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CORRECTIVE ACTION REQUEST (CAR)

THE NEW CATEGORIZATIONBY

LT KOL Hishammuddin bin Abdul RahmanTUDMPENGARAH AAMR

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SCOPEAIM

THE NEW CAR CATEGORIZATION

DefinitionExamples

CAR ImpactCAR Closure Duration

BACKGROUND

CONCLUSIONTHE NEW CAR FORM

Q&A

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AIMTO PRESENT THE NEW AMENDMENTS

ON CORRECTIVE ACTION REQUEST

(CAR) CATEGORIZATIONPU

2103

Technica

l

Airworth

ines

s Manage

ment

Manual

Edition

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BACKGROUNDCurrent CAR categorization comparison

DGTA DGTA-ADF EASA

Major CAR

Critical CAR

Severe and credible threat to the technical integrity

Level 1 findings – significant non compliance to Part 145 (immediately revoke, limit or suspend)

Minor CAR

Major CAR

Moderate & credible threat to the technical integrity

Level 2 findings -non compliance with Part 145 against one product. (max 6 months for close out & extendable period depending on the nature of the findings)

OFI

Minor CAR

Non compliance that warrants attention, but represent a negligible threat

OFI

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RISK HAZARD INDEX (RHI) EVALUATION

CONSEQUENCES OF ORGANIZATIONAL NON- COMPLIANCES

IMPACT ON SAFETY

RISK OF INJURY

LIKELYHOOD

Rationalization of Revision

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Table : Risk Hazard Index (RHI) for Compliance Assurance

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RegulationsTAMM PU 2103

Organization Maintenance Management Systems

(MMP, Procedure Manual, DOPM etc)

People, Facilities, Data, Equipment and

Actions

ConformanceCompliance

Relationship between Compliance and Conformance

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THE NEW CAR CATEGORIZATION

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CRITICAL

MAJOR

MINOR

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A non compliance that represents a severe (serious) threat and believed to be highly probable and almost certain to occur that affect the technical integrity of an aircraft or aeronautical product, which could lead to catastrophic failure. There is no evidence found where barriers such as policy or procedures have been put in place to arrest the problem effectively before the technical integrity of the product is compromised.

CRITICAL CAR

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Circumstances for Critical CAR(1) Authority & Competency issues (Regulation 4.5.1 Maintenance Authority & Regulation 5.1.5 Maintenance Certification) - Maintenance records were certified by unauthorised personnel who were also incompetent at the time of certification. (2) Maintenance Documentation issues (Regulation 5.2.4 Falsification, Reproduction & Alteration of Maintenance Records) – Falsify maintenance documentation for fraudulent purpose. (3) Tools & Equipment issues (Regulation 5.5.1 Tools & Support Equipment) - Maintenance was certified without any evidence of the appropriate tools and test equipments been used and the aircraft/aeronautical product have been released to service. 

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Circumstances for Critical CAR

(4) Publication issues (Regulation 5.1.2 Publication, Instructions, Orders & Data)- 

(a) Maintenance works were carried out and certified by using inappropriate or obsolete/outdated manuals and the pages for the maintenance were part of the List of Effected Pages (LEP) and the aircraft/aeronautical product have been released to service  (b) Outdated, uncontrolled, unapproved publication affecting critical system. 

 

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Circumstances for Critical CAR

(5) Aeronautical Product, Spares & Parts issues (Regulation 5.5.4 Aeronautical Product) - Unapproved parts were found installed and have been released to service. (6) Maintenance Record issues (Regulation 5.2.1 Maintenance Records & Documentation Requirements)-Maintenance was carried out NOT as per manual  

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Impact of Critical CAR on AMO

Critical CAR requires the immediate quarantine of affected aircraft/equipment and the immediate halt of the non-compliant processes.

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Duration for Critical CAR ClosureCritical CAR requires immediate action and is to be closed before release to service or next flight. Extension on CAR closure duration for Critical CAR is not allowed. Failure to close the Critical CAR within the stipulated time shall trigger the suspension and revocation of AMO certificate.

MONTHS 1    

WEEKS 4 weeks    

SUSPENSION  

CA REVIEW AND VERIFICATION

SUSPEND REVOKE

24 Hrs

CRITICAL CAR : CAR CLOSURE, SUSPENSION AND REVOCATION (DURATION MAX 1 MONTH)

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MAJOR CAR

A non compliance that represents a moderate & credible threat to the technical integrity of an aircraft or aeronautical product, however the few remaining barriers such as policy or procedures that were in place would need to fail before the technical integrity of the product is compromised.

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Circumstances for Major CAR(1) Authority & Competency issues (Regulation 4.5.1

Maintenance Authority & Regulation 5.1.5 Maintenance Certification) - Maintenance records were certified by authorised personnel who were incompetent at the time of certification.

(2) Maintenance Documentation issues (Regulation 5.2.4 Falsification, Reproduction & Alteration of Maintenance Records) – There is no system (SOP) established to alter, reproduce maintenance documentation.

(3)Tools & Equipment issues (Regulation 5.5.1 Tools & Support Equipment)-Maintenance was certified without any evidence of the appropriate tools and test equipments been used. However the aircraft/aeronautical product have NOT been released to service yet.

 

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Circumstances for Major CAR

(4) Publication issues (Regulation 5.1.2 Publication, Instructions, Orders & Data)- 

(a) Maintenance works were carried out and certified by using inappropriate or obsolete/outdated manuals and the pages for the maintenance were part of the List of Effected Pages (LEP).However the work has not been certified and the aircraft/aeronautical product have NOT been released to service yet. (b) Outdated but controlled publication affecting critical system.

(c) Outdated and uncontrolled publication affecting non-critical system. 

 

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Circumstances for Major CAR (5) Aeronautical Product, Spares & Parts issues (Regulation 5.5.4 Aeronautical Product) - Unapproved parts were found installed but have NOT been released to service. (6) Maintenance Record issues (Regulation 5.2.1 Maintenance Records & Documentation Requirements)-Maintenance was carried out as per manual however wrong maintenance details (e.g. Torque values) were recorded incorrectly.

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Impact of Major CAR on AMO

Major CAR requires immediate halt of the non-compliant processes.

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Duration for Major CAR ClosureMajor CAR requires action within 14 calendar days to correct the non-compliant processes. Extension on CAR closure duration for Major CAR is allowed up to maximum of 3 months only. Failure to close the Major CAR within the stipulated time shall trigger the suspension and revocation of AMO certificate.

MONTHS 0.5 0.5 0.5 1.5

WEEKS 2 weeks 2 weeks 2 weeks 6 weeksCAR

CLOSURE PERIOD

EXTENSION REQUEST

EXTENSION REQUEST

SUSPENSION 

CA REVIEW & VERIFICATION

1 2SUSPEND REVOKE

MAJOR CAR : CAR CLOSURE, SUSPENSION AND REVOCATION (DURATION MAX 3 MONTHS)

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A non compliance that warrants attention, but represent an insignificant threat to the technical integrity of an aircraft or aeronautical product, because there are sufficient barriers such as policy or procedures that exist to assure product technical integrity remains solid.

MINOR CAR

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Circumstances for Minor CAR(1) Authority & Competency issues (Regulation 4.5.1

Maintenance Authority & Regulation 5.1.5 Maintenance Certification) - Maintenance records were certified by unauthorised personnel who were competent at the time of certification.

(2) Maintenance Documentation issues (Regulation 5.2.4 Falsification, Reproduction & Alteration of Maintenance Records) – Alter maintenance documentation inappropriately (not following procedure/SOP).

(3) Tools & Equipment issues (Regulation 5.5.1 Tools & Support Equipment)-Maintenance was carried out without any evidence of the appropriate tools and test equipments been used. However the work has not been certified yet and the aircraft/aeronautical product have NOT been released to service yet.

 

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Circumstances for Minor CAR

(4) Publication issues (Regulation 5.1.2 Publication, Instructions, Orders & Data) 

(a) Maintenance works were carried out by using inappropriate or obsolete/outdated manuals. However the pages for the maintenance were NOT part of the List of Effected Pages (LEP) and the aircraft/aeronautical product have NOT been released to service yet. (b) Outdated but controlled publication affecting non-critical system. (c) Uncontrolled publication affecting non-critical system.  

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Circumstances for Minor CAR (5) Aeronautical Product, Spares & Parts issues (Regulation 5.5.4 Aeronautical Product) - Unapproved parts were found but NOT installed yet. (6) Maintenance Record issues (Regulation 5.2.1 Maintenance Records & Documentation Requirements)-Maintenance was carried out as per manual and the details were recorded NOT with the format required by the SOP.

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Impact of Minor CAR on AMO

Minor CAR requires halt of the non-compliant processes as soon as possible.

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Duration for Minor CAR Closure

Minor CAR requires action within 60 calendar days to correct the non-compliant processes. Extension on CAR closure duration for Minor CAR is allowed up to maximum of 6 months only. Failure to close the Minor CAR within the stipulated time shall trigger the suspension and revocation of AMO certificate.

MONTHS 2 1 1 2

WEEKS 8 weeks 4 weeks 4 weeks 8 weeksCAR CLOSURE PERIOD EXTENSION 

REQUESTEXTENSION REQUEST

SUSPENSION 

1 2 CA REVIEW & VERIFICATION

SUSPEND REVOKE

MINOR CAR : CAR CLOSURE, SUSPENSION AND REVOCATION (DURATION MAX 6 MONTHS)

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THE NEW CAR FORM DGTA-EA-002F(Revision 1)

* ( Tick '√' or 'X' )

CORRECTIVE ACTION REQUEST

Standard PU 2103

        *Category Critical Major                 Minor                  

SECTION 1 :  DETAILS OF AUDIT

Auditor Audit No /

Auditee *Position : CAR No of

QM X SMM Others

SECTION 2 :  NON-CONFORMANCE (Include details of objective evidence)

Directorate General Technical AirworthinessTingkat 8, Bangunan TH Selborn153, Jalan Tun Razak50400 KUALA LUMPUR

CORRECTIVE ACTION REQUEST Standard PU 2103

DGTA-EA-002F(Revision 1)

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CONCLUSIONThere are three categories of CAR that a Lead Auditor can

raise on noncompliance found during AMO audit.

These are CRITICAL, MAJOR or MINOR.

The accurate CAR categorization is important to ensure prompt action by the relevant party.

However, The Lead Auditor is ultimately responsible for deciding on the category of all noncompliances.

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Q & A