1 PIAEngineering and MaintenanceCEM E2 R5 March2011 14062011

ENGINEERING & MAINTENANCE COMPANY EXPOSITION MANUAL

CEM TITLE Edition: 02 Revision: 05 Issue: March’ 11 Page 1 of 2

COMPANY EXPOSITION MANUAL

CEM DISTRIBUTION CONTROL NO. _____________________

PCAA APPROVAL NO. _____________________

PAKISTAN INTERNATIONAL HEAD OFFICE JINNAH INTERNATIONAL AIRPORT KARACHI – 75200 PAKISTAN Telephone: (92 21) 9904-5344 / 9904-3558 Facsimile: (92 21) 924-2233 E-mail: [email protected] [email protected]

CAA/AW/01

Approved by: Pakistan Civil Aviation Authority Ref: HQCAA/2206/1/AW(Vol-XVI) dated 16-May-2011

mailto:[email protected]


CEM TITLE Edition: 02 Revision: 05 Issue: March’ 11 Page 2 of 2

INTENTIONALLY LEFT BLANK


CEM Chapter 1-0 Edition: 02 Revision: 00 Issue: November’ 07 Page 1 of 2


PART 1: PREAMBLE





CEM Chapter 1-1 Edition: 02 Revision: 05 Issue: March’ 11 Page 1 of 2

1-1 TABLE OF CONTENTS

Part 1 PREAMBLE ISSUE 1-1 Table of Contents Edition 2, Revision 5

1-2 Record of Revisions Edition 2, Revision 5

1-3 List of Effective Pages Edition 2, Revision 5

1-4 Introduction and Structure of Company Exposition Manual Edition 2, Revision 5

Part 2 ORGANIZATIONAL MANAGEMENT ISSUE 2-1 Corporate Commitment by the Accountable Manager Edition 2, Revision 5 2-2 Safety and Quality Policy Edition 2, Revision 0

2-3 Organizational Structure Edition 2, Revision 5 2-4 PIA Engineering Nominated Personnel Edition 2, Revision 2

2-5 Duties and Responsibilities of the Nominated Personnel Edition 2, Revision 5

2-6 Details of Human Resource Management Edition 2, Revision 2

2-7 Notification of Organizational Changes to the CAA (Pak) Edition 2, Revision 0

2-8 Amendments Control of Company Exposition Manual (CEM) Edition 2, Revision 2

2-9 Engineering Procedures Manual (Divisional) Edition 2, Revision 3

2-10 Safety Management System for Approved Maintenance Organisation Edition 2, Revision 3

2-11 Authorities delegated by Director Airworthiness Edition 2, Revision 3

Part 3 FACILITIES AND WORKSCOPE ISSUE 3-1 Maintenance Base Facilities Approved by the CAA (Pak) Edition 2, Revision 0 3-2 Line Stations Facilities Approved by the CAA (Pak) Edition 2, Revision 0

3-3 Approved Workscope of PIA Engineering & Maintenance Edition 2, Revision 5

3-4 PIA Aircraft Fleet Maintenance Checks and Intervals Edition 2, Revision 5

3-5 Working Conditions of PIA Engineering & Maintenance Facilities MOE 2.7

Part 4 QUALITY ASSURANCE PROCEDURES ISSUE 4-1 Aircraft Certificates Control Procedure Edition 2, Revision 0

4-2 Concessions Assessment and Control Procedure Edition 2, Revision 0

4-3 Quality Audits in PIA Engineering & Maintenance MOE 3.1 & 3.2

4-4 Quality Audits Follow-up and Records Procedure MOE 3.3

4-5 Quality Audit Authorisations Control Procedure MOE 3.6

4-6 Certifying Staff Trainings and Qualifications Procedures MOE 3.4

4-7 Inspectors / Maintenance Staff Trainings and Qualifications Procedures MOE 3.7 & 3.8

4-8 Specialized Trainings and Authorisations Procedure MOE 3.11

4-9 Competence Assessment Procedure MOE 3.14

4-10 Certifying Staff Authorisation Records Procedure MOE 3.5

4-11 Human Factors Training Procedure MOE 3.13 4-12 Concession Control for Deviation from Organisational Procedures MOE 3.10

4-13 Supplier Evaluation and Subcontract Control Procedure Edition 2, Revision 5

Part 5 AIRWORTHINESS MANAGEMENT PROCEDURES ISSUE 5-1 Returns to the CAA (Pak) on PIA Engineering & Maintenance Activities Edition 2, Revision 0

5-2 Reliability Monitoring Programme for Aircraft / Aircraft Components Edition 2, Revision 0

5-3 Accident / Incident Reporting and Investigation Procedure Edition 2, Revision 0

5-4 Procedure for Surveillance of Fuel Storage Facilities Edition 2, Revision 0



Part 5 AIRWORTHINESS MANAGEMENT PROCEDURES ISSUE 5-5 Procedure to Detect and Rectify Maintenance Errors MOE 2.25

5-6 Calibration Control for Tooling / Test Equipment MOE 2.5

5-7 Maintenance Data Control Procedure MOE 2.8

5-8 Aircraft Maintenance Program Control Procedure MOE 2.10

5-9 Airworthiness Directives Control Procedure MOE 2.11

5-10 Optional Modifications Evaluation and Accomplishment Procedure MOE 2.12

5-11 Special Repairs Procedure for Aircraft / Aircraft Components MOE 2.9

5-12 Critical Tasks and Duplicate Inspections Control Procedure MOE 2.23

5-13 Maintenance Data Inaccuracies / Ambiguities Reporting Procedure MOE 2.27

5-14 Maintenance Records Control Procedure MOE 2.14

5-15 Computerized Records Management Procedure MOE 2.21

5-16 Control of Forms in PIA Engineering & Maintenance MOE 5.1

Part 6 MAINTENANCE PROCEDURES ISSUE 6-1 Aircraft Stores Incoming Inspection and Acceptance Procedure MOE 2.2

6-2 Aircraft Stores Tagging, Storage and Issuance Procedure MOE 2.3

6-3 Tooling / Test Equipment Procurement and Acceptance Procedure MOE 2.4

6-4 Tooling / Test Equipment Handling Procedure MOE 2.6

6-5 Scheduled Maintenance Man-Hour Control Procedure MOE 2.22

6-6 Aircraft / Aircraft Components Maintenance Planning Procedure MOE 2.28

6-7 Maintenance Documentation Usage and Records Completion Procedure MOE 2.13

6-8 Aircraft Components Handling Procedure MOE 2.19

6-9 Aircraft Components Repair Abroad Procedure MOE 2.20

6-10 Shift / Task Handover Procedure MOE 2.26

6-11 Aircraft / Aircraft Components Release to Service Procedure MOE 2.16

6-12 Defects Rectification During Base Maintenance MOE 2.15

6-13 Manufacturers and Maintenance Working Teams Control Procedure MOE 3.12

6-14 Aircraft Related Specific Maintenance Control Procedures MOE 2.24

6-15 Aircraft / Aircraft Components Painting Procedure Edition 2, Revision 0

6-16 Aircraft Weighing and Test Flight Procedure Edition 2, Revision 0

Part 7 ADDITIONAL LINE MAINTENANCE PROCEDURES ISSUE 7-1 Aircraft Components and Tooling Control Procedure MOE L2.1 7-2 Aircraft Servicing / Fuelling / De-Icing Procedure MOE L2.2 7-3 Defects and Repetitive Defects Control Procedure MOE L2.3 7-4 Technical Logbook Completion Procedure MOE L2.4 7-5 Pooled Parts and Loan Parts Control Procedure MOE L2.5

7-6 Return Procedure for Defective Components, Removed from Aircraft at Line Station MOE L2.6

7-7 Critical Tasks Control Procedure at Line Station MOE L2.7 7-8 Onboard Medical Supplies Control Procedure Edition 2, Revision 0

Part 8 APPENDICES ISSUE

8-1 Appendices Edition 2, Revision 5



1-2 RECORD OF REVISIONS

Manual holders shall update their copies upon receipt of revisions. Revised pages shall be inserted in the manual and record revision table given below shall be completed. Removed pages must be discarded immediately to avoid any confusion. Upon completion of this Record of Revisions, acknowledgement shall be sent through a signed copy of ‘Manual Status Letter’.

Insertion Insertion Revision

No. Issue Date Date By Revision

No. Issue Date Date By 00 Nov’ 07 28-11-07 EQA 01 Mar’ 08 20-03-08 EQA 02 June’ 08 25-06-08 EQA 03 Sept’ 09 19-04-10 EQA 04 May’ 10 Merged with Rev 5 05 March’ 11 27-05-11 EQA






1-3 LIST OF EFFECTIVE PAGES

PART – 1: PREAMBLE Chapter Page No. Edition Revision Issue Date

CEM TITLE 1 of 2 2 5 March 2011 2 of 2 2 5 March 2011

1-0 1 of 2 2 0 November 2007 2 of 2 2 0 November 2007

1-1 1 of 2 2 5 March 2011 2 of 2 2 5 March 2011

1-2 1 of 2 2 5 March 2011 2 of 2 2 5 March 2011

1-3 1 of 4 2 5 March 2011 2 of 4 2 5 March 2011 3 of 4 2 5 March 2011

4 of 4 2 5 March 2011

1-4 1 of 4 2 5 March 2011 2 of 4 2 5 March 2011 3 of 4 2 5 March 2011 4 of 4 2 5 March 2011

PART – 2: ORGANIZATIONAL MANAGEMENT

CHAPTER Page No. Edition Revision Issue Date CEM 2-0 1 of 2 2 0 November 2007

2 of 2 2 0 November 2007

2-1 1 of 2 2 5 March 2011 2 of 2 2 5 March 2011



2-4 1 of 2 2 2 June 2008 2 of 2 2 2 June 2008

2-5 1 of 18 2 5 March 2011 2 of 18 2 5 March 2011

3 of 18 2 5 March 2011 4 of 18 2 5 March 2011 5 of 18 2 5 March 2011 6 of 18 2 5 March 2011

7 of 18 2 5 March 2011 8 of 18 2 5 March 2011 9 of 18 2 5 March 2011 10 of 18 2 5 March 2011 11 of 18 2 5 March 2011 12 of 18 2 5 March 2011 13 of 18 2 5 March 2011 14 of 18 2 5 March 2011 15 of 18 2 5 March 2011 16 of 18 2 5 March 2011 17 of 18 2 5 March 2011 18 of 18 2 5 March 2011



CHAPTER Page No. Edition Revision Issue Date

2-6 1 of 2 2 2 June 2008 2 of 2 2 2 June 2008


2-8 1 of 2 2 2 June 2008 2 of 2 2 2 June 2008

2-9 1 of 2 2 3 September 2009 2 of 2 2 3 September 2009



PART – 3: FACILITIES AND WORKSCOPE CHAPTER Page No. Edition Revision Issue Date CEM 3-0 1 of 2 2 0 November 2007


3-1 1 of 14 2 0 November 2007 2 of 14 2 0 November 2007 3 of 14 2 0 November 2007 4 of 14 2 0 November 2007 5 of 14 2 0 November 2007

6 of 14 2 0 November 2007 7 of 14 2 0 November 2007 8 of 14 2 0 November 2007 9 of 14 2 0 November 2007 10 of 14 2 0 November 2007 11 of 14 2 0 November 2007 12 of 14 2 0 November 2007 13 of 14 2 0 November 2007 14 of 14 2 0 November 2007



3-4 1 of 2 2 5 March 2011 2 of 2 2 5 March 2011

PART – 4: QUALITY ASSURANCE PROCEDURES CHAPTER Page No. Edition Revision Issue Date CEM 4-0 1 of 2 2 0 November 2007






4-13 1 of 6 2 5 March 2011

2 of 6 2 5 March 2011 3 of 6 2 5 March 2011 4 of 6 2 5 March 2011 5 of 6 2 5 March 2011 6 of 6 2 5 March 2011

PART – 5: AIRWORTHINESS MANAGEMENT PROCEDURES







PART – 6: MAINTENANCE PROCEDURES





PART – 7: ADDITIONAL LINE MAINTENANCE PROCEDURES




PART – 8: APPENDICES



8-1 1 of 8 2 5 March 2011 2 of 8 2 5 March 2011 3 of 8 2 5 March 2011 4 of 8 2 5 March 2011 5 of 8 2 5 March 2011 6 of 8 2 5 March 2011 7 of 8 2 5 March 2011 8 of 8 2 5 March 2011






1-4 INTRODUCTION AND STRUCTURE OF COMPANY EXPOSITION MANUAL

1-4.1 INTRODUCTION Company Exposition Manual is developed on the recommendations of the Competent Authority. This Exposition includes procedures, means and methods with reference to quality assurance, airworthiness management and aircraft / aircraft components maintenance, transposing applicable PCAA regulations, laid down in the Air Navigation Order (ANO) No. 92.0001, Issue 4.

1-4.2 PURPOSE Purpose of Company Exposition Manual (CEM) is to present the Competent Authority, clear picture of maintenance facilities and organizational policies / procedures, followed by all personnel, while performing maintenance on aircraft / aircraft components. Compliance with these organizational procedures shall finally demonstrate fulfilment of the applicable PCAA regulations.

1-4.3 STRUCTURE Company Exposition Manual has been structured, for ease of use, as follows:

Part 1 Preamble Part 2 Organizational Management Part 3 Facilities and Workscope Part 4 Quality Assurance Procedures Part 5 Airworthiness Management Procedures Part 6 Maintenance Procedures Part 7 Additional Line Maintenance procedures Part 8 Appendices

1-4.4 CROSS REFERENCE TABLE

Cross reference table presented below shows relationship of requirements laid down in the ANO 92.0001 with company Exposition Manual chapters:

Clause ANO 92.0001 Subject CEM Chapter MOE Reference9.1 a Chief Executive Statement 2-1 ------

b List of nominated personnel 2-4 ------

c Duties & Responsibilities of the nominated Seniorpersonnel 2-5 ------

d Organization charts 2-3 ------ e Scope of facilities 3-1, 3-2 ------ f Quality Control Part 4 Part 3 g Training programs 4-6, 4-7, 4-8 3.4,3.7,3.8,3.11

h Other requirement of Airworthiness Directorate (if any) 4-1, 4-2, 5-1, 5-2, 5-4,6-15,6-16, 7-8 N/A

9.2 CEM Review 2-8 ------ 9.3 CEM Amendment and Distribution 2-8 ------ 9.4 Copies of CEM / amendment to Airworthiness Directorate 1-4 ------ 9.5 Compliance with the CAA (Pak) requirements 2-1 ------



ANO 92.0001 (Appendix ‘E’)

Para # Subject CEM Chapter MOE Reference

1.1.2 a Scope of Approval 3-3 ------ b Organizational procedures and quality systems Part 4,5,6,7 Part 2,L2,3 c Engineering Manpower resources 2-6 ------ d Working hours of Engineering staff 6-10 2.26 e Description of Facilities 3-1, 3-2 ------ f Names and Duties of nominated personnel 2-4, 2-5 ------ g Competence assessment of maintenance personnel 4-9 3.14 h Maintenance records 5-14, 5-15, 6-7 2.13,2.14,2.21 i Release to Service 6-11, 6-15 2.16 j Certifying staff and Certification Authorization 4-5, 4-10 3.4, 3.5 k Additional requirement by the Operator 5-4 ----- l Reporting requirement as per AWN # 9 5-3 ----- m Maintenance data receiving and distribution in Organization 5-7 2.8

2.1 a Company name, document title and reference number Title Page ------ b Amendment identification 1-2 ------ c Approval by Chief Executive 2-1 ------ d Distribution list 1-4 ------ e CEM Administration responsibility 2-8 ------ f Table of Contents 1-1 ------

2.2 Purpose of CEM 1-4 ------ 2.3 Premises, Facilities and undertaking 3-1, 3-2 ------ 2.4 Terms of Approval and Company Capability list 3-3 ------ 2.5 Nominated personnel and their Duties & Responsibilities 2-4, 2-5 ------

2.5.1 Organization charts 2-3 ------ 2.5.2 Notification to the CAA (Pak) regarding changes 2-7 ------ 2.6 Facilities and associated equipment 3-1, 3-2 ------

2.7.1 a Quality program, policy and Audit system 4-3, 4-4, 4-5 3.1,3.2,3.3,3.6 b Product design & development control N/A N/A c Modification and repair procedure 5-9, 5-10, 5-11 2.9, 2.11, 2.12 d Concession procedure 4-2 ------ e Evaluation and defect investigation 5-5, 6-1 2.2, 2.25 f Reliability Program 5-2 ------ g Subcontractors control 4-13 2.1 h Manufacture and process control 5-11 2.9 i Control of stock and handling of non-conforming parts 6-2 2.2, 2.3 j Tool, test equipment control 5-6,6-3,6-4 2.3, 2.4, 2.5 k Process control 5-2 ------ l Technical records 5-13 2.15, 2.21 m Technical publications, SB evaluation 5-8, 5-9 2.8,2.11,2.12 n Overhaul, modification and repair of aircraft components 6-7, 6-11 2.13, 2.16 o Test flight procedure 6-16 ------ p Training 4-6, 4-7, 4-8 3.4,3.7,3.8,3.11 q Appendices 8-1 ------



1-4.5 COMPANY EXPOSITION MANUAL DISTRIBUTION

a) External Distribution

Control No. Addressee E01

Director Airworthiness, Airworthiness Directorate, Civil Aviation Authority, Jinnah International Airport, Karachi, Pakistan.

E02

CONTROLLER AIRWORTHINESS (SOUTH), Civil Aviation Authority, Jinnah International Airport, Karachi, Pakistan.

E03 CONTROLLER AIRWORTHINESS (NORTH),

Civil Aviation Authority, Islamabad International Airport, Islamabad, Pakistan.

E04 CONTROLLER AIRWORTHINESS (LAHORE),

Civil Aviation Authority, Allama Iqbal International Airport, Lahore, Pakistan.

b) Internal Distribution

Control No. Addressee P01 Managing Director, PIA P01-1 Deputy Managing Director P02 Director (Engineering & Maintenance) P03 Director (Procurement & Logistics) P04 Chief Engineer (Quality Assurance) P05 Chief Engineer (Airworthiness Management) P06 Chief Engineer (Maintenance Operation Centre) P07 Chief Engineer (Engineering Business Development) P08 Chief Engineer (HR, Training & Automation) P09 Chief Engineer (Line Maintenance) P10 Chief Engineer (Base Maintenance) P11 Chief Engineer (Cabin Maintenance) P12 Chief Engineer (PowerPlant Overhaul) P13 Chief Engineer (Avionics Overhaul) P14 General Manager (Procurement) P15 Deputy Chief Engineer (Quality Audit) P16 Deputy General Manager (Finance) Engineering P17 – P19 Aircraft Engineer (Quality Audit) – 03 Copies P20 Chief Engineer (PIA SSB Flying Academy) P21 General Manager (Logistics) P22 Reserved







PART 2: ORGANIZATIONAL MANAGEMENT






2-1 CORPORATE COMMITMENT BY THE ACCOUNTABLE MANAGER The exposition manual and associated referenced manual defines the organization, procedures and personnel responsibilities in accordance with the requirements laid down by Pakistan Civil Aviation Authority. These procedures are approved by the undersigned and will be complied with all the times. It is further understood that CAA Pakistan under CAR 94 reserves the right to suspend, revoke or limit this organization approval, if the Competent Authority has any evidence that the procedures are not fulfilled or standards are not held. The Organization will ensure that in respect of all work performed under the terms of this Approval, adequate human resources, appropriate facilities and proper equipment are utilized and the approved procedures are adopted. The exposition manual shall be reviewed by the organization on yearly basis. Changes required as result of internal reviews or Airworthiness Directorate surveillance audits shall be forwarded to the Competent Authority for approval. Copies of all amendments shall be furnished promptly to all whom the manual has been issued. All amendments to exposition manual shall be finalized by Chief Engineer (Quality Assurance) with the consent of undersigned prior to submission for approval. An amendment, approved by the Competent Authority shall be incorporated into the exposition manual. Captain Nadeem Khan Yusufzai Managing Director, PIAC For and on behalf of Pakistan International Airlines Corporation






2-2 PIA HEALTH, SAFETY, ENVIRONMENT & QUALITY POLICY

2-2.1 CORPORATE POLICY STATEMENT PIA Corporate “Health, Safety, Environment & Quality Policy” states as: ‘All PIA employees are committed to providing distinctive air transport services and satisfying global needs and expectations of our customers through continual improvement of:

Quality of our services and processes with a view of enhancing customer

satisfaction and loyalty Occupational health and safety of all personnel, aircraft, equipment and

facilities Environmental quality, prevention of pollution, energy and resource

conservation, reduction of waste and adoption of environment friendly practices Whilst complying with all Health, Safety, Environment and Quality system

regulatory and other requirements to which the Airlines subscribes Simply stated our organizational goal is “efficient provisioning of highest service quality, with no harm to people, property or environment”.’

2-2.2 DEPARTMENTAL POLICY STATEMENT

PIA Engineering & Maintenance “Safety and Quality Policy” states as: ‘Airworthiness and Quality Maintenance of aircraft and aircraft components is our highest priority. We are committed to continuously improve the quality of all our products and services to our customers’ satisfaction. This includes safety, reliability, performance and customer values.

Recognizing safety as a prime consideration at all times, we will ensure good maintenance practices through the application of human factor principles, and encouraging personnel to report maintenance related errors / incidents. Compliance with procedures, regulations, quality and safety standards, and cooperation with quality auditors is the responsibility of all personnel of PIA Engineering & Maintenance.’






2-3 ORGANIZATIONAL STRUCTURE

2-3.1 PIA CORPORATE STRUCTURE

2-3.2 PIA ENGINEERING & MAINTENANCE

DEPUTY MANAGING DIRECTOR

DIRECTORENGINEERING & MAINTENANCE

Chief EngineerLine Maintenance

Chief EngineerBase Maintenance

Chief EngineerHR, Training & Automation

Chief EngineerEngine O/H

Chief EngineerAerospace O/H

Chief EngineerMaint. Operation Centre

Chief EngineerAirworthiness Management

Chief EngineerEngg. Business Development

DIRECTORPROCUREMENT & LOGISTICS

General ManagerProcurement

Chief EngineerAvionics O/H

Chief EngineerSSB Flying Academy

General ManagerLogistics

CE SSB Flying Academy



2-3.3 ENGINEERING QUALITY ASSURANCE 2-3.4 AIRWORTHINESS MANAGEMENT DIVISION 2-3.5 MAINTENANCE OPERATION CENTRE

2-3.6 ENGINEERING BUSINESS DEVELOPMENT

Deputy Chief EngineerRepair Abroad

Deputy Chief EngineerRotable Planning

Deputy Chief EngineerMaterial Management

Deputy Chief EngineerScd. & Check Planning

CHIEF ENGINEERMAINTENANCE OPERATION CENTRE

Deputy Chief EngineerQuality Audit

Deputy Chief EngineerMaintenance QA

Deputy Chief EngineerExaminations

In-charge QAStandards

In-charge QAAirworthiness

In-charge QAAudit Planning

Deputy Chief EngineerHuman Factors

CHIEF ENGINEERQUALITY ASSURANCE

In-charge QABase / OH Shops

In-charge QARamp / Cabin

Technical Assistant to Chief Engineer (QA)

Deputy Chief Engineer(QA) North - Islamabad

Deputy Chief Engineer(QA) North - Lahore

Deputy Chief Engineer(M aintenance Program

& Reliability )

Deputy Chief Engineer (Aerospace)

TSE Line M aintenance

Deputy Chief EngineerTSE (Aerospace) O /H

CHIEF ENGINEERAIRW ORTHINESS M ANAGEM ENT

Deputy General M anager(Facility )

Deputy Chief EngineerTSE (PPO H)

Deputy Chief Engineer(Avionics) Engineering

Deputy Chief Engineer(A irfram e) Engineering

Deputy Chief Engineer TSE Base M aintenance

Deputy Chief Engineer (Avionics)

TSE Line M aintenance

Deputy Chief Engineer TSE (Avionics) O /H

Deputy Chief Engineer(Technical Publications

& Records)

InchargeM odification Planning

Deputy Chief EngineerProjects & Marketing

Deputy Chief Engineer(Sales) A/C Maintennace

Deputy Chief Engineer(Sales) Comp Maintenance

CHIEF ENGINEERENGINEERING BUSINESS DEVELOPMENT



Deputy Chief EngineerTest & QEC Buildup

Deputy Chief EngineerGE90 / CF6 / CFM

Deputy Chief EngineerPW / RB / APU / LG

CHIEF ENGINEERENGINE OVERHAUL

Deputy Chief Engineer(Planning) PowerPlant O/H

2-3.7 LINE MAINTENANCE DIVISION 2-3.8 BASE MAINTENANCE DIVISION 2-3.9 ENGINE OVERHAUL DIVISION 2-3.10 AEROSPACE OVERHAUL DIVISION

Deputy Chief EngineerShift - A

Deputy Chief EngineerJinnah Terminal

Deputy Chief EngineerB777 (AS)

Deputy Chief EngineerB777 (AV)

CHIEF ENGINEERLINE MAINTENANCE

Shift In-chargeA

Shift In-chargeB

Deputy Chief Engineer Line Stations

Shift In-chargeC

Shift In-chargeD

Deputy Chief EngineerB747 / 737 (AS)

Deputy Chief EngineerB747 / 737 (AV)

Deputy Chief EngineerA310 / ATR (AS)

Deputy Chief EngineerA310 / ATR (AV)

Deputy Chief EngineerShift - B

Deputy Chief EngineerShift - C

Deputy Chief EngineerShift - D

Deputy Chief EngineerNorth – Islamabad (AS)

Deputy Chief EngineerNorth – Islamabad (AV)

Deputy Chief Engineer Lahore

Deputy Chief EngineerPlanning

Deputy Chief EngineerIFE – Line Maintenance

Deputy Chief EngineerAircraft Appearance

Deputy Chief EngineerBay – I (AS)

Deputy Chief EngineerBay – II (AS)

Deputy Chief EngineerBay – I & III (AV)

CHIEF ENGINEERBASE MAINTENANCE

Deputy Chief EngineerPlanning & Development

Deputy Chief EngineerAircraft Overhaul (AS)

Deputy Chief EngineerBay – II & ACOH (AV)

Deputy Chief EngineerBay – III (AS)

Deputy Chief EngineerStructure Repair & Mod

Deputy General ManagerHangar Equipment

Maintenance

Deputy Chief EngineerIFE – Base Maintenance

Deputy Chief EngineerAircraft Furnishing

C H I E F E N G I N E E RA E R O S P A C E O V E R H A U L

D e p u t y C h i e f E n g i n e e r( P l a n n i n g ) A e r s p a c e O / H

D e p u t y C h i e f E n g i n e e r R e p a i r & M o d i f i c a t i o n

D e p u t y C h i e f E n g i n e e r F u e l & M i s c e l l a n e o u s

D e p u t y C h i e f E n g i n e e rH y d r a u l i c & W h e e l / B r a k e

D e p u t y C h i e f E n g i n e e rP n e u m a t i c O / H

D e p u t y G e n e r a l M a n a g e rW o r k s h o p E q u i p m e n t

M a i n t e n a n c e



2-3.11 AVIONICS OVERHAUL DIVISION 2-3.12 HR TRAINING DIVISION

2-3.13 SSB FLYING ACADEMY DIVISION

2-3.14 PROCUREMENT & LOGISTICS DEPARTMENT

Deputy Chief Engineer

Instrument O/H


Electric O/H


Radio O/H

CHIEF ENGINEERAVIONICS OVERHAUL


(Planning) Avionics O/H

DRECTORPROCUREMENT & LOGISTICS

Deputy General ManagerPurchases

General ManagerLogistics

Deputy General ManagerStores

General ManagerProcurement

Deputy Chief EngineerHR Training

CHIEF ENGINEERHR TRAINING

Deputy Chief EngineerSSB Flying Academy

CHIEF ENGINEERSSB FLYING ACADEMY


CEM Chapter 2-4 Edition: 02 Revision: 02 Issue: June’ 08 Page 1 of 2

2-4 PIA ENGINEERING NOMINATED PERSONNEL

2-4.1 GENERAL Purpose of this chapter is to provide organizational designations and nominated personnel involved in management of maintenance activities on aircraft / aircraft components in PIA Engineering Department.

2-4.2 NOMINATED PERSONNEL Managing Director, PIA is the Accountable Manager of PIA Engineering & Maintenance having overall responsibility for running the Organisation. Accountable Manager has basic understanding of the CAA (Pak) regulations and responsibilities that fall upon him, under the CAA (Pak) Approval. Director (Engineering & Maintenance) is Deputy to the Accountable Manager for the CAA (Pak) Approval. Managing Director, PIA designates Chief Engineer (Quality Assurance) with the responsibility of effective quality assurance and associated feedback reporting system. Director (Engineering & Maintenance), alongwith Chief Engineers / General Manager (Procurement & Logistics) shall ensure that the Organisation is in compliance with the CAA (Pak) regulations. Nominated personnel are competent to demonstrate relevant knowledge and adequate extent of experience related to aircraft / aircraft component maintenance and managerial activities.

2-4.3 NOMINATED PERSONNEL APPROVAL BY THE CAA (PAK) Chief Engineer (Quality Assurance) shall submit, under confidential cover, credentials of all nominated personnel to the Competent Authority for prior Approval. Such approval by the CAA (Pak), in original, shall be archived by Technical assistant to Chief Engineer (Quality Assurance). For any ‘Executive Appointments’ and officiating arrangements in the Organization, the CAA (Pak) letter HQCAA/2229/AW (VOL-III) dated March 4, 1993 shall be complied as under: i. The post of Deputy Chief Engineer is excluded from the ambit of ‘Executive

Appointments’. ii. All appointments of ‘Chief Engineer’ and Director (Engineering & Maintenance)

shall require prior approval of the Competent Authority with the provision that incumbent meets the prescribed qualification criteria.

iii. All officiating arrangements, exceeding one month, to the post of Chief Engineers and Director (Engineering & Maintenance) shall also require prior Approval of the CAA (Pak). For lesser periods, only intimations shall be given to the local Airworthiness office and Headquarters of the CAA (Pak).

iv. All personnel deployed for officiating arrangements must meet promotion criteria for that post.






2-5 DUTIES AND RESPONSIBILITIES OF THE NOMINATE PERSONNEL Purpose of this Chapter is to detail duties and responsibilities of the following nominated personnel, for accomplishment of all maintenance activities while ensuring that PIA Engineering & Maintenance Organisation shall remain in compliance with the PCAA regulations: 2-5.1 Managing Director, PIA 2-5.2 Deputy Managing Director 2-5.3 Director (Engineering & Maintenance) 2-5.4 Director (Procurement & Logistics) 2-5.5 Chief Engineer (Quality Assurance) 2-5.6 Chief Engineer (Airworthiness Management) 2-5.7 Chief Engineer (Maintenance Operation Centre) 2-5.8 Chief Engineer (Engineering Business Development) 2-5.9 Chief Engineer (HR Training) 2-5.10 Chief Engineer (Line Maintenance) 2-5.11 Chief Engineer (Base Maintenance) 2-5.12 Chief Engineer (Engine Overhaul) 2-5.13 Chief Engineer (Aerospace Overhaul) 2-5.14 Chief Engineer (Avionics Overhaul) 2-5.15 Chief Engineer (SSB Flying Academy) 2-5.16 General Manager (Procurement) 2-5.17 General Manager (Logistics)



2-5.1 MANAGING DIRECTOR, PIA Managing Director, PIA shall be the Accountable Manager for PIA Engineering & Maintenance regarding maintenance activities under the PCAA Organisation Approval. The Accountable Manager shall be responsible to: i. Establish PIA Engineering & Maintenance, endorse Corporate Commitment as per

CEM Chapter 2-1 and define Safety and Quality Policy for the Organisation. ii. Designate Deputy Managing Director to assist the Accountable Manager on issues

related to the PCAA Organisation Approval. iii. Implement an independent quality assurance system and appoint Chief Engineer

(Quality Assurance) for effective surveillance of organisational activities to highest standards of airworthiness and quality.

iv. Appoint / promote / transfer Directors, Chief Engineers, General Managers, Deputy Chief Engineers and Aircraft Engineers on operational / maintenance requirements.

v. Ensure that required manpower resources, facilities, tooling, test equipment and spares are available to perform maintenance and additional task that may be undertaken. Approve plans and finances for maintenance capability enhancement in the Organisation.

vi. Administrate Management Reviews with Deputy Managing Director, Director (Engineering & Maintenance), Director (Procurement & Logistics) and Chief Engineer (Quality Assurance) to check progress on corrective actions and overall organisational performance, in terms of quality.

vii. Ensure that all payments related to the PCAA Organisation Approval, prescribed by the Competent Authority, are paid within agreed frame of time.

viii. Assure free access of the Competent Authority personnel to PIA Engineering & Maintenance facilities, whenever called for in respect to the PCAA Organisation Approval.

ix. Validate the applications, for purpose of notification regarding any change in the organisational setup, before submission to the Competent Authority.

x. Operate within specific Statutory / Regulatory / Corporate directives for all PCAA Organisation Approval related activities and conform strictly to safety and operational requirements.



2-5.2 DEPUTY MANAGING DIRECTOR Deputy Managing Director shall assist the Accountable Manager for PIA Engineering & Maintenance regarding maintenance activities on PIA fleet under PCAA Organisation Approval. Acting as deputy to the Accountable Manager, Deputy Managing Director shall be responsible to: i. Accomplish the Safety and Quality Policy of PIA Engineering & Maintenance,

established by the Accountable Manager, throughout the Organisation. ii. Establish a Quality System for the Organisation to ensure that all activities are

accomplished to the highest standards of airworthiness and workmanship. iii. Recommend appointments / promotions / transfer of Directors, Chief Engineers,

General Managers, Deputy Chief Engineers and Aircraft Engineers. iv. Assist the Accountable Manager on issues related to the PCAA Organisation

Approval and to deputize during absence of the Accountable Manager. v. Attend management reviews, in the capacity of Deputy to Accountable Manager, to

check the progress of corrective actions. vi. Appraise and provide required manpower resources, facilities, tooling, test

equipment and spares to perform all scheduled and unscheduled maintenance tasks. Review and recommend to the Accountable Manager all plans and finances for maintenance capability enhancement in the Organisation.

vii. Recommend all payments related to the PCAA Organisation Approval, prescribed by the Competent Authority and apprise Accountable Manager for disbursement of such payments within agreed frame of time.

viii. Provide free access for the Competent Authority personnel to PIA Engineering & Maintenance facilities, whenever called for in respect to the PCAA Organisation Approval.

ix. Recommend any change in the organisational setup to the accountable Manager, for purpose of notification before submission to the Competent Authority.

x. Operate within specific Statutory / Regulatory / Corporate directives for all PCAA Organisation Approval related activities and conform strictly to safety and operational requirements.



2-5.3 DIRECTOR (ENGINEERING & MAINTENANCE) Director (Engineering & Maintenance) shall assist the Accountable Manager on issues related to the PCAA Organisation Approval of PIA Engineering & Maintenance. While, reporting to the Deputy to Accountable Manager, Director (Engineering & Maintenance) shall be responsible to: i. Manage organisational activities, fulfilling corporate commitment by Accountable

Manager and implementing Safety and Quality Policy in the Organisation, complying with the PCAA regulations.

ii. Recommend appointment / promotion / transfer of Chief Engineers, Deputy Chief Engineers and Aircraft Engineers to Deputy Managing Director. However, transfer of Deputy Chief Engineers / Aircraft Engineers, within department, shall be approved by Director (Engineering & Maintenance).

iii. Review requirements related to human resource, facilities, equipment, spares and maintenance capability enhancement. Such requirements must be brought into the Knowledge of Deputy Managing Director without any delay.

iv. Collaborate with Chief Engineer (Quality Assurance) for implementation of an effective quality assurance system in the Organisation to ensure that all activities are accomplished to the highest standards of airworthiness.

v. Participate in Management Reviews to present progress on corrective / preventive actions and overall organisational performance, in terms of quality. Ensure corrective actions implementation in timely manner against any finding, observed by personnel from the Competent Authority / Engineering Quality Assurance during quality audits / ramp inspections / spot checks.

vi. Ensure that required facilities, tooling, test equipment and spares are procured, maintained and utilised as per the PCAA regulations.

vii. Ensure that all required maintenance on PIA fleet shall be performed and certified in accordance as per standard required by PCAA regulations and organisational procedures. Records of maintenance performed shall be archived, in a safe / secure location, for the permissible period.

viii. Establish system for review of all applicable technical standards, in order to maintain airworthiness of aircraft / aircraft components and associated systems.

ix. Initiate approval for fee and charges related to the PCAA regulations Approval beforehand, ensuring the payments are made within the agreed frame of time.

x. Make arrangements for free access of personnel from the Competent Authority to PIA Engineering & Maintenance facilities, whenever called for in respect to the PCAA Organisation Approval.

xi. Represent PIA Engineering & Maintenance in an authorised position for all correspondences with the Competent Authority and other organisations.

xii. Propose plans for organisational capability enhancement in PIA Engineering & Maintenance and supervise timely accomplishment of all such approved plans.



2-5.4 DIRECTOR (PROCUREMENT & LOGISTICS) Director (Procurement & Logistics) shall be overall administrator for logistic support at corporate level. Procurement , storage, handling and distribution of aircraft stores shall be controlled by the same position. While, reporting to Deputy to the Accountable Manager, Director (Procurement & Logistics) shall be responsible to: i. Manage departmental activities, fulfilling corporate commitment by Accountable

Manager, implementing Safety and Quality Policy and complying with regulations laid down by the PCAA.

ii. Review requirements related to human resource, facilities and trainings for an effective and efficient procurement & logistics system. Such requirements shall be presented to Deputy Managing Director for perusal.

iii. Collaborate with Chief Engineer (Quality Assurance) for implementation of an effective quality assurance system in Procurement & Logistic division to ensure that all activities are accomplished to the highest standards of safety and quality.

iv. Ensure proper procurement procedures are developed and implemented as per corporate policies in respect of supply, procurement, storage and accounting of stores and are regularly reviewed.

v. Supervise supply management for aircraft spares, tooling / test equipment and materials from approved suppliers / subcontractors in accordance with Approved Vendor List (AVL).

vi. Supervise inventory management processes and arrangements for disposal of surplus / scrapped inventory as per organisational procedures.

vii. Participate in Management Reviews to present progress on corrective / preventive actions and departmental performance, in terms of quality. Ensure corrective actions implementation in timely manner against any finding, observed by the Competent Authority / Quality Assurance during quality audits.

viii. Ensure free access of the Competent Authority personnel to Procurement & Logistics division, in relation to the aircraft / aircraft maintenance, whenever called for in respect to the PCAA.

ix. Operate within specific Statutory / Regulatory / Corporate directives for PCAA Organisation Approval related activities and conform strictly to safety and operational requirements.

x. Represent the department in an authorised position for all correspondences with the Authorities and other organisations.



2-5.5 CHIEF ENGINEER (QUALITY ASSURANCE) Chief Engineer (Quality Assurance) is designated by the Accountable Manager for surveillance of all activities ensuring that Organisation remains in compliance with the regulations laid down by the PCAA. Chief Engineer (Quality Assurance) is authorised to manage Company Approvals (qualifications) system for the Organisation, under the delegated powers by the PCAA Airworthiness Directorate. Main responsibilities are to: i. Implement independent quality assurance system for surveillance of all

organisational activities as per the PCAA regulations, through an annual plan for procedure and product audits.

ii. Administrate processes of scheduled / unscheduled audits, spot checks and ramp inspections. Conduct audits, request corrective actions against findings and generate audit reports to communicate quality related matters to the Accountable Manager, Deputy Managing Director and Director (Engineering & Maintenance).

iii. Participate in Management Reviews to present progress on the remedial actions against significant findings, maintaining effective feedback system on quality and implementation of remedial actions by respective divisions.

iv. Develop ‘Company Exposition Manual’, control its subsequent amendments and submit amendments to the Competent Authority for Approval.

v. Manage effective technical qualifications system for AME Licences / Company Approvals applications processing in close liaison with the PCAA and conduct examinations for various categories of Company Approvals.

vi. Issue Certification Authorisations to maintenance personnel, fulfilling requirements as per laid down organisational procedures and control such authorisations in the Organisation. Manage Certification Authorisations records and maintain List of Certifying Staff for PIA Engineering & Maintenance.

vii. Evaluate and approve plans, contents, pre-qualification rules and durations for any initial and continuation training with regular review of organisational procedures effectiveness.

viii. Evaluate and approve suppliers / subcontractors for inclusion in Approved Vendors List (AVL), administer suppliers / subcontractors follow up and monitor the quality of subcontracted tasks.

ix. Appraise and present the Company Capability List (CCL) of PIA Engineering & Maintenance and its revisions to the Competent Authority whenever called for.

x. Report an un-airworthy condition to the Competent Authority and request for concession in justified cases, if deemed necessary.

xi. Ensure free access of the Competent Authority personnel to PIA facilities, in relation to the aircraft / aircraft component maintenance, whenever called for in respect to the PCAA Organisation Approval.

xii. Devote maximum time to activities for continual improvement, in respect of quality assurance concept. Supervise personnel assigned with duties in the division.

xiii. Represent PIA Engineering & Maintenance in his authorised position for all correspondences with the Authorities and other organisations.



2-5.6 CHIEF ENGINEER (AIRWORTHINESS MANAGEMENT) Chief Engineer (Airworthiness Management) shall be Incharge for development of all aircraft / aircraft component maintenance specifications, modifications control and reliability engineering activities. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy

and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of

organisational procedures, know their obligation to such procedures and check the skill of personnel.

iii. Provide required engineering support for maintenance and inspection activities. Evaluate Airworthiness Directives / mandatory modifications, Service Bulletins, unscheduled tasks and Engineering Change Orders (ECOs) related to aircraft / aircraft components, providing complete work instructions and procedures.

iv. Supervise development of maintenance specifications for maintenance tasks according to Work Order. Checking that required maintenance is carried out as per contract with customer, certified in compliance with current applicable regulations / procedures and deferred tasks have been justified.

v. Ensure that controlled maintenance data for aircraft / aircraft components shall be available, throughout the Organisation, to maintenance personnel. Administer technical libraries, update definitions and acquire all required documentation from the Authorities, manufacturers and approved sources.

vi. Review requirement of tooling / equipment / material required against scheduled maintenance / maintenance data and advise concerned division. Moreover, manage approvals for alternates against justified requirements generated by production areas.

vii. Develop maintenance specifications for aircraft / aircraft components, maintained by the Organisation, according to Work Order and obtain necessary approval from the Competent Authority for any proposed change.

viii. Ensure maintenance records completion, management of records archiving and issuance of such record to customer in accordance with the contract.

ix. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training).

x. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.

xi. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.

xii. Report without any delay, to Chief Engineer (Quality Assurance), Accountable Manager and Competent Authority in case of an unairworthy condition. Conduct investigations of all technical delays / incidents / accidents and monitor repeated defects under intimation to the Competent Authority.

xiii. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Airworthiness Management division.

xiv. Represent PIA Engineering & Maintenance in his authorised position for all the correspondences with other organisations.



2-5.7 CHIEF ENGINEER (MAINTENANCE OPERATION CENTRE) Chief Engineer (Maintenance Operation Centre) shall act as coordinator for all divisions to ensure effectiveness of major production planning activities in the Organisation. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Manage Company Capability List (CCL) and shop allocations for all components being maintained by PIA Engineering & Maintenance. Each revised list must be submitted to Chief Engineer (Quality Assurance) for appraisal and onward submission to the Competent Authority for Approval.

iv. Manage provisioning of rotables, repairables, spares and materials as per the requirements for maintenance, forwarding demands to Procurement & Logistics division.

v. Maintain database of applicable tooling / test equipment required by maintenance divisions according to the scope of work.

vi. Manage annual hangar visits plan for all checks on aircraft including customer aircraft ensuring compliance of safety and airworthiness requirements within required frame of time. Conduct pre-dock meetings for review prior to the aircraft base check. Revise all such plans and groundings, if required and issue revisions accordingly.

vii. Coordinate with divisional heads, for cost analysis, to finalise proposal on the annual budget. Submit such proposed budget for the approval of Accountable Manager.

viii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.

ix. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.

x. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager.

xi. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Maintenance Operation Centre.



2-5.8 CHIEF ENGINEER (ENGINEERING BUSINESS DEVELOPMENT) Chief Engineer (Engineering Business Development) shall coordinate with all relevant divisions of PIA Engineering & Maintenance for maintenance activities on Customers’ aircraft / aircraft components. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Develop and implement marketing / sales plans for the Organisation in an effective manner to achieve defined objectives and target revenues. Promote engineering & maintenance services and conduct surveys to explore market related to quality engineering & maintenance services.

iv. Develop feedback system to achieve customers’ satisfaction, regarding aircraft / aircraft components maintenance activities and suggest improvement in services to the Accountable Manager.

v. Administer all maintenance contracts with customer organisations in most effective manner. Manage overall control on customers’ work orders for aircraft / aircraft component maintenance.

vi. Participate in administration of organisational capability enhancement projects to attain status of self-sufficient organisation for maintenance on aircraft / aircraft components as per the PCAA Organisation Approval.

vii. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training).

viii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.

ix. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.

x. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager.

xi. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Engineering Business Development division.

xii. Represent PIA Engineering & Maintenance in his authorised position for all correspondences with the customer organisations and other related agencies.



2-5.9 CHIEF ENGINEER (HR TRAINING) Chief Engineer (HR Training) shall coordinate with all divisions of PIA Engineering & Maintenance for manpower resources, trainings and automation services for technical areas. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy


organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard.

iii. Evaluate required manpower resources and skills for intended scope of work in coordination with divisional heads. Prepare selection criteria and obtain approval of the Accountable Manager for such induction.

iv. Prepare master Man-Hour Plan in liaison with Chief Engineers and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours.

v. Ensure appropriate training need analysis for management and other personnel in the Organisation. Establish pre-qualification rules for trainings and annual plans for initial and continuation trainings on annual basis. Review effectiveness of training processes through feedback system.

vi. Establish continuous liaison with Data Processing department for provisioning and regular updating of PIA Aircraft Maintenance Management Information System (PAMMIS) in the Organisation.

vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager.

viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures.

ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of any deviation from organisational procedures and ultimately to Accountable Manager.

x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Human Resource Training.



2-5.10 CHIEF ENGINEER (LINE MAINTENANCE) Chief Engineer (Line Maintenance) shall be Incharge for line maintenance activities including aircraft appearance (cabin cleaning, disinfecting, hygiene control, etc.), defined under the PCAA Organisation Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Develop and implement plans to provide optimum aircraft utilisation effectively ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.

iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training).

v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR Training) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours.

vi. Ensure that all maintenance including defect rectification and aircraft appearance, in Line Maintenance division, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.



ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager.

x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Line Maintenance division.



2-5.11 CHIEF ENGINEER (BASE MAINTENANCE) Chief Engineer (Base Maintenance) shall be the Incharge for heavy maintenance on aircraft including aircraft furnishing (cabin renovation, surface protection, interior upkeep, aircraft painting, etc.) and the aircraft structures, defined in the intended scope of work under the PCAA Organisation Approval. Maintenance of different types of mechanically operated ground support equipment, rigs, docks and trestles as well shall also be administered by the same position. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Provide heavy aircraft maintenance to PIA and / or Customer as per organisational Hangar Visit Plan ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.



vi. Ensure that all maintenance including major checks, overhaul and modifications, in Base Maintenance division, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.




x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Base Maintenance division.



2-5.12 CHIEF ENGINEER (ENGINE OVERHAUL) Chief Engineer (Engine Overhaul) shall be Incharge for component-level maintenance on engines and APUs, defined in intended scope of work, under the PCAA Organisation Approval. Maintenance of all types of mechanical plants and workshop equipment shall be administered by the same position as well. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Develop and implement plans to provide off-wing maintenance on engines and APUs ensuring required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.



vi. Ensure that all components maintenance is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to the Competent Authority.




x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Engine Overhaul division.



2-5.13 CHIEF ENGINEER (AEROSPACE OVERHAUL) Chief Engineer (Aerospace Overhaul) shall be Incharge for the component-level maintenance on landing gears, hydraulic, pneumatic, fuel and auxiliary components, defined in intended scope of work, under the PCAA Organisation Approval. Maintenance of all types of mechanical plants and workshop equipment shall be administered by the same position as well. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Develop and implement plans to provide off-wing maintenance on landing gears, hydraulic, pneumatic, fuel and miscellaneous auxiliary components ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.







x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Aerospace Overhaul division.



2-5.14 CHIEF ENGINEER (AVIONICS OVERHAUL) Chief Engineer (Avionics Overhaul) shall be Incharge for component-level maintenance on instrument, electrical and radio / radar and auxiliary components, defined in intended scope of work, under the PCAA Organisation Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Develop and implement plans to provide maintenance on instrument, electrical, radio / radar and auxiliary components ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.







x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Avionics Overhaul division.



2-5.15 CHIEF ENGINEER (SSB FLYING ACADEMY)

Chief Engineer (SBB Flying Academy) shall be Incharge of the maintenance activities at PIA SBB Flight Academy under the PCAA Organisation Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Develop and implement plans to provide optimum aircraft utilisation effectively ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks.



vi. Ensure that all maintenance including defect rectification, at PIA SSB Flying Academy, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per organisational procedures / standards acceptable to the Competent Authority.




x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to PIA SSB Flying Academy.



2-5.16 GENERAL MANAGER (PROCUREMENT) General Manager (Procurement) shall be Incharge for procurement of all aircraft-related stores required during aircraft / aircraft component maintenance. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Maintain Approved Vendors List (AVL) for components being maintained by PIA Engineering & Maintenance. Each revised list shall be submitted to Chief Engineer (Quality Assurance) for appraisal.

iv. Manage procurement of aircraft rotables, consumables, materials and tooling / test equipment and maintenance services from approved suppliers / contractors in accordance with Approved Vendor List (AVL).

v. Keep close liaison with Chief Engineer (Maintenance Operation Centre) on regular basis for procurement support related to aircraft / aircraft component maintenance, including all AOG / Critical requirements.

vi. Ensure that adequate security of information and transparency is adopted during market research and procurement process in an ethical manner to safeguard interest of the Organisation within the statutory framework.



ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of a deviation from organisational procedures and ultimately to the Accountable Manager.

x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Procurement & Logistics division.



2-5.17 GENERAL MANAGER (LOGISTICS) General Manager (Logistics) shall be Incharge for storage, handling and distribution of aircraft-related supplies to maintenance personnel during aircraft / aircraft component maintenance. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy



iii. Ensure that aircraft rotables, consumables, materials and tooling / test equipment and maintenance services are received from approved suppliers / contractors in accordance with Approved Vendor List (AVL) and Purchase / Repair orders.

iv. Keep close liaison with Chief Engineer (Maintenance Operation Centre) on regular basis for procurement & logistics support related to aircraft / aircraft component maintenance, including all AOG / Critical requirements.

v. Ensure that adequate security measures are adopted to protect all aircraft-related stores against fire and deterioration during storage and at various stages of their handling.

vi. Identify slow moving / surplus / obsolete / dead inventory, provide assistance for perpetual inventory / physical stocktaking and arrange disposal of surplus / scrapped aircraft components / spares as per organisational procedures.



ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of a deviation from organisational procedures and ultimately to the Accountable Manager.

x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Procurement & Logistics division.



2-6 DETAILS OF HUMAN RESOURCE MANAGEMENT

2-6.1 GENERAL PIA Engineering & Maintenance shall ensure that sufficient manpower is available for all maintenance activities. Process of manpower resources, in a sequential manner, shall be based on following: Manpower assessment Recruitment of new personnel (based on manpower assessment) Training needs Analysis

2-6.2 MANPOWER ASSESSMENT

Chief Engineer (concerned) shall initiate manpower assessment process for next calendar year, in the month of October. Each divisional head shall determine required man-hours for the division, to develop Divisional Man-hour plan. Such plan shall be submitted to Deputy Chief Engineer (HR, Training & Automation). Following shall be the basis for assessment of required man-hours: Scheduled work load pattern Hangar visit plan Availability of ground time Estimated man-hour per employee Skills / specialized services required

With inputs from all divisions, Master Man-hour Plan for Organization shall be developed by Deputy Chief Engineer (HR, Training & Automation) and finalized by Chief Engineer (HR, Training & Automation), under Ref. No: E&M/CE(P&P)/MHP. Chief Engineer (HR, Training & Automation) shall assess manpower requirements with existing Human Resource Budget (HRB) of PIA Engineering & Maintenance in order to propose changes, if any. Human Resource Budget (HRB) is maintained by Deputy General Manager (HR) Engineering, under Ref. No: E&M/AM/HRB. Such HRB contains following information: Location Designation, Cadre (Technical / Administrative / Support) Expertise (Specialized Skill / Trade) Sectional Strength and Total Strength (No. of employees at division level)

Upon receipt of required manpower proposal from Chief Engineer (HR, Training & Automation), Deputy General Manager (HR) Engineering shall draft amendments, if required, in existing HRB for next calendar year and submit to the management for approval. Approved HRB for next calendar year shall then be distributed to each Chief Engineer through Deputy General Manager (HR) Engineering.

2-6.3 RECRUITMENT / PROMOTION / REDESIGNATION OF PERSONNEL Recruitment of personnel for the Organization shall be based on approved HRB for each calendar year. Recruitment policy for personnel shall be referred to PIA Personnel Policies Manual. PIA Engineering & Maintenance, in accordance with the policies defined, shall select and appoint maintenance staff on permanent or contractual basis. Contractual maintenance staff shall be personnel, working under supervision by the



qualified and authorised PIA Engineering & Maintenance personnel. Criteria for promotion / re-designation, to the cadre of Deputy Chief Engineer and above, shall be based on technical qualifications and experience, in accordance with regulations laid down by the CAA (Pak). Job Description Manual of PIA Engineering department clearly defines educational / technical qualifications and related work experience requirements for each senior position.

2-6.4 TRAINING NEEDS ANALYSIS Training requirements shall be analysed for personnel, at all levels, in the Organization. Training plan shall be developed for Initial (Basic / Type) and Continuation / Re-current trainings as per the procedures detailed in CEM Chapter 4-6 & Chapter 4-7.

2-6.5 DETAILS OF TOTAL MANPOWER Details for number of staff distribution in each division as per specialized skills / trades are demonstrated in the Master Man-hour plan. However, number of staff in various sections keeps on changing, depending on operational requirements.



2-7 NOTIFICATION OF CHANGES IN ORGANIZATION’S SCOPE / LOCATION / FACILITIES / NOMINATED PERSONNEL TO THE CAA (PAK)

With due consent of Accountable Manager, Chief Engineer (Quality Assurance) shall be responsible for notification of any change concerning organization’s scope / location / Facilities / nominated personnel to the Competent Authority.

2-7.1 NOTIFIABLE CHANGES Following are the changes, subject to notification to the Competent Authority: Name of the Organization Location of the Organization Scope of the CAA (Pak) Approval Nominated Personnel specified in CEM Chapter 2-4 Facilities, equipment, tools, material, procedures, work scope and certifying staff that

could affect the approval.

2-7.2 PROCEDURE Chief Engineer (Quality Assurance) shall inform the Competent Authority for any of the above-mentioned changes. For required change, an application shall be made through a letter requesting change alongwith justification thirty days ahead of incorporation date. Proposed amendment shall be submitted to the Competent Authority alongwith letter. In case of Accountable Manager change, a new statement for Corporate Commitment shall be signed by the successor for submission to the Competent Authority.

2-7.3 INCORPORATION OF AMENDMENT In general, changes shall not be effective before notification and receipt of Approval from the Competent Authority. For an unforeseen change of nominated personnel, the Competent Authority shall be notified within shortest possible time, but not later 72 hours from the date of change occurred. Chief Engineer (Quality Assurance) shall be responsible to notify such change to the Competent Authority.






2-8 AMENDMENTS CONTROL OF COMPANY EXPOSITION MANUAL (CEM)

2-8.1 MANAGEMENT OF CEM Company Exposition Manual procedures have been approved by Accountable Manager, as per corporate commitment in CEM Chapter 2-1. Under delegated authority, Chief Engineer (Quality Assurance) shall control amendment process of this Exposition alongwith all associated maintenance procedures and submit any amendment in this context to the Competent Authority, for approval.

2-8.2 KNOWLEDGE OF CEM Chief Engineer (concerned) / General Manager (Procurement & Logistics) shall ensure that personnel of respective divisions are well acquainted with contents / application of Company Exposition Manual (CEM) and all other associated procedures concerning job roles assigned to the individuals. Personnel in the Organisation are equally responsible to notify respective Deputy Chief Engineers / Deputy General Manager whenever there is a need for an improvement / change. Whenever, a typographic error or other discrepancy is found in any procedure, same shall be reported without any delay. In all cases, after initial assessment, respective Deputy Chief Engineer / Deputy General Manager shall forward his recommendations to Deputy Chief Engineer (Quality Audit) for evaluation of an amendment for compliance with the CAA (Pak) regulations.

2-8.3 APPROVAL OF CEM AMENDMENTS Any amendment in Company Exposition Manual (CEM), affecting scope of the CAA (Pak) Approval, must be submitted to the Competent Authority for approval, prior to its incorporation. Deputy Chief Engineer (Quality Audit) shall recommend proposed amendment to Chief Engineer (Quality Assurance), if found compliant with the CAA (Pak) regulations. Chief Engineer (Quality Assurance) shall submit copies of Company Exposition Manual pages, containing proposed amendments, with application for Amendment. Whenever an alteration is recommended by the Competent Authority in the proposed amendment, Chief Engineer (Quality Assurance) shall prepare an acceptable revision for re-submission to the Competent Authority. An amendment, such as correction due to typo-error within text, not affecting the prime intent of any procedure in Company Exposition Manual, shall be considered as “Minor Amendment”. Such proposed amendment shall be submitted to Chief Engineer (Quality Assurance) for indirect approval. However, Chief Engineer (Quality Assurance) shall notify such indirect approval to the Competent Authority for endorsement at the earliest, through revised Company Exposition Manual pages under a covering letter.

2-8.4 INCORPORATION OF AMENDMENT Upon grant of Approval from the Competent Authority for an amendment affecting scope of the CAA (Pak) Approval, Chief Engineer (Quality Assurance) shall authorise Deputy Chief Engineer (Quality Audit) to issue an amendment as per distribution list (Refer CEM Chapter 1-4). Deputy Chief Engineer (Quality Audit) shall maintain records for all amendments. Letter of Approval from the CAA (Pak) (in original) and stamped page of amendment shall be maintained by Technical Assistant to Chief Engineer (Quality



Assurance). Individual change requires revision number modification. Whereas, a complete new edition of Company Exposition Manual (CEM) shall be developed for several changes. Chief Engineer (Quality Assurance) shall submit the new draft of Company Exposition Manual (CEM) under a covering letter, requesting the Competent Authority for approval.

2-8.5 DISTRIBUTION OF CEM AND ITS AMENDMENTS

a) Paper Format For distribution of Company Exposition Manual (CEM), Deputy Chief Engineer (Quality Audit) shall issue a Manual Control Number (Refer CEM Chapter 1-4) to each controlled copy for traceability. Deputy Chief Engineer (Quality Audit) shall distribute amended pages to all addressees, as per distribution list alongwith ‘Manual Status Letter’ (Refer CEM Chapter 1-4), in duplicate. Reference of the Competent Authority’s Approval shall be mentioned on title page of each copy. An amendment shall be incorporated by inserting new (amended) page and replacing existing page. Margin line, on left-side, will identify latest revision on each affected page. Each manual holder, upon incorporation of amendment, shall complete the ‘Record of Revisions’ (Refer CEM Chapter 1-2). Each holder of Company Exposition Manual (CEM) shall retain original Manual Status Letter in the beginning of Manual. Whereas copy of letter, duly signed by the holder, shall be returned to Deputy Chief Engineer (Quality Audit) as acknowledgement for receipt and incorporation of particular amendment. Previous Manual Status Letter and the obsolete pages must be discarded immediately to avoid any confusion.

b) Electronic Copy Format Company Exposition Manual (CEM) and all associate maintenance procedures shall be available in electronic copy format on organisational intranet (http://mail01.piac.aero/) for secured accessibility through corporate e-mail accounts. Deputy Chief Engineer (Quality Audit) shall arrange in-time updates of electronic copy alongwith revision of Company Exposition Manual (CEM) in hard copy format. Certifying Staff shall be trained on amendments in Company Exposition Manual (CEM), through continuation training program. Each manual holder shall communicate any amendment in Company Exposition Manual (CEM) to personnel of respective division.

http://mail01.piac.aero/


CEM Chapter 2-9 Edition: 02 Revision: 03 Issue: September’ 09 Page 1 of 2

2-9 ENGINEERING PROCEDURES MANUAL (DIVISIONAL)

2-9.1 PURPOSE

To define PIA Engineering & Maintenance policies regarding management and control of Engineering Procedures Manual at divisional level.

2-9.2 GENERALITIES Engineering Procedures Manual being an associated document to Company Exposition Manual (CEM) shall be developed by each division of PIA Engineering & Maintenance. Chief Engineer (concerned) shall ensure that contents are in conformance to the PCAA regulations and procedures elaborated in Company Exposition Manual (CEM). Engineering Procedures Manual shall be controlled and revisions to be distributed from Chief Engineer (concerned) Secretariat as per distribution list (Engineering Procedures Manual – Part 1). Following shall be the structure of Manual: Part 1 – PREAMBLE Part 2 – DIVISIONAL ORGANIZATION, FACILITIES AND WORK SCOPE Part 3 – FUNCTIONS, DUTIES AND RESPONSIBILITIES Part 4 – PROCESSES AND DOCUMENTS

a) Part 1 – PREAMBLE

This Part shall be developed to provide general overview of divisional manual. Format shall be similar as of Company Exposition Manual (Part 1 ‘Preamble’).

b) Part 2 – DIVISIONAL ORGANIZATION, FACILITIES AND WORKSCOPE This Part shall contain following sub-parts (chapters): Divisional Structure – Organizational charts for the division Human Resource – Details of manpower at all level in the division Facilities – Major installations and equipment Workscope – as per Approval Schedule issued by PCAA Airworthiness Directorate.

Sub-parts (chapters) shall contain further details of organizational structure (all cadres), human resource, facilities at divisional level and relevant workscope, as mentioned in Company Exposition Manual and related to the division.

c) Part 3 – FUNCTIONS, DUTIES AND RESPONSIBILITIES This Part shall contain the following sub-parts (chapters): Main and Specific Function – section-wise details Duties and Responsibilities – at all levels, covering divisional functions

d) Part 4 – PROCESSES AND DOCUMENTS

This Part shall contain the following sub-parts (chapters): Processes & Flowcharts



Sample of internal documents / forms, being used in the division Processes / Flowcharts shall describe processes specific to the division, not mentioned in Company Exposition Manual (CEM). However, if a process is found common for two or more divisions, recommendation for addition of such process in Company Exposition Manual (CEM) shall be made as per CEM Chapter 2-8.

2-9.3 APPROVAL PROCESS Chief Engineer (concerned) shall submit Engineering Procedures Manual (EPM) for the division and its subsequent revisions to Chief Engineer (Quality Assurance) for review of contents. Review shall be based on the PCAA regulations and Company Exposition Manual (CEM), approved by the competent Authority. Chief Engineer (Quality Assurance) shall approve Engineering Procedures Manual of relevant division under delegated authority by the Director Airworthiness, provided the document is found in compliance with above-mentioned criteria and amendment is not affecting the PCAA Approval Schedule. Chief Engineer (Quality Assurance) shall send intimation for such approvals to the PCAA Airworthiness Directorate for regularization. An amendment, affecting the PCAA Approval Schedule or being in contradiction with the PCAA regulations, shall be reviewed by Chief Engineer (Quality Assurance) and if deemed necessary shall be submitted to the PCAA Airworthiness Directorate for policy decision. Such amendment shall not be effective unless an approval is granted by the Director Airworthiness. Upon approval of the manual or its subsequent amendment, Chief Engineer (Quality Assurance) shall authorise Chief Engineer (concerned) to distribute the document as per distribution list of relevant manual. Deputy Chief Engineer (Quality Audit) shall manage records related to Engineering Procedures Manual (EPM) in the Organisation, archiving manuals (original), subsequent amendments, related correspondence and the approval copies.



2-10 SAFETY MANAGEMENT SYSTEM FOR APPROVED MAINTENANCE ORGANISATION 2-10.1 PURPOSE

To define policies in implementation of the ICAO Safety Management System, in PIA Engineering & Maintenance as per ANO 91.0032, issued by the PCAA.

2-10.2 PROCEDURE

a) General Safety Management System (SMS) is a systematic approach for managing the safety, including necessary organisational structures, accountabilities, policies and procedures. Safety of flight is primarily dependant on Airworthiness of aircraft. Safety management in the area of aircraft / aircraft components maintenance, inspection, repair and overhaul are therefore vital to flight safety. The term “safety” in aircraft context is often considered to have two connotations. One emphasizes on the process to guarantee that Organisation provides airworthy aircraft for flight operations while second promotes the process for ensuring industrial safety and hygiene for protection of personnel, facilities and equipment but linked with Occupational Health and Safety (OHS) issues. Safety Management System deals with operational safety and works on the following methodology: Identifies safety hazards Ensures remedial action implementation, necessary to maintain safety performance Fosters continuous monitoring and regular assessment of safety performance Aims at continuous improvement of overall performance of the SMS

Implementation of Safety Management System in PIA Engineering & Maintenance shall be based on policies and procedures as defined in PIA Safety Management System Manual, duly approved by the Competent Authority.

b) Organization for Safety Management System Director (Engineering & Maintenance) shall be responsible to implement non-punitive safety culture, ensuring that the Organisation remains in compliance with ANO 91.0032 and shall demonstrate relevant knowledge and adequate extent of experience related to aircraft / aircraft component maintenance and managerial activities. Chief Engineer (Quality Assurance) shall act as Safety Manager for the Organisation, providing assistance for system development and surveillance for Safety Management System requirements, laid down in the ICAO Safety Management Manual. Chief Engineers shall be responsible for implementation of Safety Management System (SMS) in their respective divisions. Personnel at divisional level shall be involved for system implementation with regular hazard identification and risk assessments.

c) Training Trainings for Safety Management System (SMS) shall be provided to personnel in the Organisation prior to their involvement in system implementation. Chief Engineer (HR, Training & Automation), in coordination with all divisional heads, shall perform Training



Need Analysis (TNA). General Manager (Corporate Safety & Quality Assurance) shall arrange such trainings in coordination with Chief Engineer (HR, Training & Automation).

d) Hazard Identification and Risk Management Hazard identification process must take place within a non-punitive / just safety culture as per PIA Safety Management System (SMS) Manual, Chapter-6. Chief Engineer (concerned) shall formulate Safety Action Groups to perform hazard identification and risk management in the division.

e) Records Hazard identification and risk management activities shall be recorded in the form of safety risk registers, reporting forms and meeting minutes. Chief Engineer (concerned) shall ensure effective development, updating and archiving of records. A controlled copy shall be sent to General Manager (Corporate Safety & Quality Assurance) for oversight, consolidation and management / facilitation of safety database. Chief Engineer (Airworthiness Management) shall ensure administration of all technical records pertaining to aircraft / aircraft maintenance as per CEM Chapter 5-14. Deputy Chief Engineer (Technical Services Engineering) concerned shall manage technical investigations and archive all records. Technical Assistant to Chief Engineer (Quality Assurance) shall control records for technical qualifications and authorisations in the Organisation.



2-11 AUTHORITIES DELEGATED BY DIRECTOR AIRWORTHINESS 2-11.1 PURPOSE

To define the authorities delegated by Director Airworthiness to Chief Engineer (Quality Assurance) for surveillance of all activities, pertaining to aircraft / aircraft component maintenance in the Organisation, on behalf of the Competent Authority.

2-11.2 PROCEDURE

a) General Surveillance of PCAA Approval for large organisations, involved in aircraft / aircraft components maintenance, requires considerable number of activities to be performed by the Competent Authority. In order to establish effective surveillance and efficient assessment system for PIA Engineering & Maintenance, Director Airworthiness may delegate a number of authorities to Chief Engineer (Quality Assurance). Chief Engineer (Quality Assurance), being responsible to monitor all activities in the Organisation for compliance with regulations laid down by the PCAA, is authorised to perform the following tasks for Airworthiness Directorate. i. Issuance of Aircraft Engineer’s Inspection Authorisation (AEIA) Class-I Company

Approvals for specific aircraft types (Line / Base Maintenance) and aircraft components being maintained by the Organisation. ‘Inspection Permit’ (Class – II) shall also be issued to certify inspection on piece-part level during component maintenance and receiving incoming stores.

ii. Approval of Engineering Procedures Manuals (Divisional) and their subsequent amendments provided the documents are found in compliance with regulations laid down by the PCAA and Company Exposition Manual (CEM). Intimation for such approvals shall be sent in a timely manner to the Airworthiness Directorate.

iii. Approval of revisions and amendments to General Engineering Manual (GEM) / Examination Manual for technical qualifications in the Organisation, with intimation to the Airworthiness Directorate.

iv. Issuance of ‘One Time Approval / Temporary Approval’ for release of aircraft component, not covered under regular Company Approval category.

v. Evaluation / Approval of vendors for all stores related to aircraft / aircraft component maintenance.

vi. Issuance of “One Time Approval of vendor” in justified situations. vii. Arrangement for access to supplier’s facility for audits by the Competent Authority

with prior notification. viii. Surveillance of technical handlings at line stations for renewal of approvals by the

Competent Authority. A re-inspection of facilities shall be arranged in every five-year period or whenever deemed necessary by the Airworthiness Directorate.

ix. Assessment of all aspects regarding concession request for aircraft maintenance schedule or Airworthiness Directive / mandatory modification, particularly impact of safety / airworthiness of aircraft / aircraft component, justification presented by the Organisation and completeness of request.

x. Oversight on incident / accident reporting and tracking of technical investigations to keep the Competent Authority well informed alongwith relevant documents / information.







PART 3: FACILITIES AND WORKSCOPE






3-1 MAINTENANCE BASE FACILITIES APPROVED BY THE CAA (PAK)

3-1.1 ENGINEERING & MAINTENANCE PREMISES PIA Engineering & Maintenance has its maintenance base at JINNAH International Airport Karachi, where all maintenance shall be carried out on aircraft / aircraft components, under the CAA (Pak) Approval. Total covered area of PIA Engineering & Maintenance facilities, located at Karachi, is 83270 m2. The premises, facility and scope of undertaking is presented as follows:

PREMISES FACILITY SCOPE OF UNDERTAKING

LINE MAINTENANCE – I

(Bays 1 & 2) 9260 m2

Refer Plan [3-1.1/A] &

[3-1.1/B]

2 bays each 49 m x 41m; 5241-m2 area for Aircraft Appearance, Stockroom, Tool Store, offices, etc.

Aircraft components being wrapped in packing material for dust protection.

Ear muffs / plugs are provided to maintenance personnel for noise protection. Adequate lighting is being provided.

Portable fire fighting equipment is available with centrally controlled fire alarm system.

Compressed air outlets & electric power pits for 115 VAC / 400 Hz are available.

Line maintenance on B777, B747 & B737 series aircraft. B747: Upto Check A. B777 & B737: Up to and incl. Check A.

Aircraft Appearance. Stockroom – SR 81 for aircraft consumables

LINE MAINTENANCE - II

(Bays 1 & 2) 3450 m2


[3-1.1/C]

2 bays (37 m x 31m and 37m x 23 m); 1450-m2 area for Support Shops, Stockroom, Tool store, offices and amenities.

Metallic storage racks are available for aircraft components. Dust protection is achieved by wrapping in packing material.

Adequate lighting is being provided. Earplugs are available for noise protection.

Portable fire extinguishers are placed with centrally controlled fire alarm system.

Compressed air outlets & electric power pits for 115 VAC / 400 Hz are available.

Line maintenance on A310, A300 & ATR42 series aircraft. A310, A300 & ATR42: Upto and incl. Check A.

Stockroom – SR A1 for aircraft rotables

ANNEX between LINE

MAINTENANCE – I & II

2600 m2


[3-1.1/C]

NDT Shop, Battery Shop, Avionics Stockrooms, Cardex Control section.

dust / weather protection is provided through proper air-conditioning in shops.

Portable fire extinguishers are available with centrally controlled fire alarm system.

Compressed air and electric powers (115 VAC / 400 Hz, 28 Volts DC) with standby generator.

Battery Shop. NDT Shop. Cardex Control & Technical records.

Stockroom – SR 14 for consumables.

Stockroom – SR 26 for rubberized material.



AIRCRAFT O/H HANGAR 3370 m2


[3-1.1/D]

1 bay 49 m x 15 m; 1450-m2 area for support shops, Tool Store, offices and amenities.

Weather / dust protection by closing doors. Ground water drains are available. Adequate lighting is provided with emergency

electrical power for offices and hangar. Earplugs are available for noise protection. Foam type fire fighting system is available with

centrally controlled fire alarm system. Racks are available for storage of parts. Compressed air outlets & electric power pits for

115 VAC / 400 Hz are available

Heavy maintenance and Major checks of B737 & ATR42 aircraft.

ISPAHANI HANGAR

35460 m2


[3-1.1/E]

Hangar (135 m x 96 m) to accommodate two aircraft simultaneously with complete docking. 22500m2 area for support shops, Tool Stores, Stockrooms (Flight Pack, aircraft consumables, aircraft tyres and raw material), offices and amenities with paint booths.

Movable hangar doors to ensure weather / dust protection in adverse weather condition.

Water drains are available. Hangar is well ventilated for appropriate

working. Adequate lighting available with standby

support. Noise protection is achieved by use of

earplugs. Medium expansion foam fire fighting system. Compressed air, 115 VAC / 400 Hz electrical

power, water, central vacuum cleaning, fuel tank purging, service lifts and overhead cranes are available.

Heavy maintenance and Major checks of: B747: Check ‘A’ & ‘D’ B777: Check ‘C’

A300 & A310: Check ‘D’ and 4 / 8 yearly checks.

Painting of aircraft exterior, Livery and Decals (complete).

Stockroom- SR B2 for consumables

Stockroom- SR 09 for aircraft tyres

STRUCTURE REPAIR SHOP (Structures / Composites)

2543 m2

Refer Plan [3-1.1/E]

Shop, offices, tool store and amenities. Shop is provided with dust / weather protection

and comfortable working conditions. Adequate water drains are available. Adequate illumination is available. Portable fire extinguishers are available with

centrally controlled fire alarm system. Compressed air / electrical Power supply of 220

Volts 50 HZ available with overhead cranes. Racks available for storage of structural Parts.

Structural Repairs / Modifications on B747, A300, A310, B737 & ATR42 aircraft.

Repairs on ducts and floor panels.

Stockroom – SR 80 for raw material

AIRCRAFT FURNISHING SHOP

3200 m2

Refer Plan [3-1.1/E]

Seats, Galleys, Renovation, PAX survival equipment, Upholstery shops are air-conditioned for dust / weather protection. Stockroom for aircraft component / material (furnishing).

Plastic Repair, Sign & Art, Interior Paint shops, Tool Store, Work control centre and Check shift are well ventilated for working atmosphere, providing dust / weather protection.

Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air / electrical Power supply of 220

Volts 50 HZ available with overhead cranes.

Maintenance on: Seats (crew / PAX). Survival equipment Galleys and Toilets. Stitching of curtains / seat covers.

Cargo fencing repair. Painting of aircraft interior / placarding.

Stockroom – B3 for consumables



ENGINE O/H SHOP

14200 m2


[3-1.1/F]

Specialized shops, offices and amenities including, machine tools, heat treatment and processing area. Stockrooms for aircraft component / material (Engine / APU / landing gear) and Chemicals.

Shop is dust / weather protected. Adequate water drains are available. Adequate illumination is being provided. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks are available for storage of parts and

spares. Movable trolleys are also available. Storage of complete engine is also facilitated.

Compressed air / electrical Power supply of 220 Volts 50 HZ available with overhead cranes.

Maintenance of all Powerplants as per CEM Chapter 3-3.

Landing gears of A300, A310, B737 & ATR42 series aircraft.

Wheel assemblies of B777, B747, A300, A310, B737 & ATR42 series aircraft.

Stockroom – SR 04 for chemicals

Stockroom – SR 45 for consumables

Q.E.C BUILD-UP SHOP

2200 m2

Refer Plan [3-1.1/A]

Offices, stores and required amenities. Shop is provided with dust / weather protection. Adequate water drains are available. Adequate illumination is available. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air / electric powers are available. Overhead Cranes are also available.

Final build-up of all Powerplants as per CEM Chapter 3-3.

JET ENGINE TEST COMPLEX

1240 m2


Test cell, preparation area, control room, fuel room and amenities.

Shop is provided with dust / weather protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Adequate racks available for storage of parts. Electric power is available.

Testing of engine: CF6-50, CF6-80C2, CFM56-3

APU TEST BENCH 30 m2


Shop is providing dust / weather protection and comfortable working conditions.

Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks are available for storage of parts /

spares. Electric power is available.

Testing of APUs fitted on B747, A300 & B737 series aircraft.



COMPONENT O/H

SHOP 3500 m2

(Fuel & Misc. / Hyd.,Brakes & Brakes) Refer Plan [3-1.1/A] &

[3-1.1/C]

Shop equipment, offices, stores and amenities. Shop is provided with dust / weather protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks available for storage of parts / spares. Electric power is available.

Maintenance on: Fuel, Hydraulic & Misc. system components and Brake assemblies fitted on B777, B747, A300, A310, B737 & ATR42 series aircraft.

PNEUMATIC O/H SHOP

2300 m2

Refer Plan [3-1.1/A] & [3-1.1/G]

Shop equipment, offices, aircraft consumables (pneumatic) Stockroom, store and amenities.

Shop is provided with dust / weather protection.Adequate water drains are available.

Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air / power supplies (115 VAC &

28 Volts DC) are available with Standby generator.

Maintenance on: All Pneumatic and air-conditioning system components of B747, A300, A310, B737 & ATR42 series aircraft.

Stockroom – SR 89 for consumables

RADIO O/H SHOP

1050 m2


[3-1.1/C]

Shop equipment, offices, stores and amenities. Shop is provided with dust / weather protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air / power supplies (115 VAC &

28 Volts DC) are available with Standby generator.

Maintenance on: Wireless, radar & video system components of B747, A300, A310, B737 & ATR42 series aircraft.

INSTRUMENT O/H SHOP

1850 m2


[3-1.1/C]

Shop equipment, offices, stores and amenities. Shop is air-conditioned for dust / weather

protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air and power supplies (115 VAC

& 28 Volts DC) are available with Stand by generator.

Maintenance on: Instruments of B747, A300, A310, B737 & ATR42 series aircraft.

ELECTRICAL OVERHAUL SHOP

2500 m2


[3-1.1/C]

Shop equipment, offices, stores and amenities. Shop is air-conditioned for dust / weather

protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with


spares. Compressed air and power supplies (115 VAC

& 28 Volts DC) available with Stand by generator.

Maintenance on: Electrical components of B747, A300, A310, B737 & ATR42 series aircraft.



TOOL MANUFACTURE

SHOP 540 m2


[3-1.1/F]

Shop, equipment including machine tools and fitting benches, offices, stores and amenities.

Shop is adequately ventilated to ensure working of personnel is not impaired.

Adequate water drains are available. Adequate illumination is available. Portable fire extinguishers are available with

centrally controlled fire alarm system. Racks / Stands available for storage of parts. Pneumatic & Electric powers are available with

standby arrangements.

Manufacture, repair and modification of special tools and fixtures.

WORKSHOP EQUIPMENT

MAINTENANCE 1270 m2


[3-1.1/F]

Shop equipment, offices, stores and amenities. Shop is ventilated for suitable working

atmosphere, providing dust and weather protection.

Adequate water drains are available. Adequate illumination is available. Individual areas are isolated to suppress noise. Portable fire extinguishers are available with


spares. Pneumatic & Electric powers are available.

Periodic maintenance on overhead cranes, fixed equipment and air compressors

Supply of dry air and nitrogen gas

Stockroom – SR 06 for bulk storage (in stores building)

HANGAR EQUIPMENT

MAINTENANCE 840 m2


Shop equipment, offices, stores and amenities. Working area is in open space so dust

protection is achieved by wrapping the parts in packing material.

Water drains are available. Illumination is available. Earplugs are available in the stores. Portable fire extinguishers are available. Racks available for storage of parts and spares. Pneumatic & Electric powers are available.

Maintenance of ground support equipment (GPU, rig, dock, trestle, etc.)

3-1.2 HANGAR OCCUPATION / AIRCRAFT HANAGAR VISIT PLAN A projected Hangar Visit Plan shall be prepared in accordance with Aircraft Maintenance Schedule requirements and availability of hangar bays on yearly basis, by Planning Officer. There are four bays altogether, three in Ispahani Hangar and one in Aircraft Overhaul Hangar. Deputy Chief Engineer(Schedule & Check Planning) shall check and submit Hangar Visit Plan for review and approval of Chief Engineer (Maintenance Operation Centre). Approved plan is issued under the Ref. No. E&M/CE (P&P)/HVP. Annual Hangar Visit Plan shall be reviewed on quarterly basis and may be revised to accommodate for the following also: i. For line maintenance, major jobs upon requirement, ii. For customer’s aircraft major checks iii. For contingencies and reasons beyond control Revised Hangar Visit Plan (with the Revision No. / Revision date) shall be transmitted to all concerned as a controlled document, under the approved distribution list maintained by Chief Engineer (Maintenance Operation Centre).



3-1.3 APRON An apron covering an area of approx. 121,000 m2 is located in front and on the eastern side of ISPAHANI Hangar. It provides eight additional parking / maintenance bays and two run-up bays. The run-up bays are provided with blast deflectors to divert engine exhaust and reduce noise. Parking / maintenance bays and run-up points are provided with under ground pits with service point for compressed air and 400 Hz AC power pits. Apron is well illuminated with tower mounted high-pressure sodium vapour floodlights. Ground markings and lightening fixtures are as per JEPPESSEN Manual.

3-1.4 TECHNICAL LIBRARIES Technical Libraries setup comprise of a main Technical Library at Karachi that receives all publications from the Authorities / Associated Bodies, manufacturers and vendors. In addition to hard copies, the literature is also available on microfilms and manufacturers’ Compact Discs. Main Technical Library has fully qualified librarians, who are assigned functions of ordering all required maintenance data, performing inventory check and maintaining all data in an amended / updated status. Facilities such as personal computers and printers are also available. A set of relevant maintenance data is made available in different sections at the maintenance base (Karachi) and Line Station Libraries (Islamabad and Lahore).



[3-1.1/A] PIA ENGINEERING & MAINTENANCE



[1.8.2] LINE MAINTENANCE – I [3-1.1/B] LINE MAINTENANCE - I

1- Bay 2 Line Maint -I 2- Bay 1 Line Maint – I 3- Stock Room 4- Stock Room 5- Aircraft Appearance 6- Tool Stores 7- Offices



[1.8.3] LINE MAINT. – II / COMPONENT OVERHAUL / AVIONCS OVERHAUL [3-1.1/C] LINE MAINTENANCE – II / AVIONICS OVERHAUL / COMPONENT OVERHAUL

1

LINE MAINT II BAY 1- Line Maint –II Bays 2- Component & Hydraulic Shop 3- Instrument O/H 4- Instrument O/H Ext. 5- Radio Overhaul 6- Stock Room 7- Offices 8- Planning & Projects



[1.8.4] BASE M AINTENANCE (HANG AR # 3) AIRCRAFT O/H HANGAR [3-1.1/D] AIRCRAFT OVERHAUL HANGAR



(ISPHAHANI HANGAR)[1.8.5] BASE MAINTENANCE (HANGAR # 4) – ISPAHANI HANGAR ISPAHANI HANGAR [3-1.1/E] ISPAHANI HANGAR

1- Hangar Area 2- Tools Store / Technical Library 3- Structure Repair Shop 4- Time Office / Change Over 5- Composites Repair Shop 6- Stock Room 7- Aircraft Furnishing (Level 2) 8- Flight Pack Section



[3-1.1/F] ENGINE OVERHAUL / TOOL MANUFACTURING SHOP

[3-1.1/F] ENGINE OVERHAUL / TOOL MANUFACTURING SHOP



[1.8.7] PNEUMATIC OVERHAUL COMPLEX [3-1.1/G] PNEUMATIC OVERHAUL COMPLEX






3-2 LINE STATION FACILITIES APPROVED BY THE CAA (PAK)

3-2.1 PURPOSE To define PIA Engineering & Maintenance policies regarding aircraft maintenance at line stations approved by the CAA (Pak) and maintenance on PIA aircraft, provided by the foreign agencies / personnel.

3-2.2 PROCEDURE

a) General Line station shall be a location, other than maintenance base, at which line maintenance activities are performed on an aircraft under the CAA (Pak) Approval. Such a line maintenance location shall be capable of aircraft transit checks upto minor maintenance, approved by the Competent Authority. All maintenance on PIA aircraft shall be certified by Aircraft Engineer (Production) concerned holding an appropriate Certification Authorisation for the particular type of aircraft. At some foreign line stations, availability of PIA Engineering & Maintenance Certifying Staff may be found impracticable. In such cases, maintenance on PIA aircraft may be subcontracted to Technical Handling Agencies. Such foreign agency / personnel shall be approved / authorised by the Competent Authority upon satisfactory survey of the facilities of Technical Handling Agency.

b) PIA Line Stations All line stations shall be approved by the Competent Authority for maintenance on PIA aircraft. A List of line stations, where aircraft transit checks are being performed on PIA aircraft, shall be maintained by Deputy Chief Engineer (Line Stations). Such list shall clearly provide information regarding agencies / personnel performing any maintenance with limitations on different aircraft types. List of line stations shall be reviewed and updated on operational requirements within the approved scope of work. An amendment in the list shall be proposed through Chief Engineer (Line Maintenance) to Chief Engineer (Quality Assurance).

c) Technical Handling Agency Approval Process For approval of Technical Handling Agency to perform maintenance on PIA aircraft, Chief Engineer (Quality Assurance) shall submit an application on Form CAA-468 to the Competent Authority. After satisfactory survey of agency’s facilities by the Competent Authority, foreign agency / personnel shall be approved / authorised for the type of aircraft. Aircraft Engineer (Quality Assurance) shall assist the Competent Authority for such inspections. Chief Engineer (Quality Assurance) shall submit performance report on annual basis to the Competent Authority for renewal of Technical Handling Agency approval. A re-inspection of facilities shall be arranged after an interval of five years or whenever deemed necessary by the Competent Authority.






3-3 WORK SCOPE OF PIA ENGINEERING & MAINTENANCE

3-3.1 GENERAL PIA Engineering & Maintenance shall carry out maintenance that includes any one or combination of overhaul, repair, inspection, replacement, modification or defect rectification of aircraft / aircraft components, under the PCAA Approval.

3-3.2 WORKSCOPE Summary of maintenance to be carried out under the PCAA Approval, mentioning classes, rating and the limitations is given as under:

a) Aircraft

LEVEL OF MAINTENANCE AIRCRAFT ENGINES

LINE BASE Boeing 707 JT3D

Boeing 737-200 JT8D ----

Boeing 737-300 CFM56

Boeing 747-200 CF6-50 / JT9D

Boeing 747-300 RB211

Boeing 777-200 ER / LR GE90

Boeing 777-300 ER GE90

Airbus A300B4 CF6-50

Airbus A310-300 Series CF6-80 / PW 4152

Fokker F27 RR DART 528 / 532

De-Havilland DHC6-300 PW PT6A-27

ATR42-500 PW 127E

Cessna 172 Lycoming O-320-H2AD

b) Engines and APUs

SCOPE OF WORK RATING LIMITATION

Insp QEC Build-up Test Mod Repair Modules Overhaul

PW PT6A-27 series (Hot Section)

PW JT3D series

PW JT9D series ---- RR DART 528 / 532 series

GE CF6-50 series (Modules)

GE CF6-80 series (Modules)

CFMI CFM56-3B series (Modules)

PW 4000 series ---- GE 90 series ----

Turbine

Lycoming O-320-H2AD ---- TSCP 700 series

GTCP 660 series

GTCP 85-129 series APU

GTCP 331-250 / 500 series



c) Aircraft Components other than Complete Engines or APUs Aircraft components of B777, B747, B737, A310, A300, ATR42 and Cessna 172 series shall be referred in Company Capability List alongwith Shop Allocation List, maintained on PIA Aircraft Maintenance Management Information system (PAMMIS).

3-3.3 DESCRIPTION OF ACTIVITIES

AREA OF ACTIVITY DESCRIPTION

BASE

The maintenance activities include: • Scheduled Heavy maintenance. • Unscheduled maintenance. • Repair and Inspection work. • Major Checks up to CHECK “D”. • Modifications, Major and Minor. • Application of approved repairs • Incorporation of ADs, SBs. • Limited scope of fabrication as per maintenance

data provided by the Manufacturer / TC holder.

AIRCRAFT

LINE

The line maintenance activity covers: • Servicing. • Pre-flight / Transit. • Daily and Weekly Checks. • Rectification of Defects.

ENGINES / APUs

Activities comprise: • Scheduled and Unscheduled maintenance. • Routine Inspections. • Defect Rectification in accordance with the AMM, EMM or

Approved Documentation. • Testing, Repair and Overhaul.

COMPONENTS

Activities comprise: Bench test, repair and overhaul of aircraft components other than Engines and APUs.

3-3.4 COMPANY CAPABILITY LIST

Company Capability List of PIA Engineering & Maintenance shall be maintained by Chief Engineer (Maintenance Operation Centre), under reference # E&M/CE(MOC)/CCL. The list shall provide following information:

ATA Chapter No. LRU Control No. Description Part No. Vendor code Shop allocation Type of Repair

Company Capability list shall be compiled by integrating capabilities, for maintenance on relevant components, from all divisions through respective Chief Engineers. This list shall be submitted to Chief Engineer (Quality Assurance) for approval, against the approved workscope. Approved list shall be available online (PIAC website, www.piac.com.pk).



Deputy Chief Engineer (production) concerned shall maintain Shop Capability List for respective section, endorsed by Chief Engineer (concerned). Company Capability List shall be printed for presentation to the Competent Authority, whenever called for. Deputy Chief Engineer (production) concerned shall review Company Capability list, available online, on regular basis. An amendment in Company Capability List, may be addition / deletion of any component from list, enhancement / reduction of work scope (maintenance level) or a combination of both.

a) Amendment affecting scope of approval Chief Engineer (Quality Assurance) shall evaluate any amendment affecting scope of approval, forwarded to him by Chief Engineer (concerned). A letter from Chief Engineer (Quality Assurance) and two copies of proposed amendments shall accompany the request. Upon receipt of approval from the Competent Authority, Chief Engineer (Quality Assurance) shall authorise Chief Engineer (Maintenance Operation Centre) / his nominee for incorporating amendments and updating the ‘Record of Revisions’ accordingly. Record for amendments (letter of agreement, revised Approval Certificate, etc.) shall be maintained by Chief Engineer (Quality Assurance). Chief Engineer (Maintenance Operation Centre) shall transmit a feedback for incorporation to originator.

b) Amendment not affecting scope of approval Amendments in Company Capability List, such as addition / deletion of a component in already approved category (Product Line), change in type and / or level of maintenance for already listed component can be authorized by the Chief Engineer (Quality Assurance). Deputy Chief Engineer (production) concerned shall submit following details to Chief Engineer (concerned):

Part number and description LRU control number Type or level of maintenance Original Equipment Manufacturer Maintenance data (reference / details) Tool / test equipment required Training / qualification requirements

Chief Engineer (concerned) shall review and if found justified, ‘Request For Change in CCL / Capability Enhancement’ shall be forwarded to Chief Engineer (Quality Assurance) for endorsement. Chief Engineer (Quality Assurance) shall assess whether submitted amendment request, with required information, is not affecting the scope of approval. Upon verification, Chief Engineer (Quality Assurance) shall endorse the amendment, communicating such change to the PCAA, within 72 hours. Endorsement shall then be communicated to Chief Engineer (Maintenance Operation Centre) for incorporation of amendments in Company Capability List. Originals of amendment requests are retained with Chief Engineer (Maintenance Operation Centre), whereas copies of these are sent to the originator for their record.






3-4 PIA AIRCRAFT FLEET MAINTENANCE CHECKS AND INTERVALS

3-4.1 PURPOSE To define PIA Engineering & Maintenance policies regarding the administration of maintenance checks and their intervals for aircraft under the PCAA Approval.

3-4.2 PROCEDURE

a) General ‘PIA Fleet Maintenance Checks and Intervals’, developed by Deputy Chief Engineer (Maintenance Program & Reliability), shall be utilized for effective production planning during aircraft maintenance checks in PIA Engineering & Maintenance.

3-4.3 PIA FLEET MAINTENANCE CHECKS AND INTERVALS

Type of Line Checks Routine Checks Major Checks * C of MR Aircraft Transit Layovers ‘A’ ‘B’ ‘C’ MID - D 'D' Issuance

B777-200 / -300

Transit (Outstation

& Base)

** Daily check Service check1

250FH Service check2

500FH

75 days / 1000 FH

--- 750 days --- 3000 days As per PCAA ANO 92.0001 Requirements

B747-300

Transit (Outstation

& Base)

Daily check 36 elapsed Hrs. Weekly Check Not exceeding 8

elapsed days

Not exceeding

600FH --- 6000 FH /

18 Months --- 6 years As per PCAA ANO 92.0001 Requirements

B747-200 Combi

Transit (Outstation

& Base)

Daily check 36 elapsed Hrs. Weekly Check Not exceeding 8

elapsed days 110 FH 225 FH

Not exceeding

600FH --- 6000 FH /

18 Months --- 6 years As per PCAA ANO 92.0001 Requirements

A310-300

Transit (Outstation) Pre-flight

(12 elapsed Hrs. at Base)

*** Layover 36 elapsed Hrs. Weekly Check

(8 calendar Days)

500 FH / 04 Months --- 6000 FH /

24 Months 6 Yearly 12 Yearly As per PCAA ANO 92.0001 Requirements

B737-300

Transit (Outstation

& Base)

Turnaround (First Flight from

KHI,LHE,ISB, PEW)

250 FH 1000 FH 4000 FH /15 Months --- 24000 FH

As per PCAA ANO 92.0001 Requirements

ATR42-500 Transit

(Outstation & Base)

Daily check 24 elapsed Hrs.

Line check 48 elapsed Hrs Weekly Check 7 calendar Days

500 FH --- 5000 FH Check “4C” 20,000 FH

As per PCAA ANO 92.0001Requirements

Cessna 172N

Pre-flight (Prior to

first flight of the day)

---- Operation Check 1 (50 FH)

Operation Check 2 (100 FH)



As per PCAA ANO 92.0001Requirements

* Certificate of Maintenance Review (C of MR) must be completed and signed by the PCAA authorized person, after base check or before validation / renewal of Certificate of Airworthiness (C of A) and subsequently after every three months. C of MR shall be retained for two years from its date of issue.

** Before first flight of the day from KHI. Before 48 elapsed hours at ISB / LHE, if away from KHI.*** In case, aircraft completes 36 elapsed hours at line station, layover check shall be performed when aircraft returns to base.







PART 4: QUALITY ASSURANCE PROCEDURES






4-1 AIRCRAFT CERTIFICATES CONTROL PROCEDURE

4-1.1 PURPOSE To define PIA Engineering & Maintenance policies regarding control of release certificates related to aircraft / aircraft components.

4-1.2 PROCEDURE

a) Certificate of Release to Service (CRS) Certificate of Release to Service (CRS) shall be issued after overhaul, repair, replacement, scheduled maintenance task, modifications and mandatory inspection have been carried out in accordance with requirements prescribed by manufacturers of aircraft / aircraft component. i. Line Maintenance Certificate of Release to Service in Line Maintenance is given on Technical Log Slip after carrying out a pre-flight check / required maintenance / defect rectification on aircraft in accordance with applicable maintenance data by appropriately authorised Certifying Staff. ii. Base Maintenance Certificate of Release to Service in Base Maintenance is given on Task Card / ARO after carrying out required maintenance tasks / subtask on aircraft in accordance with applicable maintenance data by appropriately authorised Certifying Staff. iii. Overhaul Shops Certificate of Release to Service in Overhaul Shops is given on LRU Tracking Tag / Serviceable Tag (blue) after carrying out required maintenance on aircraft component in accordance with approved maintenance data by appropriately authorised Certifying Staff.

b) Maintenance Release (MR) Maintenance Release (MR) shall be issued for an aircraft subsequent to a major check completion. Maintenance Release is issued to certify that all maintenance work, specified in the approved maintenance schedule, have been completed in accordance with applicable maintenance data. Maintenance Release shall only be issued when CRS for all task / sub-tasks, required by Check-Work-Package, have been signed. Maintenance Release is issued by a Certifying Staff authorised by Chief Engineer (Quality Assurance) to issue Maintenance Release for a particular aircraft. List of such authorisations shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance). Maintenance Release shall be issued in duplicate and one copy shall be carried on board the aircraft and other is to archived with Technical Records.

c) Certificate of Maintenance Review (C of MR) Certificate of Maintenance Review (C of MR) shall be issued for an aircraft after a major check or before Validation / Renewal of Certificate of Airworthiness and subsequently after every three months. The certificate is issued to certify that all maintenance



specified in approved maintenance schedule, mandatory modifications and all other mandatory requirements have been appropriately carried out within specified time period and documented accordingly. The certificate shall be issued in duplicate, one copy shall be carried on board the aircraft and other is to be archived with maintenance records. Certificate of Maintenance Review shall be issued alongwith ‘C of MR Status Report’ and ‘C of MR Renewal Record Sheet’ as sampled in ANO 92.0001 Appendix ‘J’. Airworthiness Directorate, CAA (Pak), shall authorise to an appropriately qualified / experienced Aircraft Engineer holding full set ‘A’ & ‘C’ or full set ‘X’ & ‘R’ to issue C of MR. CAA (Pak) approved Chief Engineer / Deputy Chief Engineer shall only be considered as authorised persons for issuance of C of MR. Technical Assistant to Chief Engineer (Quality Assurance) shall maintain such list of authorisations.

d) Certificate of Fitness for Flight (C of FF) Certificate of Fitness for Flight (C of FF) shall be issued prior to Test Flight, to certify that aircraft and aircraft systems are airworthy and the aircraft is fit to perform a test flight in accordance with requirements prescribed by the manufacturer and regulations of the CAA (Pak). Certificate of Fitness for Flight shall be issued by a Certifying Staff authorised by Chief Engineer (Quality Assurance). List of such authorisations shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance). The certificate shall be valid for a period of seven days from the date of its issue and shall be retained for two years.

e) Certificates Onboard Following aircraft certificates are carried onboard. All such certificates have validity dates and are subjected to renewal Certificate of Airworthiness (C of A) Maintenance Release (MR) Certificate of Maintenance Review (C of MR) Certificate of release to service (on aircraft Technical Log) Certificate of Registration Air Operator Certificate Insurance Certificate. Noise Certificate Certificate of Radio Installation Licence for Radio set Operators Weight and Balance Schedule

Certifying Staff issuing Certificate of Release to Service (CRS) for aircraft in Line Maintenance, shall verify above-mentioned certificates on board.



4-2 CONCESSION ASSESSMENT AND CONTROL PROCEDURE

4-2.1 PURPOSE To define PIA Engineering & Maintenance policies for concessions sought from the Competent Authority regarding deviations from aircraft maintenance schedule, overhaul and test schedule, instructions of Overhaul / Repair Manuals or other mandatory requirements.

4-2.2 GENERALITIES Induction of new aircraft / aircraft component, hold-up of aircraft spare in unavoidable circumstances are examples of situations, where it is very difficult for the Organization to manage qualified personnel for Maintenance Certification, follow Aircraft Maintenance Schedule or comply with the schedule / mode for an Airworthiness Directive (AD) or mandatory requirement. Whenever such an exigency arises, PIA Engineering & Maintenance shall submit an application to the Competent Authority for concession, clearly defining specific period of time to facilitate / continue the operation without compromising on the safety / airworthiness standards. Instance, whereby a concession is requested shall be categorized under the following main areas: Unavailability of qualified personnel for maintenance certification on aircraft / aircraft

component. Deviation from approved aircraft maintenance schedule / overhaul life of aircraft

component. Deviation from the Airworthiness Directives / mandatory modification in terms of

specified time schedule / mode of compliance.

4-2.3 PROCEDURE Before submission of application for concession, Chief Engineer (concerned) must adopt all measures to resolve the situation at divisional level. If not viable, Technical Assistant to Chief Engineer (Quality Assurance) shall be contacted to prepare a case for concession, providing all relevant information. Prior to submission of an application regarding concession for aircraft maintenance schedule or Airworthiness Directive / mandatory modification, Chief Engineer (Quality Assurance) shall thoroughly assess all aspects, particularly the impact of safety / Airworthiness Standards of the aircraft / aircraft component. Chief Engineer (Quality Assurance) shall formally submit a request for grant of concession to the CAA (Pak) Airworthiness Directorate through the respective field office on form CAA-056 (in duplicate), furnishing complete justification of case, one week prior to the affectivity date. Scope of concession shall be exercised upon receipt of Approval from the Competent Authority. After the endorsement of subject concession, Technical Assistant to Chief Engineer (Quality Assurance) shall communicate the authorisation to all concerned in the Organization. All concession cases shall be serially numbered for tracking purposes. Each case for concession shall be followed up and subsequently shall be recorded and archived by Technical Assistant to Chief Engineer (Quality Assurance).

4-2.4 CONCESSION TERMINATION REPORT



Upon expiry of granted concession or whenever such requirement stands concluded, Chief Engineer (Quality Assurance) shall submit a ‘Concession Termination Report (CTR)’ to the respective CAA (Pak) field office. A copy of the ‘Concession Termination Report (CTR)’ shall also be archived with the respective case file. Technical Assistant to Chief Engineer (Quality Assurance) shall clearly communicate such termination to all concerned at the same time, who have previously been informed of granted concession, to avoid any ambiguity. Record for such communication shall be maintained at the office of Technical Assistant to Chief Engineer (Quality Assurance).



4-13 SUPPLIER EVALUATION AND SUBCONTRACT CONTROL PROCEDURE 4-13.1 PURPOSE

To describe PIA Engineering & Maintenance policies regarding suppliers’ evaluation, qualification, inclusion in Approved Vendor List (AVL) and performance follow-up of such approved vendors for aircraft components (rotable / repairable / consumable), material (consumable / raw), tools, test equipment and maintenance services.

4-13.2 PROCEDURE a) General All aircraft components intended to be installed on aircraft / aircraft component (NHA – Next Higher Assembly), shall be accompanying applicable authorised release certificate issued by Original Equipment Manufacturer (OEM) or OEM authorised distributor explicitly EASA Form 1, FAA Form 8130-3 or TCA 24-0078 (Refer Company Exposition Manual Chapter 6-1 for details of authorised release certificates). Procurement of aircraft components, material and tooling / test equipment shall be made through Purchase Order, from vendor listed in effective ‘Approved Vendor List (Procurements)’, maintained by General Manager (Procurement). On the other hand, Repair Orders for maintenance and calibration services shall be made to maintenance providers listed in effective ‘Approved Vendor List (Services)’, managed by Chief Engineer (Maintenance Operation Centre). Amendment in both lists shall only be made after obtaining approval from Chief Engineer (Quality Assurance). Requisition for aircraft components (parts / consumables) shall be made in order of priority to one of the following sources, as per laid down categorization / sequence: i Original Equipment Manufacturer (OEM) of an aircraft / aircraft component ii Distributor, recommended / authorised by the OEM in maintenance data iii Airline / maintenance organization holding approval / acceptance from PCAA iv Part supplier providing aircraft components / material with applicable authorised

certificates from Original Equipment Manufacturer (OEM), PCAA, EASA, FAA or TCCA Approved Maintenance Organisation

(Note: aircraft component, obtained from part supplier, shall have clear traceability to the source and back-to-birth history, if applicable.)

Material (fabric, adhesives or raw material) and tooling / equipment with approved specifications, not requiring authorised release shall be accepted with Certificate of Conformity from supplier national regulatory authority / Original Equipment Manufacturer (OEM). Suppliers for material and tooling / test equipment, recommended / authorised by Original Equipment Manufacturer (OEM) in maintenance data and approved by Chief Engineer (Quality Assurance) shall be included in Approved Vendor List. Maintenance services may also be contracted to PCAA Approved Technical Handling Agents at line stations, under technical handling agreement, to ensure that aircraft is fit for intended flight. Substantial maintenance on aircraft / aircraft components such as heavy aircraft maintenance and engine overhaul may be outsourced under maintenance contracts to maintenance providers, holding valid PCAA Approval. Other aircraft components and tooling / test equipment shall be sent for repair / calibration to service providers, approved by PIA Engineering Quality Assurance. Customer-provided aircraft components / material for fitment on its own aircraft, with



applicable authorised release certificate showing clear traceability, shall be acceptable. Copy of authorised release certificate must be required with customer serviceability documents (certificate / tag) as demonstration of component / material traceability.

b) Evaluation for Parts / Material / Tooling Suppliers Prior to inclusion in Approved Vendor List (Procurements), comprehensive evaluation process for vendor shall be implemented. Such vendor shall provide aircraft components with applicable authorised certificates from Original Equipment Manufacturer (OEM), EASA, FAA, TCCA or PCAA Approved Maintenance Organisation. Original Equipment Manufacturer and its distributor, recommended / authorised in the maintenance data shall directly be included in Approved Vendor List, upon receipt of initial request from General Manager (Procurement). However, relevant documents showing traceability shall be provided with such request. Chief Engineer (Quality Assurance), upon receipt of initial request from General Manager (Procurement), shall despatch ‘Vendor Approval Questionnaire’ (Form # EM/SD&D/GEN084) to potential supplier for evaluation of scope. All essential information and relevant documents, provided by potential supplier, shall be reviewed by Deputy Chief Engineer (Quality Audit) for conformance to statuary and organizational requirements. Subsequent to evaluation, supplier’s data shall be presented to Chief Engineer (Quality Assurance) on ‘Supplier Qualification and Follow-up Sheet’ (Form # EM/SD&D/GEN087) alongwith recommendation. Chief Engineer (Quality Assurance) shall issue ‘Vendor Approval Certificate’ (Form # EM/MP&R/GEN083) clearly stating desired scope and limitations. Original shall be despatched to qualified vendor through General Manger (Procurement). Copies shall be distributed within the Organisation for information / records. All vendor approval records shall be controlled and archived by Deputy Chief Engineer (Quality Audit). Qualified supplier shall be included in the Approved Vendor List (Procurements) for following categories: i Aircraft parts and spares ii Raw and consumable materials iii Tools and Equipment Whenever there arises urgent need of aircraft part / material / tool / equipment to meet operational requirement and availability of such item is only viable from unapproved source, General Manager (Procurement) shall submit request for “One Time Approval of Vendor” alongwith relevant information to Chief Engineer (Quality Assurance). Purchase Order for particular item shall only be issued after obtaining such approval. Potential vendor shall be evaluated by Deputy Chief Engineer (Quality Audit) on priority on the basis of provided / available information and recommendation shall be made upon satisfactory assessment. Chief Engineer (Quality Assurance) shall issue “One Time Approval of vendor” to the supplier.

c) Evaluation for Maintenance Providers Approved Vendor List (Services) shall be maintained by Chief Engineer (Maintenance Operation Centre) for following categories: i Aircraft Technical handling at line stations



ii Aircraft heavy maintenance (base check, major repairs, etc.) iii Engine / APU / landing gear overhaul iv Aircraft components repair services v Calibration services for tools / equipment For aircraft technical handling, Chief Engineer (Maintenance Operation Centre) shall submit request to Chief Engineer (Quality Assurance) for inclusion of Technical Handling Agent in Approved Vendor List (Services). Such request shall accompany pertinent information for organisation and certifying staff alongwith copies of AME licences. Upon successful evaluation, Chief Engineer (Quality Assurance) shall apply to PCAA for approval of Technical Handling Agent. Grant of approval by PCAA shall qualify Technical Handling Agent to be included in Approved Vendor List. For substantial maintenance (heavy aircraft maintenance and engine / APU / landing gear overhaul), Chief Engineer (Quality Assurance) shall perform initial evaluation prior to sending an application to the PCAA. Upon grant of approval by PCAA, maintenance provider shall be considered for inclusion in Approved Vendor List. Original Equipment Manufacturer (OEM) and its authorised vendor, providing aircraft component repair and calibration services for tooling / test equipment shall directly be included in Approved Vendor List, upon issuance of approval by Chief Engineer (Quality Assurance). In such case, request from Chief Engineer (Maintenance Operation Centre) shall accompany relevant documents necessary for evaluation.

d) Contracts Management Unless otherwise not possible or not in interest of Organisation, maintenance contracts shall be non-exclusive. For all contracts (exclusive / non-exclusive), the final authority shall be in accordance with effective Schedule of Powers. Deputy General Manager (Finance) Engineering shall provide expertise on financial issues. Draft contract shall be submitted to obtain clearance from Legal department, if deemed necessary. i Contracts with Vendors Chief Engineer (Maintenance Operation Centre), in consultation with Chief Engineer (Quality Assurance), shall manage maintenance contracts for outsourced substantial maintenance such as heavy aircraft maintenance and engine / APU / landing gear overhaul, in addition to technical handling agreements. Once finalised, Chief Engineer (Maintenance Operation Centre) shall sign the maintenance contract on behalf of PIA Engineering & Maintenance, being Operator. It shall be ensured by the Signatory that maintenance contract, made with maintenance provider (Contractor), identify specifically industry standard to be used during maintenance and certification activities. Contracts shall further include: Reference to approval process for Contractor by Operator and Operator’s Authority List of facilities including satellite locations where maintenance is to be performed Scope of approvals, technical requirements and level of maintenance Obligations of both parties and their regulatory counterparts on airworthiness issues Reference to Contractor’s approved exposition explaining applicable regulations,

safety requirements and quality management system Provisioning and control of logistics, turn around times, warranties, etc. Effective reporting process to immediately notify any significant defect to Operator



Access to Contractor’s facilities for Operator’s Quality Assurance / Authority Process for control of deviations from maintenance data Provisioning of technical records to Operator for assessment of achievement of

ongoing quality levels ii Contracts with Customer Organisations For maintenance services, contract shall be made with customer organisation. Contracts formulated in accordance with PCAA regulations, shall contain following information: Pertinent aircraft / aircraft component identification Scope of approvals, technical requirements and level of maintenance Obligations of both parties and their regulatory counterparts on airworthiness issues Management of applicable maintenance data Technical records requested by Customer Customer obligations for provisioning of maintenance data, components / material,

work order, approved maintenance schedule, defect reporting, release to service and continued airworthiness requirements.

Turn around times, warranties, etc. Effective reporting process to immediately notify any significant defect to Customer Reference to Contractor’s exposition explaining quality management system

Provisioning of technical records to Operator’s Engineering for assessment of achievement of ongoing quality levels

Contracted maintenance tasks shall never exceed the PCAA approved scope of work / capabilities. Technical aspects of each contract shall be readily available, whenever deemed necessary by the Competent Authority. Chief Engineer (Engineering Business Development) shall draft maintenance contracts, consulting Chief Engineer (Quality Assurance) with regards to PCAA approval. Other divisions may be contacted for issues pertaining to approved Company Capability List, continuing airworthiness and maintenance activities. Upon approval, Chief Engineer (Engineering Business Development) shall sign contract on behalf of PIA Engineering & Maintenance.

e) Procurement of Stores ‘Purchase Order’ for an aircraft component / material / tooling / test equipment shall be generated by Deputy General Manager (Purchase) concerned. For each procurement, a statement requesting appropriate authorised release certificates shall be made on the Purchase Order. ‘Repair Orders’, in a similar manner, shall only be generated for maintenance / calibration services by Deputy chief Engineer (Repair Abroad). A statement requesting appropriate authorised release certificates shall be made on the Repair Order.

f) Market Research Procurement of aircraft component (rotable / consumable), material (consumable / raw) and tooling / test equipment, etc. shall be made from suppliers listed in Approved Vendor List (Procurements). General Manager (Procurement) shall be responsible for market research of potential suppliers and initiating request to Chief Engineer (Quality Assurance), for evaluation of such supplier. For aircraft / aircraft components maintenance and calibration services for tooling / test equipment, Chief Engineer (Maintenance Operation Centre) shall be responsible for



market research and initiating request to Chief Engineer (Quality Assurance), for evaluation of supplier.

g) Vendors Follow-up All approved vendors / service providers shall be made obligated to follow ‘Terms & Conditions’ provided in ‘Vendor Approval Certificate’. For any change in Company Name, location or scope of approval, Chief Engineer (Quality Assurance) shall issue a revised ‘Vendor Approval Certificate’. Deputy Chief Engineer (Quality Audit) shall control following items for each vendor: Vendor approval questionnaire Supplier correspondences and provided documents Supplier Qualification and Follow-up sheet Certificate of approval (copy)

Vendor’s qualification for Organisation included in Approved Vendor List (Procurements) shall be reviewed by Deputy Chief Engineer (Quality Audit) every two years. In addition, Technical Assistant to Chief Engineer (Quality Assurance) shall generate monthly report on objections / discrepancies raised during incoming stores inspections. Service providers included in Approved Vendor List (Services) shall be reviewed through PIA Reliability Program for aircraft / aircraft components, in coordination with Technical Services Engineering. General Manger (Procurement) / Chief Engineer (Maintenance Operation Centre) may be informed by Chief Engineer (Quality Assurance) as to whether vendor / service provider qualification shall be maintained, suspended or withdrawn by means of Supplier Qualification and Follow-up Sheet. Record for a particular supplier shall be archived three years from the date, on which the supplier provided last services. An access to Approved Vendor List, Purchase / Repair Orders and supplier’s facility for audit with prior notification to Chief Engineer (Quality Assurance) and concerned vendor shall be granted whenever deemed necessary by the Competent Authority.







PART 5: AIRWORTHINESS MANAGEMENT PROCEDURES






5-1 RETURNS TO THE CAA (PAK) ON PIA ENGINEERING & MAINTENANCE ACTIVITIES

5-1.1 PURPOSE

To define PIA Engineering & Maintenance policies regarding preparation and submission of monthly return on PIA Engineering & Maintenance activities, related to aircraft / aircraft components, to the CAA (Pak) Airworthiness Directorate.

5-1.2 PROCEDURE

a) General It is the statuary requirement of the CAA (Pak) Airworthiness Directorate to submit a monthly Engineering Statistical Return of all aircraft in PIA fleet. The report shall be submitted on CAA form No. RCN/842/Rev-B.

b) Engineering Statistical Return Monthly statistical returns shall be prepared by Deputy Chief Engineer (Technical Services Engineering) concerned for maintenance related activities on PIA aircraft / aircraft components at the end of each month. Such returns from all areas shall be compiled and reviewed by Chief Engineer (Airworthiness Management). A monthly report shall be submitted to the Competent Authority by mid of successive month. Following information shall be provided in the monthly statistical return:

i. Serviceability of Aircraft

Registration mark Type of aircraft Manufacturing serial number Type of engine & serial numbers Base station of the aircraft Certificate of airworthiness expiry date Serviceability in number of days Flight Hours Actual oil & fuel consumption per flying hour in litres Total engine hours since new or complete overhaul

ii. Engines Spare Float

Number of spare engines Type and serial number Hours / Cycles since new or complete overhaul

iii. Particulars of Certifying Staff

AME / Approval number Name & description AME endorsement and approvals held Date of joining Date of leaving station Station of present posting

iv. Accidents / Incidents / Special Occurrences



Date of occurrence Flight Number Location of occurrence Registration mark Type of aircraft Details of occurrence Rectification Status

v. Delays

Registration mark Type of aircraft Station Summary of delays (Technical, Non-Technical, Total).

vi. Major checks of aircraft and heavy maintenance / overhaul of engines

Registration marks Engine type & serial number Check intervals Aircraft weighing date Date of test flight / Engines Tests on Test Bed



5-2 RELIABILITY MONITORING PROGRAMME FOR AIRCRAFT / AIRCRAFT COMPONENTS

5-2.1 PURPOSE

To define PIA Engineering & Maintenance policies regarding reliability monitoring of aircraft / aircraft components through a comprehensive Reliability Programme.

5-2.2 PROCEDURE

a) General To maintain PIA aircraft fleet in continued state of airworthiness, it is ensured that all PIA aircraft / aircraft components shall be maintained in accordance with approved maintenance schedule. Such schedule necessitates accomplishment of scheduled and as well as unscheduled maintenance tasks to maintain inherent design reliability levels for aircraft / aircraft component. Reliability Programme improves comprehensive maintenance schedule to ensure that adequate maintenance is being performed at proper intervals to prevent any system deterioration and restore aircraft's inherent reliability. PIA maintenance schedule utilizes three maintenance types (Hard Time, On-Condition and Condition Monitoring). i. Hard Time Preventative means, in which known deterioration of an item is limited to an acceptable level by performing maintenance at intervals related to time in service (calendar time, number of cycles / landings, etc.). Prescribed actions normally include servicing and such other actions as overhaul, repair, replacement in accordance with maintenance data so that the affected aircraft system / component / structure is replaced / restored to such a condition that it can be released to service for a further specified period. ii. On-Condition On-condition is also preventative method, but in this case, aircraft system / component / structure is inspected / tested at specified intervals to determine condition. such an inspection may reveal need for servicing action. Basic reason for such maintenance is to remove an aircraft system / component / structure before its failure in service. iii. Condition Monitoring ‘Condition Monitoring’ is not a preventative maintenance. Statistical data obtained from operational assessment is collected, analyzed and interpreted on a continuing basis as means of implementing corrective actions.

b) PIA Reliability Programme PIA Reliability Programme is information system that enables data on maintenance experience gained from effective maintenance schedule, to be collected, compiled and analyzed so that condition of aircraft can be ascertained. Thus appropriate requirement is initiated for accomplishment at proper intervals to improve aircraft's inherent reliability. Reliability data is collected for aircraft / aircraft components for overall surveillance. Analysis of collected data shall also indicate performance and effectiveness of PIA maintenance schedule. Information collected under Reliability Programme shall vary



according to exact needs. All collected data is sorted and analysed by Deputy Chief Engineer (Maintenance Program & Reliability). It shall be assured that any adverse defect rate, trend or apparent failure is identified. Such aircraft / aircraft components data shall be summarized for review by Deputy Chief Engineer (concerned) as per allocation of such aircraft / aircraft components. Deputy Chief Engineer (concerned) shall then prepare and submit a report against each investigation providing reasons / justifications and recommended corrective action to Reliability Review Board (MRB). Deputy Chief Engineer (Maintenance Program & Reliability) shall prepare instructions for actions to be taken on identified aircraft / aircraft components, finalized by PIA Maintenance Review Board. The instructions shall then be despatched to Deputy Chief Engineer (concerned) for follow-up of the corrective action implementation. With support of Reliability Programme, maintenance schedule shall be amended and submitted to the Competent Authority for Approval. An annual audit to determine effectiveness of Reliability Programme shall be carried out Engineering Quality Assurance.



5-3 ACCIDENT / INCIDENT REPORTING AND INVESTIGATION PROCEDURE 5-3.1 PURPOSE

To define PIA Engineering & Maintenance policies for reporting of accident / incident / reportable defect arising within or outside Pakistan, to the Competent Authority. Investigations procedure, followed by initial reporting of accident / incident / reportable defect defines policies to determine the root cause in view of establishing appropriate corrective actions to prevent recurrence.

5-3.2 PROCEDURE

a) General Accident / incident / reportable defect on PIA owned / operated aircraft shall be immediately reported to the Competent Authority by Deputy Chief Engineer (Technical Services Engineering – Line Maintenance) concerned giving following information using fastest means available: Type, Nationality and registration mark of aircraft. Name of the Pilot in command of aircraft. Date and time when the accident/incident occurred Last departure point, intended landing point of aircraft and the nature of flight. Location of the accident with reference to some easily defined geographical point. Number of fatalities (if any) and injured, where possible names of each individual. Nature and cause of the accident as far as known. Extent and type of damage to the aircraft.

Investigations are carried out with not to ascribe blame but to determine exact causes for identifying corrective actions to prevent recurrence. Investigation shall be objective and exhaustive, final report must be precise and concise with recommendations addressed to relevant division / department. Personal opinions should be avoided.

b) Reporting of Defect All reportable defects shall be reported on Form CAA-055 to Airworthiness Field office alongwith investigation report and necessary action taken to prevent recurrence, within 48 hours of the occurrence. CAA (Pak) Airworthiness Notice No. 09 shall be used for ready reference of reportable defects. If nature of reportable defect is such that immediately threatens safety of aircraft / personnel (onboard) / equipment, requires rectification before further flight / operation or calls out inspection of other aircraft for such defect, defect must be reported to Airworthiness Field office within 24 hours of finding of defect. If Investigation of reportable defect could not be concluded within reporting time, the defect shall initially be reported alongwith progress reports. Final report shall be submitted on completion of the investigation. Defective aircraft component / material shall be held for further investigation by the Competent Authority. However if defective part is required urgently for rectification and reuse, request shall be made to Airworthiness field Office for grant of permission.

c) Investigation Process



Deputy Chief Engineer (Technical Services Engineering) concerned shall generate an incident report, after obtaining all relevant details encompassing accident / incident / reportable defect. A comprehensive response is sought from Deputy Chief Engineer (production) concerned with an agreed target date. Following shall be considered significant while performing investigations: Precise timings of all events / activities / conditions Immediate spot check Photographic documentation of evidence / events and conditions Removal and quarantine of FDR / CVR if necessary Interviews of witnesses Quarantine of all evidence

Following guidelines shall be adhered to for raising an incident report: Nature of defects shall, as far as possible, reflect exact wordings of original report. Report shall be itemised for ease of reference. Photographs, diagrams shall be included for ease of understanding. Reliability of affected component shall be reviewed. If defect involves component, requiring disassembly by some other organization,

incident report shall be left open or pending till a technical report is received. Conclusion shall identify the cause of accident / incident / reportable defect. Corrective actions shall be recommended to relevant division / department.

Deputy Chief Engineer (Technical Services Engineering) concerned shall forward draft of incident report to Chief Engineer (Quality Assurance) who shall submit finalized report to the Competent Authority alongwith relevant documents / information. Chief Engineer (Quality Assurance) shall despatch a copy of report to Deputy Chief Engineer (Technical Services Engineering) concerned for records. Deputy Chief Engineer (Technical Services Engineering) concerned shall coordinate with Deputy Chief Engineer (production) concerned for implementation of the corrective action.



5-4 SURVEILLANCE PROCEDURE FOR FUEL STORAGE FACILITIES

5-4.1 PURPOSE

To define PIA Engineering & Maintenance policies regarding surveillance of fuel storage at the suppliers’ facilities.

5-4.2 PROCEDURE

a) Generalities Surveillance of fuel storage facilities includes periodic spot checks to ensure availability of acceptable quality of fuel for aircraft refuelling. Sample check at delivery point of supplier storage facility is required on must basis, if quality check of the fuel at refuelling is inadequate. If the repeated contamination of fuel is observed on refuelling, it is necessary to direct the supplier for a sample to be taken from fuel storage facility.

b) Process Deputy Chief Engineer (AS) Technical Services Engineering – Line Maintenance shall administer spot checks for fuel storage facilities surveillance on regular basis. Aircraft Engineer (AS) Technical Services Engineering – Line Maintenance shall perform recorded spot checks of fuel storage facilities. Following checks shall be performed during such surveillance visit: Inspection of fuel storage tanks for rust, etc. Results of Millipore test of fuel Traces for water in the fuel during storage Filter / separator availability and its inspection / check interval with proper recording

must be ensured. Such a filter / separator used while transferring fuel from storage to the fuel vehicle.

Any special checks performed by supplier on fuel storage after calamities like heavy rain / flooding, etc.

Deputy Chief Engineer (AS) Technical Services Engineering - Line Maintenance shall maintain results of such spot checks. Any significant fuel contamination shall be considered as “Reportable Defect” and must be reported by Deputy Chief Engineer (AS) Technical Services Engineering – Line Maintenance to the Competent Authority on Form CAA-055 (Refer CEM Chapter 5-3).







PART 6: MAINTENANCE PROCEDURES






6-15 AIRCRAFT / AIRCRAFT COMPONENTS PAINTING PROCEDURE 6-15.1 PURPOSE

To define PIA Engineering & Maintenance policies regarding painting / striping / polishing / finishing / refinishing / of aircraft / aircraft components so as to avoid any possibility that could cause an unairworthy condition for aircraft / aircraft component.

6-15.2 PROCEDURE

a) Paint Jobs Requiring Certificate of Release to Service (CRS)

Following are tasks, but not the only tasks, related to painting / striping / polishing / finishing / refinishing work that requires a separate Certificate of Release to Service: Painting on control surfaces and critical lifting surfaces Painting in area with critical orifices, like pitot and static ports Painting involving mandatory markings Finishing of Radome, antenna and composites used in primary / secondary surfaces Extensive polishing of surfaces where fastener head dimension are critical Conversion from paint finish to polished metal

In case, painting on the entire aircraft or large portion of aircraft is required, separate Task card / ARO shall be generated for each of the subtask mentioned above.

b) Certificate of Release to Service (CRS) Certifying Staff, holding appropriate category ‘Airframe’ rating, shall issue Certificate of Release to Service after successful completion of paint job. Any other signatory would require CAA (Pak) Airworthiness Directorate authorisation to issue such Certificate of Release to Service. Certifying Staff, issuing such Certificate of Release to Service, shall take responsibility of the process, ensuring that: Bill of work (in form of Task card / ARO) is available for each paint job being

performed and that no paint job is carried out without an available Bill of work. Approved maintenance data is available and is being referenced. Instructions from paint manufacturer are available and being complied with. Before commencing paint job, work force is briefed according to Bill of work and is

supervised throughout the process. Weight and balance requirements for control surfaces, being painted, have been

catered for as per approved maintenance data. Provisioning was made for corrosion detection after removal of paint. Corrosion inhibition compounds, removed by solvents / paint removers, have been

appropriately restored in areas adjacent to those being repainted. Excessive paint thickness is avoided to evade possible hindrance to NDT techniques In case of inadvertent placard / marking deletion, proper restoration has been made. ‘Paint Checklist’ has been followed and signed accordingly by personnel, supervising

the paint job.

c) Additional Information Following are the cases of potential damage / hazards and must be avoided: i. Inadvertent placard / marking deletion, failure to renew them or comply with

required specification (Registration marks, mandatory door markings and break-in



zone identification). ii. Blockage of vents / drains and other openings by debris, masking tape and

residues of paint remover, paint or particle blast material. Possible ingress of water into fuel tanks through vent apertures or filler cap seals when using high-pressure hoses for washing down.

iii. Jamming of flight control and landing gear mechanisms by preparation treatments and paint.

iv. Inadequate finishing schemes of manufacturer for antennas and Radomes. v. Damage caused during preparation work that could adversely affect structural

integrity of the aircraft, such as:

Reduction in fastener head size by uncontrolled use of power tools and abrasive media.

Surface scratching by use of paint scrapers. Degrading of composite surface by abuse of particle blasting technique. Aluminium surface contamination by steel wool particles. Use of incorrect chemical paint strippers.

vi. Damage of transparencies, composites and sealants by solvent / paint removers

due to inadequate protection and / or retention of these products in crevices. vii. Loss of current mass balance moments on flight control surfaces. viii. Uncontrolled variations to aircraft basic weight. ix. Variation to surface profile and aerodynamic smoothness at critical points such as

surface leading edges, by uncontrolled use of fillers or excessive paint thickness. x. Effects of excessive paint thickness on Non Destructive Testing techniques such

as Eddy Current / Ultrasonic Inspection.

d) Painting / Finishing on Aircraft Components

Complete painting / finishing of aircraft components shall be carried out as per relevant instructions detailed in approved maintenance data. If separate maintenance data does not exist, as in case on various interior panels of aircraft, then relevant instructions in Aircraft Maintenance Manual (AMM) or instruction of Deputy Chief Engineer (production) concerned paint shop are to be followed. Such paint jobs shall be initiated using ‘Fractional Work Order’ and concluded by signing ‘Work Accomplishment advice’ at the bottom of ‘Fractional Work Order’.



6-16 AIRCRAFT WEIGHING AND TEST FLIGHT PROCEDURE 6-16.1 PURPOSE

To define PIA Engineering & Maintenance policies regarding Aircraft Weight and Balance check in accordance with Aircraft /Maintenance Schedule and test flights requirements to avoid any possibility that could cause an unairworthy condition for aircraft / aircraft component.

6-16.2 PROCEDURE

a) Aircraft Weight and Balance Repeat determination of weight and centre of gravity of aircraft shall be accomplished in accordance with the maintenance program or if considered necessary in the light of a flight reported snag or as and when required by the PIA Flight Operations. As per the CAA (Pak) regulations, if the basic weight is estimated to have changed by more than 0.5 percent of maximum certified take-off weight or if the centre of gravity is estimated to have changed by more than 0.5 percent of MAC (mean aerodynamic chord) then the aircraft shall be re-weighed physically. It shall be the responsibility of the PIA Flight Operations to keep a complete, current and continued record of changes in empty weight and empty centre of gravity. PIA Engineering & Maintenance shall also keep records of performed weight and balance. At least two working days before the estimated release date of the aircraft from a major check , Chief Engineer (Base Maintenance) sends advice to Flight Operations and to Deputy Chief Engineer (Technical Services Engineering) Base Maintenance indicating expected release date of aircraft and flight on which it is scheduled to depart after release, together with following data. List of all Modifications and Engineering Change Orders (ECOs) incorporated or any

configuration change, noting against each the resultant change in basic weight and the change in basic moment.

List of all significant structure repairs carried out, noting against each the respective change in basic weight and the change in basic moment.

Weighing and determination of centre of gravity is carried under supervision of Deputy Chief Engineer (Technical Services Engineering) Base Maintenance. Representatives of PIA Flight Operations and Competent Authority are present during weight and balance activity. Records of activity are shall be maintained by Deputy Chief Engineer (Technical Services Engineering) Base Maintenance.

b) Test Flight A ground and flight test is performed after completion of a heavy maintenance visit. A flight test will also be performed if a problem cannot be duplicated on ground by means of standard maintenance checks, or if maintenance manual calls for it after a maintenance action. In consultation with the Chief Pilot Technical (Flight Operations department) a test flight plan will be defined. Chief Engineer (Quality Assurance) shall authorize for Test Flight. A test flight plan may also be defined in consultation with customer in case where operator is different from PIA.



i. Authority The call for Test Flight of an aircraft can be raised by any of the following: Aircraft Engineer (Line Maintenance / Base Maintenance) concerned Deputy Chief Engineer (Line Maintenance / Base Maintenance) concerned Chief Engineer (Line Maintenance / Base Maintenance / Quality Systems) Chief Pilot (Technical)

Test Flight report will be given by the pilot on the standard Flight Operations Proforma for the aircraft type as appropriate or on the Aircraft Technical Log for the information/record for further necessary action by PIA Engineering and Maintenance personnel. Necessary number of Aircraft Engineers (concerned) may be on board the aircraft for observation or for recording purposes during the Test Flight. ii. Applicability Test flight shall be carried out for the following case: Following upon major maintenance, repair, conversion or modification which may

effect the operation or flight characteristics of an aircraft . For the purpose of performance evaluation with respect to flight characteristics, fuel

consumption, engine power checks etc. To facilitate in trouble shooting a reported defect in a system or component if the

fault could not be reproduced during the prescribed ground checks. Following upon repair done to the aircraft as a result of major damage. On specific requirement by Chief Engineer (Quality Assurance) On specific requirement by Chief Pilot (Technical)

iii. Limitation A Test Flight is not to be carried out unless : A valid "Certificate of Fitness for Flight" has been issued following major

maintenance. A Certificate of Maintenance Review is in force. The test flight has been called out or authorized by an appropriate authority The Aircraft Technical Log book and other relevant documents as required are on

board the aircraft. It should be realized that the act of normal maintenance and/or replacement of

standard parts and or components during the course of routine inspection and certification does not normally constitute grounds for a test flight.




PART 7: ADDITIONAL LINE MAINTENANCE PROCEDURES






7-8 ONBOARD MEDICAL SUPPLIES CONTROL PROCEDURE 7-8.1 PURPOSE

To define PIA Engineering & Maintenance policies regarding control of medical supplies on-board the aircraft in case of an unforeseen emergency during the flight.

7-8.2 PROCEDURE

a) Generalities All aircraft shall carry, medical supplies, sufficient for the treatment of injuries and other medical emergencies to the occupants, likely to occur, in flight or in case of accident / incident. Two types of medical supplies should be provided: First aid kit for carriage in all aircraft. Medical kit for carriage where aircraft is authorized to carry 250 passengers or more.

It is essential that required first aid kits be distributed as evenly as practicable in the passenger compartment and should be readily accessible to cabin crew. In view of possible use of medical supplies outside aircraft in an emergency situation, they should be located near an exit.

b) Contents of First Aid Kit Medical supplies should be contained in a metal box plainly marked with a Red Crescent and the words "First Aid" or "Medical Aid", as the case may be painted on it in English and Urdu Language. The boxes must be sealed and seal shall be checked by Certifying Staff on daily basis before releasing the aircraft. First aid kit is intended for emergency use only and is supplementary to medical kit carried by cabin crew for use in-flight. If medical kit is not carried on flight, then the contents of first aid box shall be replenished as early as practicable and first aid kit shall be resealed. Following shall be the contents of Aircraft First Aid Kit: A handbook on first aid "Ground-air visual signal code for use by survivors" Materials for treating injuries Ophthalmic ointment A decongestant nasal spray Insect repellant Emollient eye drops Sunburn cream Water-miscible antiseptic/skin cleanser Material for treatment of extensive burns Oral drugs such as analgesic, antispasmodic, central nervous system stimulant,

motion sickness medications An artificial plastic airway and splints

c) Contents of Medical kit

Following Equipment should be part of Medical Kit: One pair of sterile surgical gloves Sphygmomanometer



Stethoscope Sterile scissors Haemostatic forceps Haemostatic bandages or tourniquet Sterile equipment for suturing wounds Disposable syringes and needles Disposable scalpel handle and blade Drugs such as coronary vasodilators, analgesics, diuretics, anti-allergies, injectable

steroids, sedatives, ergometrine, injectable broncho-dilator, etc. Where compatible with regulations of appropriate authority a narcotic drug in

injectable form

d) Certification of the First Aid / Medical Kit Contents of each kit should be checked at intervals of three months and expired / inadequate items shall be replaced. Serviceability of contents should be duly certified by a Medical Officer. Also a copy of list of medicines should be carried in the container.




PART 8: APPENDICES






8-1 APPENDICES

8-1.1 PCAA APPROVAL CERTIFICATE 8-1.2 EASA PART-145 APPROVAL CERTIFICATE 8-1.3 THAI DCA REPAIR STATION APPROVAL CERTIFICATE 8-1.4 QCAA ACCEPTANCE CERTIFICATE 8-1.5 KCASR PART-145 APPROVAL CERTIFICATE



8-1.1 PCAA APPROVAL CERTIFICATE







8-1.2 EASA PART-145 APPROVAL CERTIFICATE



8-1.3 THAI DCA REPAIR STATION APPROVAL CERTIFICATE



8-1.4 QCAA ACCEPTANCE CERTIFICATE



8-1.5 KCASR PART-145 APPROVAL CERTIFICATE

Documents

1 PIAEngineering and MaintenanceCEM E2 R5 March2011 14062011