manager is directly responsible for the complete administration of Icon Aerospace, LLC as such, and prior to assigning these duties and responsibilities and placing the individual’s name on the Repair Station Roster, it shall be determined that the individual – 1. Understands, reads, and writes English. 2. Understands the procedures set forth in this manual. 3. Has the appropriate experience, evidenced by employment history, training, or certification to perform in the supervisory position assigned. Once the above information has been ascertained, the individual will be designated the title Accountable Manager and assume the duties and responsibilities. That person will also be placed on Icon Aerospace, LLC’s roster which is kept in a separate manual named Repair Station Roster Manual by the Chief Inspector. Quality Assurance Manager Prior to being assigned as the Quality Assurance Manager, or any person assigned technical supervisory responsibilities and being listed on Icon Aerospace, LLC’s Roster, Icon Aerospace, LLC shall determine that the individual – 1. Understands, reads, and writes English. 2. Has the appropriate experience through training, employment history or practical tests and that this information has been documented and is available in the individual’s employment file. 3. Has experience in the procedures, practices, inspection methods, materials, tools, machine tools, and equipment generally used in the work for which the Repair Station is rated. 4. Understands the CFRs, Airworthiness Directives, methods, techniques, and practice contained in the applicable manufacturer’s maintenance and alteration documents, and/other data acceptable to or approved by the FAA used by the Repair Station. 5. Understands the current specifications, involving inspection tolerances limitations and procedures established by the manufacturer or by an Airworthiness Directive, of the articles being inspected and approved for return to service. 6. Is thoroughly familiar with the applicable CFRs and with the inspection methods, techniques, practices, aids, equipment, and tools used to determine the airworthiness of the article on which maintenance, preventive maintenance, or alterations are being performed. 7. Is proficient in using various types of mechanical and visual inspection aids appropriate for the articles being inspected and approved for return to service. 8. Understands the procedures set forth in this manual for documenting the work performed. Page Revision Number 23 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC President and Director of Operations Before any person is assigned any responsibilities as the President and/or Director of Operations, and is placed on the Repair Station Roster to make final airworthiness determinations and is allowed to approve articles for return to service, Icon Aerospace, LLC shall determine that the individual – 1. Understands, reads, and writes English. 2. Is appropriately certificated under 14 CFR Part 65. 3. Is familiar with the applicable CFRs and with the inspection methods, techniques, practices, aids, equipment, and tools used to determine the airworthiness of the article on which maintenance, preventive maintenance, or alterations are being performed. 4. Is proficient in using various types of mechanical and visual inspection aids appropriate for the articles being inspected and approved for return to service. 5. Has the appropriate experience through training, employment history or practical tests and that this information has been documented and is available in the individual’s employment file. 6. Understands the current specifications, involving inspection tolerances limitations and procedures established by the manufacturer or by an Airworthiness Directive, of the articles being inspected and approved for return to service. Chief Inspector/Inspectors Prior to assigning an inspector preliminary, in-process or final inspection authority and adding/amending the Repair Station Roster, the Repair Station shall determine that the individual – 1. Understands, reads, and writes English. 2. Is appropriately certificated under 14 CFR Part 65. 3. Has a minimum of eighteen (18) months of practical experience in the procedures, practices, inspection methods, materials, tools, machine tools, and equipment generally used in the work for which the Repair Station is rated. 4. Is thoroughly familiar with the applicable CFRs and with the inspection methods, techniques, practices, aids, equipment, and tools used to determine the airworthiness of the article on which maintenance, preventive maintenance, or alterations are being performed. 5. Is proficient in using various types of mechanical and visual inspection aids appropriate for the articles being inspected and approved for return to service. 6. Understands the current specifications, involving inspection tolerances limitations and procedures established by the manufacturer or by an Airworthiness Directive, of the articles being inspected and approved for return to service. Page Revision Number 24 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Technician Prior to being authorized to perform unsupervised maintenance, preventive maintenance or alterations duties, the Repair Station shall determine that the individual – 1. Understands, reads, writes English. 2. Has experience, through training, knowledge, employment history or practical tests necessary to perform the scope of work assigned. 3. Is proficient in using the tools, equipment, and inspection aids applicable to the scope of work assigned. 4. Understands the methods, techniques and practices outlined in the manufacturer’s maintenance documents, Airworthiness Directives, Service Bulletins, service letters, specifications and other data acceptable to or approved by the FAA. Page Revision Number 25 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Rosters and Roster Records Roster Records The repair station roster lists the personnel within the repair station who are authorized to perform certain functions, such as approval for return to service or signing off required inspection items, or that hold certain management and supervisory positions. This repair station maintains a roster of all managerial, supervisory and inspection personnel that have responsibility for compliance with the CFRs. For each person on the roster, this repair station maintains current the following information— • Present title and scope of employment. • Total years of experience in the type of work assigned by reference to the date the experience started. • Employment history, including name of previous employer and length of employment by year. • Type of any certificate held along with any ratings or limitations. This repair station, through the Chief Inspector, will revise the roster within 5 business days in the following situations: • Termination of employment. • Reassignment. • Changes in current duties or scope of assignment. • Personnel additions. The Chief Inspector will maintain the roster and make it available for review by all employees. Each supervisor or manager who becomes aware of a change in personnel, termination or change in assignment that would affect the roster must notify the Chief Inspector by e-mail, telephone, or in person. The Chief Inspector will obtain the required information from the supervisor or concerned employee and update the roster within five (5) business days of any change. Repair Station Roster FLOW CHART CAN BE FOUND IN SEPARATE MANUAL LABLED ROSTER Page Revision Number 26 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Repair Station Roster Inspection Personnel Name & Title Certificate Type & Number Signature Initials *Authorization . * Authorization Delegation: REPAIRMAN CERTIFICATE PRIVILEGES OF CFR 65-103 ARE VALID FOR INSTRUMENTS, RADIOS, AND ACCESSORIES ONLY WHILE EMPLOYED BY ICON AEROSPACE. A. Authorized to sign FAA Form 8130-3. B. Authorized to return instruments, radios, and accessories to service in accordance with Federal Aviation Administration Regulations, within the scope of the repair station ratings. Authorized to sign all official FAA documents on behalf of the repair station. To include vendor Audits. C. D. Authorized to sign internal documents to include Audits performed on behalf of the repair station. E. Authorized to sign internal documents to include, Training, Incoming and Receiving Inspections and Work Orders. F. G. Authorized to sign scrap and mutilation reports for scrap parts being deemed B.E.R. Is not authorized to sign any release for return to service or 8130-3. NC = NON-CERTIFICATED Page Revision Number 27 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Repair Station Roster Employee Summary Employee Summary: NAME Name: Title: Scope: Certificate Type & No: Total Years’ Experience: years Date From: Position: Rating: Limitations: Previous Employers History: To: Detailed Employee Summaries are maintained in the Roster (Table of Contents 8) Page Revision Number 28 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC FACILITIES Physical Description LOCATION: Icon Aerospace, LLC is located in the United States at 600 Radiator Road, Indian Trail, NC 28079 CONSTRUCTION: One facility of 55,000 sq. ft. 2 level Concrete floor construction. A digitally controlled climate environment: cooling and heating are accomplished by use of HVAC. Air-conditioned work areas (administrative and shops). Indirectly lighted (LED) will meet or exceed OSHA 1910, emergency lighting exists, fire extinguishers. Non-smoking facility. SECURITY: The facility is equipped with a central alarm system monitored 24 hours a day and tested every thirty days (30) by the monitoring company. All doorways are protected with dead bolts and sensors to prevent unwanted access. A computer-controlled video surveillance system is also in place monitoring and recording 24 hours a day. Remote viewing via network capability and recoding capability of 30 days. WORK AREAS: Workshop 40,000 sq. ft Administrative 15,000 sq. ft Smoking is not allowed inside the building or any other designated work areas. Eating or drinking is not allowed in any of the designated test/work areas. Description of Operation A full description of operation’s performed at Icon Aerospace, LLC is available in the QCM Section 1.3 Page Revision Number 29 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Facility Layout Page Revision Number 30 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Facility Layout Page Revision Number 31 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Facility Layout Page Revision Number 32 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Procedures for Location, Housing or Facility Changes No changes will be made to location, housing or facilities that could have a significant effect on the ability of the Repair Station to perform work in an airworthy manner, without written approval from the FAA. The Quality Assurance Manager will decide which changes might have a “significant effect” on the ability of the Repair Station to accomplish its work in accordance with all applicable CFRs. If determined to be significant, the revision must be approved by the FAA. If insignificant, the revision will be distributed as otherwise required by this manual. If the revision is found to have a “significant effect” the Quality Assurance Manager will prepare the appropriate paperwork along with a copy of a draft revision and will be sent to the FAA for approval. After receiving FAA approval and any FAA-prescribed conditions or limitations that affect this Repair Station’s work during the transition, the Quality Assurance Manager will ensure the final manual revision is created and is properly distributed. Procedures for Accomplishing Work Outside of Fixed Location All work performed and released for return to service will be accomplished at Icon Aerospace, LLC, fixed facility only. No work will be performed away from the facility. Procedures for Contract Maintenance, Maintaining and Revising The actual contract maintenance functions including maintaining and revising can be found in the QCM Section 1.6. Equipment, Materials and Technical Data All equipment, materials and technical data needed for the work at 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. A detailed procedure is provided in the QCM Section 1.4. Page Revision Number 33 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC TRAINING General Program Description This Repair Station’s Accountable Manager is responsible for ensuring that adequate numbers of personnel are available to accomplish the types of work authorized under the Repair Station certificate. These personnel must have detailed knowledge of the particular maintenance function or technique they are involved in, based on formal training or extensive experience. All employees, including inspection personnel, shall receive training as determined necessary for the qualifications and performance of their work assignment. Initial and/or recurrent training may be required as determined by the nature of the work, the qualifications necessary for the position, experience, knowledge, certification, and previous training of the individual. Training may be on-the-job or by classroom instruction. All employees shall receive continual on-the-job training on parts handling, cleaning, and identification; the requirements of this manual and standard practice manuals relating to their job assignment; the general policies and procedures of this Repair Station and the applicability of the CFRs to the work performed by the Repair Station. To support this process, this Repair Station maintains in its personnel records the basic qualifications, training, and experience of its maintenance technicians, supervisors, and managers. The records shall indicate the type of training method, duration of each session, date each segment or session was completed, the location of each session, any certificates received, completion or passage of any testing required, the name of the trainer or instructor and his qualifications if pertinent. Most training will be recorded on the appropriate Repair Station form located in the Forms Manual, however, any documentation establishing the information listed above may be used to determine an employee’s qualifications for any job assignment. Training records will be maintained as long as the individual accomplishes work for this Repair Station and for at least two (2) years thereafter. Page Revision Number 34 12 Revision Date Original Issue Date Jul 17, 2023 November 15, 2009 REPAIR STATION MANUAL ICON AEROSPACE, LLC Procedures for Revising the Training Program The Training Programs requirements, limitations and procedures are contained in a separate manual named Training Manual (TM). All revisions to the Training Manual must be approved by the FAA before implementation. The Accountable Manager is responsible for continuously evaluating the training program to ensure its meets all of Icon Aerospace, LLC’s needs, and the applicable CFRs. If a change is required or desirable, the Accountable Manager along with the Quality Assurance Manager will develop a proposed revision to the training program. Once the proposed revision is drafted, a copy of that draft revision will be sent to the FAA office with oversight responsibility for Icon Aerospace, LLC for approval. After receiving FAA approval, the Quality Assurance Manager which has the responsibility of the training program will create a final manual revision, taking into account any FAA recommendations or requirements. The revision will then be distrib
