FOR - Structural Testing Systems, Inc. Rev 9, 16 Jan 2017 Manual 3 Shop... · Web viewAll STS employees shall be trained in detecting SUPs in accordance with Structural Testing Systems

STRUCTURAL TESTING SYSTEMS INC.REPAIR STATION / QUALITY CONTROL MANUAL

FAA CERTFICATE NUMBER ES1R124K

FAA REPAIR STATION

FAA Certificate Number ES1R124K

Structural Testing Systems Inc.L.I. MacArthur Airport

2221 Smithtown AvenueRonkonkoma, NY 11779

COMPLIANCE WITH FAR PART 145

MANUAL NO. 3Shop Copy



TITLE: TABLE OF CONTENTSPAGE: 1DATE: 01/06/14Revision: 7

TABLE OF CONTENTS

Page Number

INTRODUCTION i

MANUAL CONTROL AND REVISION SYSTEM ii

RECORD OF REVISION iii

REVISION LIST iv

LIST OF EFFECTIVE PAGES v

MANUAL ACCEPTANCE PAGE vi

SECTION I Organization Structure 1-8

SECTION II Personnel Roster / Non-Certificated Personnel 1Maintaining and Revising Contract 2Maintenance Information

SECTION III Description of OperationsLocation and Detailed Drawing of Facility 1-2Description of Tools Equipment used to 3Perform Maintenance Operations 3

SECTION IV Training Program 1

SECTION V Procedures Governing Work at Another Location 1-2And Work Performed for 121 and 135 Operators

SECTION VI Establishing and Maintaining Current 1Technical Data



TITLE: TABLE OF CONTENTSPAGE: 2DATE: 01/06/14Revision: 7

SECTION VII INSPECTION SYSTEM Page Number

Tagging, and Identification & Segregation of Parts 1Work Order Forms 1Log Book Entry 1Records / Work Order Review 1-2Record of Work 2Continuity of Insp. (Work Turnover) 2Preliminary Inspection 2Malfunction or Defect Report 2Detecting Suspected Unapproved Parts 3Materials and Parts Receiving 3-4Shelf Life 4-5Rejected or Scrapped Items 5Hidden Damage Vendor / Sub-contractor Audit 6Vendor Evaluation, Audit, Follow-up 7STS Evaluation, Audit, Follow-up 8

SECTION VIII CALIBRATION OF TESTING EQUIPMENT 1-3

SECTION IX INSPECTION FORMS AND INSTRUCTIONSWork Order (Forms #1, 1A and 2, 2A) 1-6FAA Form 8130-3, Airworthiness Approval Tag 7-9Serviceable Part Tag (Form #5) 10-12 Rejected Part Tag (Form #6) 13-15Log Book Entry 16-18Log Book Entry (Defects Found) 19-21Malfunction or Defect Report (FAA Form #8010-4) 22-23Suspected Unapproved Parts (FAA Form # 8120-11) 24-26 Shelf Life Six Month Audit (Form #9) 27-29Vendor / Sub-contractor Audit, (STS FORM #10) 30-34Structural Testing Systems Audit, (STS FORM #11) 35-37



TITLE: INTRODUCTIONPAGE: iDATE: 01/06/14Revision: 7

This Repair Station/Quality Control Manual (RSQCM) explains the internal inspection system in detail, including the continuity of inspection responsibility. It gives samples of inspection forms used and their method of execution. The manual gives a detailed explanation of the following portions of the inspection system: incoming materials, preliminary inspection, hidden damage, inspection continuity and final inspection of the article being maintained at this facility.

The general Nondestructive Testing / Inspection of products will be performed in accordance with the current Federal Aviation Regulations, current overhaul manuals, drawing packages with industry general shop practices, service bulletins, related Civil Aeronautics Manuals, technical orders, airworthiness directives or other technical data approved by the Administrator for the particular rating. This repair station will not maintain or alter any item for which it is not rated, and will not maintain or alter any article for which it is rated if it requires technical data, equipment, materials, facilities or trained personnel that are not available.

The technical library and this inspection procedures manual, required for the operation of this repair station, will be maintained in a current status at all times.

Each Key Personnel and Inspector will have read a current copy of this manual, sign and date a log, on file in the General Manager’s office, that they thoroughly understand its contents. It will also be available to other repair station personnel.

This manual has been approved by the Structural Testing Systems President and General Manager.



TITLE: MANUAL CONTROL AND REVISION SYSTEMPAGE: iiDATE: 01/06/14Revision: 7

Each manual will have a control number and an assignment entry on the record of revision page. A master list containing the manual number, location, type of media, revision status and revision date will be kept in the General Manager’s office.

The General Manager will authorize, as instructed by the President, by signature and date, when a manual is to be released for disposition to an organization. It will be recorded and logged on the master list. The General Manager and the President will authorize any changes or revisions needed to keep this manual current. They will sign and approve the Manual Acceptance Page of this manual.

The General Manager shall submit revisions to the FAA for review and acceptance by providing a letter stating the revision and providing the pages which are to be revised. Upon acceptance of this manual by the FAA, sufficient copies will be made and distributed to each manual holder deemed necessary by the General Manager. Changes made to this manual will be identified by a solid black vertical bar located on the left side of the page identifying the changes. Pages affected by the revision are noted by the date change and revision number on the revised page(s) and List of Effective Pages and correlates with the date of the revision listed on the Record of Revision page. Any maintenance / administrative actions performed under the revisions that were not found acceptable by the FAA will be reviewed, corrected and resubmitted by the President and General Manager to the FAA.

Upon receipt of a revision, each manual holder will be responsible for signing and returning the acknowledgment form (provided with the revision) to the General Manager showing the holder has revised its manual. The acknowledgement form may be signed digitally if the manual holder has such capability. The manual holder may also fax the acknowledgement form or mail the acknowledgement form to Structural Testing Systems. It is the responsibility of the manual holder to discard the obsolete manual or revised pages.

A list of effective pages will be issued with each revision so each manual can be checked and kept current.

The RSQCM Distribution list is kept in the General Manager’s office.



TITLE: RECORD OF REVISIONPAGE: iiiDATE: 01/16/17Revision: 9

Manual No. 3 Assigned to: Shop Copy

Note: Pages affected by the revision are noted by the date change on the effected page and correlates with the date of the revision listed on the Record of Revision page.

Retain this record in the manual. Upon receipt of revisions, sign the acknowledgement form and return it to STRUCTURAL TESTING SYSTEMS. Discard the obsolete manual.

Any revisions or changes to this manual must be approved by the General Manager.

Return acknowledgment form to the General Manager at:

STRUCTURAL TESTING SYSTEMS2221 Smithtown AvenueRonkonkoma, NY 11779

Revision Number Revision Date Initials & Insertion Date

Original 06/01/02 _____________

1 1/28/04 As per AC 145-9

2 07/15/07 _____________

3 05/01/09 _____________

4 05/01/11 _____________

5 05/01/12 _____________

6 06/01/13 _____________

7 01/06/14 _____________

8 05/01/14 _____________

9 01/16/17 _____________

10 _____________



TITLE: REVISION LISTPAGE: ivDATE: 01/16/17Revision: 9

Revision List:

Original (06/01/02): Complete Re-Issuance of RSM

Revision 1 (1/28/04): Changed complete manual per FAA requirement for the new FAR 145 per AC 145-9.

Revision 2 (07/15/07): Corrected miscellaneous errors in the manual and added FAA Form 8130-3, Airworthiness Approval Tag. Complete Re-Issuance of RSM.

Revision 3 (05/01/09): Corrected miscellaneous errors, address on page iii, updated revision and LOEP pages, modified responsibilities and titles in organizational structure, tools and equipment, records review, shelf life and contract facilities.

Revision 4 (05/01/11): Changed Repair Station address, updated new address on forms added pages on table of contents, corrected errors in Quality manager responsibilities, defined CHDO, change to STS form # 10, add STS form #12

Revision 5 (05/01/12): Deleted STS Form #21, Work Authorization Form. Changed STS Forms #1, 1A, 2, and 2A, Work Order Forms, to include aircraft hours, aircraft cycles, and collection information for FAR Part 121, 125, and 135 Operators General Maintenance Manuals.

Revision 6 (06/01/13): Changed Office Lay-out. Added additional office changing square footage of Office Space from 652 to 932 square feet.

Revision 7 (01/06/14): Changes include correcting typographical errors, removing outdated information. Changed STS Form #5 Rejected Part Tag to STS Form #6. Re-issued STS Form #5 Serviceable Part Tag. Changed Logbook Entry / Logbook Reject form instructions and changed the airworthiness and un-airworthiness statements. Added rooms for Radiographic operations and Shipping/Receiving changing square footage of total occupied space from 932 to 2000 square feet. Updated FAA Forms utilized within repair station. Changes are identified by a solid black vertical bar located on the left side of the page.

Revision 8 (05/01/14): Updated FAA Form 8130-2 (02/14).

Revision 9 (01/16/17): Updated shop layout, removed X-ray Vault and Darkroom layout page.



TITLE: LIST OF EFFECTIVE PAGESPAGE: vDATE: 01/16/17Revision: 9

Rev No. Section Page No. Date Action

7 Table of Contents 1 01/06/14 Changed7 Table of Contents 2 01/06/14 Changed7 Introduction i 01/06/14 Changed7 Manual Control ii 01/06/14 Changed9 Record of Revision iii 01/16/17 Changed9 Revision List iv 01/16/17 Changed9 List of Effective Pages v 01/16/17 Changed9 List of Effective Pages vi 01/16/17 Changed9 Manual Acceptance Page vii 01/16/17 Changed7 Section I, Org. Structure 1 01/06/14 Changed2 Section I, President 2 07/15/07 Changed7 Section I, G/Acct Mgr/ DOT 3 01/06/14 Changed7 Section I, G/Acct Mgr/ DOT 4 01/06/14 Changed7 Section I, G/Acct Mgr/ DOT 5 01/06/14 Deleted7 Section I, Quality Manager 5 01/06/14 Changed7 Section I, Quality Manager 6 01/06/14 Changed7 Section I, Lead Tech 7 01/06/14 Changed3 Section II, Personnel Roster 1 05/01/09 Changed4 Section II, Contract Maint. 2 05/01/11 Changed9 Section III, Main Facility 1 01/16/17 Changed9 Section III, Equipt. / Operations 2 01/16/17 Changed2 Section IV, Training 1 07/15/07 Changed7 Section V, Work at Locations 1 01/06/14 Changed7 Section V, 121 and 135 Oprs 2 01/06/14 Changed2 Section VI, Tech. Data 1 07/15/07 Changed7 Section VII, Tags, WO, LBE 1 01/06/14 Changed7 Section VII, Records, MDR 2 01/06/14 Changed2 Section VII, SUPs, Parts 3 07/15/07 Changed3 Section VII, Parts, Shelf life 4 05/01/09 Changed7 Section VII, Rejected Items 5 01/06/14 Changed2 Section VII, Vendor Audit 6 07/15/07 Changed2 Section VII, Vendor / STS 7 07/15/07 Changed2 Section VII, STS Audit 8 07/15/07 Changed7 Section VIII, Calibration 1 01/06/14 Changed2 Section VIII, Calibration 2 07/15/07 Changed7 Section VIII, Calibration 3 01/06/14 Changed7 Section IX, WO Forms Instr. 1 01/06/14 Changed5 Section IX, WO Forms Instr. 2 05/01/12 Changed5 Section IX, Sample WO Form 3 05/01/12 Changed



TITLE: LIST OF EFFECTIVE PAGESPAGE: viDATE: 05/01/14Revision: 8

Rev Section Page No. Date Action

5 Section IX, Sample WO Form 4 05/01/12 Changed5 Section IX, Sample WO Form 5 05/01/12 Changed5 Section IX, Sample WO Form 6 05/01/12 Changed2 Section IX, 8130 Form Instr. 7 07/15/07 Changed8 Section IX, 8130 Form Instr. 8 05/01/14 Changed8 Section IX, Sample 8130 Form 9 05/01/14 Changed7 Section IX, STS Form #5 Instr. 10 01/06/14 Added7 Section IX, STS Form #5 Instr. 11 01/06/14 Added7 Section IX, Sample Form #5 12 01/06/14 Added7 Section IX, STS Form #6 Instr. 13 01/06/14 Changed7 Section IX, STS Form #6 Instr. 14 01/06/14 Changed7 Section IX, Sample Form #6 15 01/06/14 Changed7 Section IX, LBE Form Instr. 16 01/06/14 Changed7 Section IX, LBE Form Instr. 17 01/06/14 Changed7 Section IX, Sample LBE Form 18 01/06/14 Changed7 Section IX, LBE Defects Instr. 19 01/06/14 Changed7 Section IX, LBE Defects Instr. 20 01/06/14 Changed7 Section IX, Sample Def. Form 21 01/06/14 Changed7 Section IX, 8010-4 Form Instr. 22 01/06/14 Changed7 Section IX, Sample 8014 Form 23 01/06/14 Changed7 Section IX, 8120-11 Form Instr. 24 01/06/14 Changed7 Section IX, Samp 8121-11 Form 25 01/06/14 Changed7 Section IX, Samp 8121-11 Form 26 01/06/14 Changed7 Section IX, STS Form #9 Instr. 27 01/06/14 Changed7 Section IX, STS Form #9 Instr. 28 01/06/14 Changed7 Section IX, Sample Form #9 29 01/06/14 Changed7 Section IX, STS Form #10 Inst 30 01/06/14 Changed7 Section IX, STS Form #10 Inst 31 01/06/14 Changed7 Section IX, Sample Form #10 32 01/06/14 Changed7 Section IX, Sample Form #10 33 01/06/14 Changed7 Section IX, Sample Form #10 34 01/06/14 Changed7 Section IX, STS Form #11 Inst 35 01/06/14 Changed7 Section IX, STS Form #11 Inst 36 01/06/14 Changed7 Section IX, Sample Form #11 37 01/06/14 Changed



TITLE: Manual Acceptance PagePAGE: viDATE: 01/16/17Revision: 9

Accepted by

President Date

General Manager Date



SECTION I

ORGANIZATIONAL STRUCTURE



SECTION: IPAGE: 1TITLE: ORGANIZATIONAL STRUCTUREDATE: 01/06/14Revision: 7

Organizational Chart

President

Quality Manager Lead Technician

Technician

General / Accountable Manager / Director of

Training




Personnel

PRESIDENT

The president is responsible for the complete overall management of the Repair Station. He is responsible for providing adequate housing and facilities. He is responsible for the financial integrity of the facility.

The duties of the President may be delegated by him as necessary. However, such delegation does not relieve him of the overall responsibilities.




GENERAL / Accountable Manager / Director of Training

The General Manager is directly responsible to the President for the overall operation of the maintenance, overhaul and repair functions of the Repair Station. He is responsible for assuring that such activities are performed in accordance with company standards, policies and procedures in concurrence with the Federal Aviation Administration's requirements.

He is responsible for directing, planning, and laying out details of inspection standards, methods and procedures used by the Repair Station in complying with all applicable Federal Aviation Regulations and Manufacturers requirements.

He is responsible for checking that the housing and facilities are adequate as the Repair Station needs change and requests such additional needs to the President.

He is responsible for checking that adequate equipment, material and competent personnel are available to conduct business under the guidelines of the repair station.

His duties will be to schedule personnel for training on an as needed basis which will include manufacturers training and / or on the job training.

It is his duty to supervise all personnel assigned to the Repair Station. It is his duty to ascertain that all inspections are properly performed on all completed work before it is released to service and that the proper inspection records and forms used by this Repair Station are properly executed.

It is his duty to collect and maintain a file on work orders and inspection forms in such a manner that the specific file pertaining to the assembly or unit can be located within a reasonable length of time.

It is his duty to maintain a current file on pertinent Airworthiness Directives FAR’s and maintain current manufacturer’s data on equipment serviced by the Repair Station.

Determine adequacy of stock and initiating requisitions for stock and materials as required by the Repair Station facility.




GENERAL / Accountable Manager / Director of Training (cont.)

Insure proper stock and material storage, control, segregation and identification of all items or units.

He is responsible for the full compliance with all applicable Federal Aviation Regulations.

He is the custodian of the company Repair Station/Quality Control Manual.

All records pertinent to training extended to personnel will be maintained by the General Manager.

Direct and coordinate the activities of all departments within the Repair Station so as to minimize delays, increase production efficiency and to assure airworthiness of the product.

Responsible to determine that all departments are expediently provided with the necessary current Manufacturers Overhaul Manuals, Service Bulletins, Airworthiness Directives and any other required technical data and assure that all pertinent publications necessary to support the Repair Station are maintained in current status.

Determine the adequacy of the tools and merchandise on hand for the various functions by the Repair Station. Maintain all shop equipment and tools in a working condition and within calibration standards traceable to NIST.

Maintain the premises of the Repair Station in a clean and orderly manner. This is inclusive of work functions performed at other facilities away from the home base.

The duties of the General Manager may be delegated by him to any qualified person as he deems necessary, however, such delegation does not relieve him of his overall responsibility.




Quality Manager

The Quality Manager is responsible to the General Manager for the overall operation of the Repair Station.

It is the duty of the Quality Manager to ascertain that all inspections are properly performed on all work and is completed before it is released to service and that inspection reports and forms used by the Repair Station are properly executed.

It is his responsibility to insure that no defective or unairworthy parts are installed in any component or unit released by the Repair Station.

He is responsible for the final acceptance of all incoming materials.

He is responsible for Preliminary, Hidden Damage, Inspection Continuity and Final Inspections of all items processed by the Repair Station.

He is responsible for the tagging and identification of all parts.

He is responsible for the safe and final release of all work performed by the Repair Station, at the Repair Station or away.

He is responsible for accomplishing customer Vendor Audits.

He is responsible for making periodic checks on all inspection tools and the calibration of precision test equipment. He will maintain a system on keeping records of checks and calibration of inspection tools and precision test equipment, with proper paperwork showing traceability of calibration standards to NIST, taking steps to insure that the established check periods are not exceeded.

He is responsible for the proper execution of the malfunction or defect report when required. This report will be filed in accordance with the procedures outlined in chapter VII of this manual.

He is responsible for the preparation and proper execution of all documents executed by the Repair Station.




Quality Manager (cont.)

He is responsible for the final acceptance of all incoming material including new parts, and supplies.

It is his duty to see that rejected and unserviceable parts, after proper marking, are returned to the owner

All duties of the Quality Manager may be delegated by him to any qualified individual as he deems necessary, however, such delegation does not relieve the Quality Manager of the overall responsibility.




LEAD TECHNICIAN

The lead technician is directly responsible to the General Manager for the overall operation of the Repair Station.

It is his responsibility to plan, direct, lay out and coordinates the activities of the Station so as to minimize delays, increase production and efficiency.

He is responsible for training and assisting his subordinates in proper procedures, methods and practices to be followed in each respective duty.

He is responsible for making available to all, the necessary manufacturer’s manuals, service bulletins, airworthiness directives and any other required technical data.

He is responsible for maintaining all shop equipment and tools in a serviceable and working condition.

He is responsible for assigning job tasks, supervising the work schedule of subordinates, and ascertaining that all necessary work records are properly executed by the responsible technician.

He is responsible for maintaining the premises of the Repair Station in a clean and orderly manner.

He is responsible for the proper handling of all parts while in repair process.

He is responsible for the preservation of all units or parts during the process through the shop and after work is completed.

He is responsible for initiating requisitions for stock and materials as required.

He is responsible for all stock storage, control, and segregation of equipment supplies.

All duties of the lead technician may be delegated by him to any qualified assistant as he deems necessary, however, such delegation does not relieve him of the overall responsibility.



SECTION II

PERSONNEL ROSTER



SECTION: IIPAGE: 1TITLE: PERSONNEL ROSTERDATE: 05/01/09Revision: 3

The Personnel Roster is on file in the General Manager’s Office.

The General Manager is authorized to make changes to the Personnel Roster. The Quality Manager is authorized as an alternate when the General Manager is not available.

Within 5 business days of the change, the roster will reflect changes caused by termination, reassignment, and change in duties, scope of assignment or addition of applicable personnel.

When the repair station has a requirement for a technician to become a repairman, the following application and surrendering procedures shall be complied with.

Application Procedure:

1. The technician must be eligible per the requirements of part 65.101 of the Federal Aviation Regulations.

2. The technician’s eligibility requirements shall be reviewed by the General Manager to ensure he meets the limitations of the rating. The General Manager will then a issue a letter to the FAA stating the eligibility of the technician and requesting that the Technician apply for the repairman’s certification.

3. The technician will fill out application form 8610-2 then give the application and letter of request to the FAA District Office.

4. Upon certification the repairman shall be responsible for the duties invoked by part 65.103 and shall display it in the immediate area where he works and have it available for review by the FAA or any other official requiring to inspect it.

Surrendering Procedure:

1. If the employee is terminated or deemed necessary to be removed from the requirements of a repairman of the repair station, the repairman who is rescinding his certificate must write a letter to the FAA District Office stating the reason why he is turning in his certificate and sign the letter.

2. The repairman must then be turn in his repairman certificate and the letter to the FAA District Office.



SECTION: IIPAGE: 2TITLE: PERSONNEL ROSTERDATE: 05/01/11Revision: 4

Maintaining and Revising Contract Maintenance Information ( Non-Certificated Personnel )

In the event that Structural Testing Systems can not perform a maintenance function in any capacity for which it is rated and has the need to employ a Contract Maintenance Facility, the Quality Manager shall perform an Audit of the facility for consideration in accordance with the Vendor Audit requirements outlined in Section VII of this Manual.

If the contract maintenance facility and /or the personnel performing the maintenance at that facility are deemed to be non-certificated, then the General Manager shall contact the FAA District Office to approve the maintenance functions of the contract maintenance facility. The General Manager will provide the results of the Audit and request the approval in writing stating the reason for the need of the contract maintenance facility.

When more than one approved contract maintenance facility is used by STS, the General Manager will maintain a list in his office of each contract maintenance facility. This list shall include the type of certificate and ratings, if any, held by each facility and any limitations rendered.

Each contract maintenance facility shall be audited semi-annually in accordance with the Vendor Audit requirements outlined in Section VII of this Manual. The Audit results shall be provided to the Certificate Holding District Office (CHDO) upon completion of the Audit and updates and revisions shall be submitted to the CHDO as well to determine if the current approval is still applicable or if a renewal of the approval status must be accomplished.



SECTION III

DESCRIPTION OF OPERATIONS



SECTION: IIIPAGE: 1TITLE: DESCRIPTION OF OPERATIONSDATE: 01/16/17Revision: 9

Structural Testing Systems Inc. occupies an area of ExcelAire. This area is located at 2221 Smithtown Avenue, Ronkonkoma, New York, at Long Island MacArthur Airport, encompassing a total of 1452 square feet of space.

Main Facility – (1452 Sq. Ft.)

The offices are lighted with fluorescent light fixtures and air conditioning system for cool and heat. There are fire extinguishers and smoke detectors placed in key locations throughout the offices.

A – Storage / Cable & Phone Lines B – Administration / Technician Office

C – Accounting and Administration D – Break room

E – Shipping / Receiving F – Stock and Equipment Storage


FAA CERTFICATE NUMBER ES1R124KSECTION: IIIPAGE: 2TITLE: DESCRIPTION OF OPERATIONSDATE: 01/16/17Revision: 9

Description of Tools and Equipment used to perform Maintenance

Equipment (which includes tooling) used to perform maintenance shall be handled with care and stored in a clean, dry location and protected from the elements in accordance with STS NDT Quality Procedures. Storage and handling of Liquids, gels, chemicals and film shall meet the requirements of the manufacturer. All STS technicians shall be trained in accordance with STS NDT Quality Procedures to use equipment on site at STS and away from the repair station and technicians shall follow the procedures outlined in SECTION VIII of this manual for calibration and leased equipment requirements.

If equipment, tools, or materials other than those recommended by the manufacturer are used, the equivalency of those items shall be determined by meeting the specifications and / or equivalency of the test procedure (i.e. Airframe or Engine manufacturer etc.) If equivalency standards do not exist, then the requirements outlines in STS NDT Quality Procedures shall be followed. STS will use equipment concurrent with its Repair Station Rating.

Operations

All forms required in the operation of the repair station are listed in INSPECTION FORMS AND INSTRUCTIONS Section IX.

Upon receipt of a work request for work covered by the Repair Station Certificate, the Maintenance Department will issue to Structural Testing Systems Inc. Repair Station a Purchase Order to authorize the work to be accomplished. A work order (Forms #1 or #2) will be generated with inspection instructions along with applicable forms, to assure proper inspection for the work involved. The number of additional forms used will be identified on the work order. The printed and numbered purchase order form will be retained in the work order folders located in the General Manager’s office.

A logbook entry will be maintained in the General Manager’s office for recording each work order in numerical order, identifying the customer, the product for which it was issued along with the serial number, special instructions and the work accomplished.

It will be the responsibility of the General Manager to assure that proper supplemental instructions are furnished to assure inspection and testing of the product involved.

A list of authorized inspector’s signatures will be located in the General Manager’s office.



SECTION IV

TRAINING PROGRAM



SECTION: IVPAGE: 1TITLE: TRAINING PROGRAMDATE: 07/15/07Revision: 2

For All Training to Include Air Carrier Training for Part 121 and Part 135 Operators, Refer to Structural Testing Systems Repair Station Training Manual



SECTION V

PROCEDURES GOVERNING WORK AT ANOTHER LOCATION



SECTION: VPAGE: 1TITLE: PROCEDURES GOVERNING WORK AT ANOTHER LOCATIONDATE: 01/06/14Revision: 7

Structural Testing Systems, Inc. will provide NDT service for its customers on an on-call basis at a place away from the repair station. In these cases a determination by the general manager will be made of facilities, housing, necessary tools, equipment, and supplies to insure the FAA and the customer that all FARs are being complied with. Structural Testing Systems, Inc. can only provide this service for work for which the repair station is rated.

The General Manager will ensure that the article to undergo NDT inspection and the work force will be in an area safe for the work to be performed and that they will be protected from the elements. The General Manager will be responsible for providing all the necessary manpower, work forms, technical data, tools, and equipment necessary for the accomplishment of the maintenance. The General Manager will establish a system of communications between the field force and the repair station by telephone, email or fax. Work order numbers will be assigned and initiated by the General Manager. This may be delegated to the Lead Technician or assigned representative.

Technical data will be acquired from the customer by the following procedure.

1. When the customer requests STS to perform NDT, the technician will inform the customer that current technical data must be provided to ensure the proper NDT task can be performed.

2. Upon arrival or prior to arrival at the facility, the customer will provide the technician with a current copy of the technical data needed to perform the NDT task.

3. The customer will also, provide documentation stating that the technical data provided is current. Such data may be a listing of revisions from the manufacturer’s publications department, an internal publications audit document or similar. This data will be kept on file with the work order package.

The work will be performed in accordance with Inspection Procedures outlined in this manual. All records of work and inspection records will conform to the recording procedures in this manual. All technicians must have a current Structural Testing Systems RS/QC Manual readily accessible to them when performing work away from the repair station. This may be in the form of a hard copy, on magnetic/digital media, or accessible on the internet.



SECTION: VPAGE: 2TITLE: PROCEDURES GOVERNING WORK AT ANOTHER LOCATIONDATE: 01/06/14Revision: 7

WORK PERFORMED FOR TITLE 14 CFR Part 121 and 135 OPERATORS Structural Testing Systems with FAR 145.205 and the applicable portions of FAR’s, when performing Nondestructive Testing for FAR 121, 125, 129, and 135 operators will perform the work in accordance with the manual of the certificate holder concerned as follows:

Structural Testing Systems will request that the carriers attach or include in their purchase orders, copies of the section, page or pages of the carrier’s GMM/GOM Procedures that cover the requirements for performance of the Nondestructive Testing that Structural Testing Systems is rated to perform.

This will be noted in the space(s) provided on STS Work Order Forms #1, and #2.



SECTION VI

ESTABLISHING AND MAINTAININGCURRENT TECHNICAL DATA



SECTION: VIPAGE: 1TITLE: ESTABLISHING AND MAINTAINING CURRENT TECHNICAL DATADATE: 01/06/14Revision: 7

The currency of technical data is noted by a “Technical Publications Revision Status Verification” page located in the front of each technical publication. There is one copy of each technical publication and they are located in a secure area of the STRUCTURAL TESTING SYSTEMS facility. Software used for component testing has a “Technical Publications Revision Status Sticker” located on the cover of the software package. The original copy is kept in a secure area of the Structural Testing Systems facility.

Quality Control checks for the currency of technical publications and testing software shall be accomplished as follows.

1. Every six months General Manager or his designee shall contact the manufacturer’s publication representative by phone, fax, email, or internet website to ensure that the status of the technical data is current.

2. The publication representative shall provide a data sheet showing the current status of the technical data.

3. The data sheet shall be kept in the front of each technical manual.



SECTION VII

INSPECTION SYSTEM



SECTION: VIIPAGE: 1TITLE: INSPECTION SYSTEMDATE: 01/06/14Revision: 7

TAGGING AND IDENTIFICATION OF PARTS

All parts or units will be properly identified / tagged by the customer prior to arrival to STS for NDT inspection. The customer’s tag will be appropriately completed and attached to units or parts for means of identifying a part, its owner and any comments. FAA Form 8130-3, Airworthiness Approval Tag, and Serviceability Parts Tag STS Form #5, will be attached to completed units which have received final inspection and are found serviceable. Rejected Parts Tag (STS Form #6) will be attached to completed units which have received final inspection, are found to be rejected parts, and are waiting to be returned to the customer. The FAA Form 8130, Serviceability Parts Tags, and Rejected Parts Tags will be appropriately completed to identify the part or unit and status. The Rejected Parts Tag will include the reason for rejection.

FAA Form 8130’s, Serviceability Parts Tags, and Rejected Parts Tag will be properly executed and signed by an authorized individual as specified in Chapter IX of this manual. FAA Form 8130’s, Serviceability Parts Tags, and Rejected Parts Tags will be made part of the appropriate work order file maintained by the Repair Station. FAA Form 8130’s, Serviceability Parts Tags, and Red tags will remain attached to parts or units being returned to customers.

WORK ORDERS (FORM #1 AND #2)

The company work order form will be identified by a work order number, the customers name, date and appropriate identification required to identify any item or unit that will be utilized by this Repair Station. This work order will contain all work that is to be accomplished in sufficient detail so that it will be readily understandable to the assigned technician. Space will be provided for the signature of the technician who accomplished the work.

LOG BOOK ENTRY

After completion of work, the technician who performed the work will print a Log Book Entry for the customer using electronic media. The technician will provide information on the Log Book Entry as described in Section IX.

RECORDS / WORK ORDER REVIEW

Upon the technician’s completion of the work order, the technician will give the work order file to the Quality Manager at the STS facility. The Quality Manager will review the work order file




RECORDS / WORK ORDER REVIEW CONT’D

to ensure that the Log Entry and Work Order is annotated as outlined in Section IX, ensure that the billing is accurate and identify any clerical or grammatical discrepancies. If there are any errors, the Quality Manager will return the file to the technician for corrections.

Once the review is accomplished, errors (if any) are corrected and the billing is complete, the General Manager will accomplish a follow-up review prior to filing the work order. If any additional errors are identified, the General Manager will return the file to the Quality Manager for correction.

RECORD OF WORK

A copy of the work order will be kept on file in the Administrative Office as a permanent record for all work accomplished for a minimum of 2 Years. The work order will contain the discrepancy reported, a description of the work accomplished and the signature of the technician and inspector as appropriate who accomplished the work.

CONTINUITY OF INSPECTION RESPONSIBILITY (WORK TURN-OVER)

When more than one shift is working, or if the need arises for an unfinished job to be completed by a different technician, all means shall be exercised to ensure pass down / turn over of the work assignment. A written status report of inspection progress will be provided by each of the technicians leaving the job before completion of a project to assist the succeeding technician.

MALFUNCTION OR DEFECT REPORT

If a defect or malfunction is found that could result in an imminent hazard to flight, the Repair Station will use the most expeditious methods at hand to inform the FAA. This information will be submitted on FAA Malfunction or Defect Form 8010-4. Such report will completely describe the nature of the defect or malfunction. The Malfunction or Defect Report will be completed in accordance with FAR 145.63(a)(b) & (c) and will be reported within 72 Hours. In cases where the filing of such reports my result in a situation prejudicial to the interest of the Repair Station, each case in question will be reported to the FAA. If the Repair Station performs work for an Air Carrier, the Air Carrier representative will be notified in person or by phone and given a copy of the Form 8010-4 within 72 hours. This will be accomplished by the General Manager.




DETECTING AND REPORTING SUSPECTED UNAPPROVED PARTS (SUPs)

All parts received by Structural Testing Systems for Nondestructive Testing will be visually inspected to identify any SUPs. AC 21-29B or the latest revision should be used as a guide in both detecting any SUPs and reporting them to the FAA. Refer to Chapter IX of this manual for an example of FAA Form 8120-11, SUSPECTED UNAPPROVED PARTS NOTIFICATION and instructions on how to complete it as outlined in Section IX of this manual.

The following may be indications of SUPs:

Two parts (i.e. wheel halves) with the same Serial numbers. Quoted or advertised price that is significantly lower than the price quoted by other

distributors and/or suppliers of the same part Delivery schedule that is significantly shorter than that of other distributors and/or

suppliers (when stock is in short supply). Distributors and/or suppliers inability to provide substantiating documentation that the

part was produced pursuant to FAA Approval.

Report any SUPs to the General Manager for investigation. Suspect Parts will be locked in the General Manager’s office until a course of action has been determined. All STS employees shall be trained in detecting SUPs in accordance with Structural Testing Systems Repair Station Training Manual.

MATERIALS AND PARTS RECEIVING POLICY / PRELIMINARY INSPECTION

The General Manager or his designee are responsible to see that all incoming materials / NDT materials, hardware, parts, components, equipment and other products procured for use by the Repair Station are subject to a receiving inspection. To assure conformance, received items will be visually inspected for shipping damage, contamination. Documents will be inspected for proper traceability back to the appropriate agency that shipped or manufactured the item. Parts / Components for NDT inspection shall be inspected proper documentation, identification, traceability, conformity, acceptable quality, state of preservation and if any Airworthiness Directives or Service Bulletins are required for the item.




MATERIALS AND PARTS RECEIVING POLICY: Cont’d

The General Manager or his designee will be responsible for the training of all Structural Testing Systems personnel in the methods of receiving and inspecting all incoming material or items in accordance with Structural Testing Systems Repair Station Training Manual. Any products that fail to conform to approved receiving methods as stated in this Manual will be red tagged as unserviceable, a description of the discrepancy will be annotated on the red tag and the item will be given to the General Manager or his designee. To preclude the item from being used, the General Manager or his designee will lock the item in the General Manager’s office for quarantine. The item will be repacked and shipped back to the vendor to resolve the discrepancy. Particular attention should be given to Suspected Unapproved Parts (SUPs). Refer to Detecting and Reporting Suspected Unapproved Parts (SUPs) in this section.

All liquid penetrant and magnetic particle spray cans, ultrasonic gels, radiographic film development chemicals and other materials having shelf life shall be identified by material control labels showing date of shelf life as established by the manufacturer. Technicians will dispose of any materials found in the shop or store rooms without such identification or with expired shelf life.

SHELF LIFE

A Shelf Life item is an item subject to deterioration or which possesses unstable characteristics to the degree that a storage period must be assigned to assure that an item will perform satisfactorily in service. This information is conveyed through the military specification, the product manufacturer’s specification or the “CP” (Consumable Products) document. Shelf life items are of two Categories: -- Type I – Non-extendible period of Shelf Life; Type II – may be extended after satisfactory completion of the appropriate processing requirements in accordance with STS Quality Procedures or the manufacturer’s recommendations.

Manufacturers may list a manufacturing date, which is printed on the material container. This date is used as a guideline to determine if the material may still be used.

The General Manager or delegated personnel will maintain a listing of Shelf Life items. The listing will include a description of the material and the storage location. Any new material that is not already included in the database will be added.




SHELF LIFE (Cont,)

When Shelf Life items are received, a Shelf Life label will be affixed to the container. The Shelf Life requirement should be found on the incoming paperwork documents. If the life requirement is not found on the incoming paperwork, the applicable manufacturer will be contacted for a shelf life recommendation. The Shelf Life expiration date will be entered on the label. The material is then put in stock and the Batch #, Part #, name and date put in stock is annotated on STS Form # 9 which is contained in Chapter IX of this manual.

A six-month audit of the Shelf Life items contained in the stores area will be conducted by the General Manager or delegate to check for expired Shelf Life. The audit will be recorded on a Shelf Life audit log, which will be kept in the shelf life area. This log will be maintained by the General Manager or delegated personnel. If expired material is found, the date removed from stock will be annotated on STS Form # 9 and the material will be properly segregated and disposed of.

All personnel will be responsible for verifying that Shelf Life material drawn from stock has not expired. All personnel will be responsible for verifying that Shelf Life material has not expired prior to subsequent usage.

Expired Shelf Life items will be segregated from current material to prevent inadvertent use. The General Manager or delegated personnel will be responsible for disposing the expired items in accordance with established Environmental, Health and safety procedures.

PROCEDURES FOR REJECTED OR SCRAPPED ITEMS

When items are determined by Structural Testing Systems or the customer to be Beyond Economical Repair or returned As-Is, the work order and Rejected Parts Tag shall include the reason for rejection. A Rejected Parts Tag, STS Form #6, will be attached to the item and returned to the customer.




HIDDEN DAMAGE INSPECTION

Before this repair station starts work, all units and components known to have been involved in an accident will be given a thorough inspection for possible hidden damage. Hidden damage inspections may also be generated by noted discrepancies during the inspection process. When a hidden damage inspection is required, it will be accomplished in accordance with the specific instructions provided by the applicable manufacturer of the article. The inspection will include areas adjacent to or likely to have been affected by the obviously damaged unit or component.

VENDOR/ SUB-CONTRACTOR AUDIT: Initial Audits

Structural Testing Systems will audit vendors and sub-contract agencies (companies) who perform Nondestructive Testing on aircraft or components as requested by Structural Testing Systems. This audit may be conducted by mail, telephone, fax, email, physical evaluation of the vendor or other electronic means of communication and will ascertain that:

a. The Vendor / Sub-contractor is in compliance with this manualb. Facilities, equipment and personnel are qualified and technical data and

resources are adequate for the work being performed.c. NDT personnel are qualified and record keeping procedures are adequated. Procurement of materials and their processing sufficiently meet the

requirements of the original manufactures standardse. Drug Testing implementation is in effectf. All additional information requested on STS Form # 10 is obtained.

All Vendor / Sub-contractors shall be audited annually to verify that the information on file at STS is current.

Vendor Audit Evaluation, Discrepancies and Corrective Action

Audits will be conducted / evaluated by the General Manager or his delegate. Any discrepancies will denote annotation on STS Form # 10. The actual findings of the discrepancies will be communicated to the applicable agency for immediate corrective action using a letter format on STS Company Letterhead and will be emailed, faxed or mailed to the agency if applicable. The agency will then submit in writing on their company letter head actions taken to clear the discrepancy. This letter will be held with the vendors’ audit file as a permanent record of compliance.




Vendor Audit Follow-up

Every six months, the General Manager will review Audits that have taken place during the current calendar year to ensure that a resolution has been found to any discrepancy. Any Vendor / Sub-contractors who have not responded or resolved the discrepancies found during the previous six months will be contacted to correct the discrepancies. If the discrepancies are not resolved upon the next Audit of the agency, then the agency will be notified in writing using STS Company Letterhead and electronic media of their removal from Structural Testing Systems’ list of approved Vendor / Sub-contractors until the discrepancies can be resolved.

Structural Testing Systems Audit Evaluation for Discrepancies and Corrective Action

Structural Testing Systems will take corrective action on any deficiencies to remedy any undesirable situation related to the repair station. These deficiencies can be two types and are only addressed if the deficiency is committed by a person authorized to perform work for the Repair Station.

Type 1 - If a deficiency is caused by Structural Testing Systems and found before an article is returned to Service, the deficiency shall be corrected using the Structural Testing Systems Audit Program as outlined in Section VII of this manual. The type of deficiency is treated as an in-house discrepancy, corrective action and audit and does not require notification to any outside agencies.

Type II - If a deficiency is found after an article is returned to service, the General Manager or his designee will notify the CHDO ( FAA District Office) and the owner operator of any potential problems and recall any unairworthy product as outlined in Section VII of this manual, Structural Testing Systems Audit Program . The article will also be reported to the Suspected Unapproved Parts (SUPs) Program Office, in accordance with Section VII of this manual, Detecting and Reporting Suspected Unapproved Parts (SUPs). Additionally, the deficiency shall be corrected using the Structural Testing Systems Audit Program as outlined in Section VII of this manual.




Structural Testing Systems Audit Program

Audits will be conducted / evaluated by the General Manager or his delegate whenever a Type I or Type II deficiency occurs at Structural Testing Systems. The objective of the investigation is to determine the Root Cause of the deficiency, to take corrective action as applicable and to prevent a recurrence of the same or similar problem. Any discrepancies will denote annotation on STS Form # 11.

The actual findings of the discrepancies and any product requiring recall will be communicated to the applicable agency within 72 hours for immediate corrective action using a letter format on STS Company Letterhead and will be emailed, faxed or mailed to the agency if applicable. This letter will be held in the Structural Testing Systems Audit file as a permanent record of compliance. Corrective action will be addressed not to exceed 30 days from the date of the discrepancy on STS form # 11.

Structural Testing Systems Audit Follow-up

Every six months, the General Manager will review the Structural Testing Systems Audit Program file for Audits that have taken place during the current calendar year to ensure that a resolution has been found to any discrepancy. Any open corrective action items or unresolved discrepancies found during the previous six months will be re-addressed to correct the discrepancies. If any discrepancies or corrective action items are not resolved at this time, then the appropriate agency will be notified in writing using a letter format on STS Company Letterhead and will be emailed, faxed or mailed to the agency if applicable. The open discrepancies or corrective action items will be audited on the next six month audit interval.



SECTION VIII

CALIBRATION OF MEASURING AND TESTING EQUIPMENT



SECTION: VIIIPAGE: 1TITLE: CALIBRATION OF MEASURING AND TESTING EQUIPMENTDATE: 01/06/14Revision: 7

This Repair Station will maintain a record to assure that all equipment is kept within the manufacturer’s tolerances. Records of the test and calibration of the equipment along with the methods and time periods used, will be kept on file for two years or as required by the FAA.

Documentation of equipment listing, which includes Item, Model, Part Number, Serial Number and Calibration dates may be kept on magnetic media (i.e. computer hard drive) providing a hard copy is attainable for inspection or review.

All equipment will be identified, by means of engraving or a sticker, in order that the record log will reflect the last test of calibration for each piece of precision equipment. Approved calibration facilities use a data sticker, which they attach to the equipment calibrated, with the pertinent information.

Equipment will be re-inspected as called out on the Test Calibration Log. If the records show the item under test is out of calibration during test, equipment inspection will be decreased by 1/3. If an item under test shows that after 3 inspection cycles there is no calibration required, the re-inspection cycle can be ascertained.

Equipment test frequency may be extended up to 5 years based upon four (4) consecutive satisfactory calibration cycles completed with no adjustments necessary by the metrology agency. This extension shall be verified and approved by the FAA prior to implementation.

EQUIPMENT CALIBRATION RECORDS

A master Test Equipment Inspection record will be originated by the General Manager for each piece of test equipment. The Records shall be kept in the administration office. Record information shall include (as applicable):

Calibration Log:1. Structural Testing Systems Equipment Number2. Mfr./Part Number/Serial Number3. Nomenclature / Description4. Calibrated by / Date5. Calibration Due6. Calibration Interval




Equipment Test Record Sheet:1. Structural Testing Systems Equipment Number2. Mfr./ Part Number/Serial Number3. Nomenclature4. Date Acquired5. Method of Inspection6. Measurement Standards7. Calibrated By / Date8. Calibration Due9. Work Performed / History10. Status

Calibration Label:1. Equipment Number2. Calibration Date3. Calibration Due4. Serial Number5. Inspected By

EQUIPMENT CALIBRATION PROCESS

Each unit of equipment, while in active service, shall be subjected to inspection and calibration (as applicable) by Structural Testing Systems or a contracted agency using Equipment Standards traceable to the National Institute of Standards and Technology, at intervals established by Structural Testing Systems or on recommendation from the original manufacture. All test equipment shall be tested not to exceed the due date indicated on the calibration label.

All test equipment identified as standards are maintained using the same systems and procedures as other equipment.

Re-certification will be performed either by the original supplier or by a qualified and certified laboratory, using masters traceable to the National Institute of Standards and Technology. A file of certificates is maintained at Structural Testing Systems. These standards, however, are not to be used for production testing.

During calibration and re-certification of test equipment, the actual readings shall be compared to the normal readings. When an out of tolerance condition exists, the re-certification inspector shall note such condition exists and forward this information to the




EQUIPMENT CALIBRATION PROCESS: Cont’d

General Manager for review. This information shall include the serial number of the equipment, the date of last calibration, and the out of tolerance readings. It shall then be determined if this out of tolerance condition is significant enough to notify the user of the product of such test equipment. If the test equipment is removed from service, it will be tagged appropriately with the discrepancy and segregated so that it will not be used for return to service items.

Equipment pertinent to the maintenance of the articles is distributed throughout the facility. When the use of equivalent equipment is involved, the determination of equivalency will be the primary responsibility of the repair station in accordance with HBAW 00-20A dated 12-04-00. A list of all equipment used for maintenance of the articles is kept in the General Manager’s office.

The leasing of special equipment is the responsibility of the General Manager. Leased equipment is based upon manufacturer’s specifications and / or equivalency and shall be traceable to NIST. The Inspection Record Book located in the inspection department contains the record of all equipment used to maintain the articles.

Equipment that does not require calibration is labeled as “Shop Aid” or “Reference Only”.

Employee owned tools must meet the same calibration criteria as Structural Testing Systems owned tools.

All equivalent equipment, leased equipment and employee tools are maintained with the same system and procedures as Structural Testing Systems equipment.



SECTION IX

SAMPLES OF INSPECTION FORMS AND INSTRUCTIONS FOR COMPLETION



SECTION: IXPAGE: 1TITLE: SAMPLES OF INSPECTION FORMS AND INSTRUCTIONS

FOR COMPLETIONDATE: 01/06/14Revision: 7

WORK ORDER (STS FORM #1 or 1A and #2 or 2A)

1. PURPOSE

The work order STS Form #1 or 1A will be used to record the work control number and pertinent information relative to the customers work requirements. The work order form will also reflect the customer’s name, date and job description of the work to be accomplished. Additionally the form provides a space for recording discrepancies found during inspections and the initial or signature of the authorized individual who accomplished the work.

2. RESPONSIBILITY

STS Form #’s1 or 1A and 2 or 2A will be initiated by the General Manager, Lead technician, or assigned representative, who will note the date, customer name, work order number, registration number of aircraft or part and a description of the job/work to be accomplished.

A. Discrepancies The individual noting the discrepancy will record discrepancies found during inspection in the appropriate block.

B. Signature Spaces are provided for the signature of the authorized individual who accomplished the work.

C. Work Order Form Control Upon completion of the job, the technician will note on the bottom right hand corner of the sheet, the number of sheets that make up the complete work order. For Example: Sheet 1 of 4, Sheet 2 of 4, etc.

Note: STS Form #2 or 2A will be used as a supplement work sheet to STS form #1 or 1A when additional space is required.





WORK ORDERSTS FORM #1 and 1A or #2 and 2A

1. P.O. Enter PO #2.* Work Order Number Enter Work Order Number3. Company Enter Name of Customer4. Facility Enter facility location5.* Aircraft Enter make/model/series

(If part fill out 5a)

6.* Registration Number Enter registration number of aircraft (If part enter part # in 6a)

7.* Serial Number Enter serial number of aircraft (If part enter part’s serial # in 7a)

8. ACFT Hours Enter the current aircraft hours9. ACFT Cycles Enter the current aircraft cycles10. Work Started Date Enter date work started11. Work Completed Date Enter date work completed12.* Item Enter item # (i.e. 1, 2, 3,)13.* Inspection Description Describe inspection to accomplish 14.* Discrepancy Enter Yes or No if discrepancy found during inspection.

15.* Inspector’s signature Enter signature of Authorized individual who performed the work.

16. Form 8130-3 Enter Yes or No if Form 8130-3 was issued.17. Log entry Enter Yes or No for log entry.18. GMM / GOM Procedures Check appropriate box, Yes, No, N/A19. Inspection performed at FAR 145 Check appropriate box, Yes or No 20. GMM/GOM Available Check appropriate box, Yes, No, N/A21.* Remarks/Discrepancies Noted Remarks and discrepancies will be noted in this

Section.

22.* Sheet ___ of ___ Complete this item

* Applicable for completing STS Form #1A or 2A





WORK ORDERSAMPLE COPY OF STS FORM #1





WORK ORDER SAMPLE COPY OF STS FORM #1A





WORK ORDERSAMPLE COPY OF STS FORM #2



SECTION: IX PAGE: 6TITLE: SAMPLES OF INSPECTION FORMS AND INSTRUCTIONS


WORK ORDERSAMPLE COPY OF STS FORM #2A





FAA Form 8130-3, Airworthiness Approval Tag (Parts Returned To Service)

1. PURPOSE

FAA Form 8130-3, Airworthiness Approval Tag is to identify acceptable parts that are returned to the customer based on inspection findings.

2. DESCRIPTION

FAA Form 8130-3 is printed on a white card stock or may be computer generated for local reproduction but must duplicate the original Government printed form.

NOTE: A separate Form 8130-3 shall be used for each component which is returned to service.





PROCEDURES FOR COMPLETING FAA Form 8130-3, Airworthiness Approval Tag

1. Approving National Aviation Enter United States (May be Pre-Printed)Authority / Country

2. FAA Form 8130-3, No Entry required (Pre-Printed)Airworthiness Approval Tag

3. Form Tracking Number Enter Structural Testing Systems Work Order Number4. Organization Name and Enter Structural Testing Systems, Address

Address

5. Work Order/Contact/Invoice Enter Structural Testing Systems Work Order Number and CustomersNumber Purchase Order Number

6. Item Enter a name of the product

7. Description Enter a name or description of the product

8. Part number Enter part number of the product

9. Quantity Enter the quantity of each described product

10. Serial Number Enter serial number of each product

11. Status / Work Describe status of the product, i.e. newly manufactured, repaired, in-service, etc.

12. Remarks Enter Tech. data, type inspection, results, STS Repair Station # and remarks

BLOCKS 13a TRHU 13e ARE LEFT BLANK FOR ITEMS RETURNED TO SERVICE

14a. Return to Service Check “Other” since the work was accomplished IAW data provided in Block # 14a

14b. Authorized Signature Enter signature of authorized individual performing inspection for the repair station.

14c. Approval / Certificate number Enter Structural Testing Systems Repair Station number

14d. Name (Typed or Printed) Type or Print the name of the individual identified in block # 14b.

14e. Date Enter the date the form is signed and the product is returned to service.





SAMPLE COPY OF FAA Form 8130-3, Airworthiness Approval Tag


FAA CERTFICATE NUMBER ES1R124KSECTION: IXPAGE: 10TITLE: SAMPLES OF INSPECTION FORMS AND INSTRUCTIONS


SERVICEABLE PART TAG ( STS FORM #5)

1. PURPOSE

Serviceable Part Tag, Form #5 is used to identify serviceable parts that are returned to the customer based on Inspection findings.

2. DESCRIPTION

Form #5 is printed on yellow card stock with provisions for recording components identification and inspection method utilized to determine serviceability.

NOTE: In the case of large quantities of serviceable parts being returned to customer, parts will be placed in large container marked "SERVICEABLE PARTS" and returned to customer.





PROCEDURE FOR COMPLETING SERVICEABLE PART TAG

STS FORM #5

1. Item Description Enter item description

2. P/N Enter part number of item

3. S/N Enter serial number of item

4. Manufacturer Enter name of manufacturer if available

5. Remarks Enter technique part was inspected IAW (i.e. Inspected IAW STS QP-04)

6. Inspection Method Enter the method of inspection (i.e. Eddy Current)

7. Customer PO Enter the Purchase Order number provided by customer.

8. W/O # Enter STS work order number

6. Date Enter date of serviceability

7. Authorized Signature Insert signature of authorized inspector





SAMPLE COPY OF SERVICEABLE PART TAG

STS FORM #5

SERVICEABLE PART TAG

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#5

ITEM DESCRIPTION

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CUSTOMER P.O. W.O. #

DATE AUTH. SIGNATURE

(Actual Form Color is Yellow)





REJECTED PART TAG ( STS FORM #6)

1. PURPOSE

Rejected Part Tag, Form #6 is used to identify rejected parts that are returned to the customer based on Inspection findings.

2. DESCRIPTION

Form #6 is printed on red card stock with provisions for recording components identification and reason for rejection.

NOTE: In the case of large quantities of rejected parts being returned to customer, parts will be placed in large container marked "REJECTED PARTS" and returned to customer. All other rejected parts not required by customer will be placed in a container marked "REJECTED PARTS" and scrapped.





PROCEDURE FOR COMPLETING REJECTED PART TAG

STS FORM #6

1. Item Description Enter item description

2. P/N Enter part number of item

3. S/N Enter serial number of item

4. Reason for rejection Briefly describe reason for rejection

5. W/O # Enter work order number

6. Date Enter date of rejection

7. Inspector Insert signature of authorized inspector





SAMPLE COPY OF REJECTED PART TAG

STS FORM #6

REJECTED PART TAG

STS

Form

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W.O. #

DATE AUTH. INSP.

(Actual form color is Red)





LOG BOOK ENTRY

1. PURPOSE

Permanent Record Entry is required when a log book entry is required to reflect the inspections accomplished by Structural Testing Systems Inc.

2. DESCRIPTION

Permanent Record entry will be printed on Company Letterhead using electronic media, stating the inspection(s) performed, inspection results, and provisions for recording WO#, Date, Signature, Aircraft Total Time, etc.

The log entry may be printed on a sticky label providing the STS logo is located in the top left corner of the entry.





PROCEDURE FOR COMPLETINGSTS LOG BOOK ENTRY

1. Customer Name Enter the Customers Name

2. W. O. Enter the assigned work order number

3. Type Aircraft Enter the aircraft type

4. Date Enter date inspection was completed

5. Aircraft Registration Number Enter the aircraft Registration Number

6. TT Enter Aircraft total time

7. S/N Enter the Aircraft Serial Number

8. TL Enter the Aircraft Total Landings

9. Inspection Item Enter the inspections due on the aircraftand what they were complied with. List each separately i.e. 1. 2. 3. etc.

10.No defects noted This will be entered after each inspection item.If defects were noted, use Logbook EntryDefects Found

11.Authorized Sign. Signature of authorized individual returning the aircraft to service for the inspection performed by the repair station.





SAMPLE COPY OF STS LOG BOOK ENTRY

LOG BOOK ENTRY

1 Customers Name W.O.: 2 3 Type Aircraft Date: 4 5 Aircraft Registration Number TT: 6 S/N 7 TL: 8

1. 9 Inspection Item

10 No defects were noted.

The Aircraft was inspected in accordance with Non-Destructive Testing Methods in compliance with currentregulations of the Federal Aviation Administration and

is approved for return to service for the work performed. Pertinent details of the NDT Inspection areon file at Structural Testing Systems facility No. ES1R124K under the above Work Order number.R/S Authorized Signature 11





PERMANENT STS LOG BOOK ENTRY (DEFECTS FOUND)

1. PURPOSE

Permanent Record Entry is placed in the log book when a log book entry is required to reflect an aircraft inspection accomplished by Structural Testing Systems Inc. during which a discrepancy or defect was found.

2. DESCRIPTION

Permanent Record entry will be printed on Company Letterhead using electronic media, with provisions for recording WO #, Date, Signature, Aircraft Total Time, etc.

The log entry reject may be printed on a sticky label providing the STS logo is located in the top left corner of the entry.





PROCEDURE FOR COMPLETING STS LOG BOOK ENTRY (DEFECTS FOUND)

1. Customer Name Enter the Customers Name

2. W. O. Enter the assigned work order number

3. Type Aircraft Enter the aircraft type

4. Date Enter date inspection was completed

5. Aircraft Registration Number Enter the aircraft Registration Number

6. TT Enter Aircraft total time

7. S/N Enter the Aircraft Serial Number

8. TL Enter the Aircraft Total Landings

9. Inspection Item Enter the inspections due on the aircraftand what they were complied with. List each separately i.e. 1. 2. 3. etc.

10. Defects noted Note defects noted as results of the inspection(s)Provide as much information as possible.An entry will be made for each item noting a defect

11. Authorized Sign. Signature of authorized individual





SAMPLE COPY OF STS LOG BOOK ENTRY (DEFECTS FOUND)

LOG BOOK ENTRY

1 Customers Name W.O.: 2 3 Type Aircraft Date: 4 5 Aircraft Registration Number TT: 6 S/N 7 TL: 8

1. 9 Inspection Item

10 Defects noted.

I certify that the Aircraft has been inspected in accordance with the above NDT inspection procedure(s) and the discrepancies noted are the results of the inspection(s). This places the aircraft in an unairworthiness status and will remain so until proper corrective action is taken. Pertinent details of the NDT Inspection are on file at Structural Testing Systems facility No. ES1R124K under the above work order number. R/S Authorized Signature 11





MALFUNCTION OR DEFECT REPORT (FAA FORM 8010-4)

1. PURPOSE

Form 8010-4 may be used to provide the FAA and industry with a service record of service difficulties encountered with airframe, power plants, propellers, or appliances / components.

2. DESCRIPTION

Form 8010-4 is printed on a white card stock or may be computer generated for local reproduction but must duplicate the original Government printed form.

3. RESPONSIBILITY

Form 8010-4 will be initiated by the General Manager or Lead Technician, who will ensure proper annotation, issuing procedures and filing in accordance with AC 20 – 109A – Service Difficulty Program (General Aviation).

4. INSTRUCTIONS

This form can be found on the FAA’s web site at http://www.faa.gov/forms.

This form is to be used and completed in accordance with the guidelines of AC 20-109 as revised.

http://www.faa.gov/forms





SAMPLE COPY OF MALFUNCTION OR DEFECT REPORT

FAA FORM 8010-4





REPORTING SUSPECTED UNAPPROVED PARTS (SUPs) FAA FORM 8120-11

1. PURPOSE

Form 8120-11 may be used to provide the FAA and industry with a service record of Suspected Unapproved Parts (SUPs).

2. DESCRIPTION

Form 8120-11 is printed on a white card stock or may be computer generated for local reproduction but must duplicate the original Government printed form.

3. RESPONSIBILITY

Form 8120-11 will be initiated by the General Manager or Lead Technician, who will ensure proper annotation and send it to the SUP Program office via mail or email on the FAA.gov website.

4. INSTRUCTIONS

This form along with the instructions can be found on the FAA’s web site at http://www.faa.gov/forms.

http://www.faa.gov/forms









SAMPLE COPY OF SUSPECTED UNAPPROVED PARTS (SUPs) FAA FORM 8120-11





SHELF LIFE SIX MONTH AUDIT FORM (STS FORM # 9)

1. PURPOSEThis form will be used to record and audit in stock Shelf life items information located Structural Testing Systems, Inc.

2. DESCRIPTION

STS Form #9 is printed on letter size paper with for provisioned for annotating instock Shelf Life items Batch #, Part #, name, date put in stock and date removed form stock.

3. RESPONSIBILITY

The General Manager or his designee is responsible to ensure the form is administered.





PROCEDURE FOR COMPLETINGSHELF LIFE FORM # 9

1. Batch # Enter item batch #

2. Part # Enter item’s part #

3. Description Enter item’s name/description

4. Location Enter the location of the item at STS

5. Date In Stock Enter the date the item is put in stock or received at STS.

6. Audit date Enter the date the audit is conducted

7. Date removed Enter the date the item is removed from stock

STRUCTURAL TESTING SYSTEMS INC.REPAIR STATION MANUAL




Shelf Life Six Month Audit Form

This form is to be completed every six months to audit shelf life limited items that are stored in the material control areas in accordance with the Structural Testing Systems, Inc. Repair Station Manual, Rev. 2, 07/15/07.

STS Form # 9, Rev. 2, 07/15/07

Batch #

Part #Description

Location Date In

Stock

Audit Date

Audit Date

Audit Date

Audit Date

Audit Date

Date Removed

1 2 3 4 5 6 7

STS Form #9





VENDOR/ SUB-CONTRACTOR AUDIT, STS FORM # 10

1. PURPOSE

To acquire Vendor / Sub-contractor name, location, contact information, Certification documentation and fill out the Self Audit checklist. Additionally, the form requires the / Sub-contractor to provide copies of Repair Station, drug program documents, and capabilities for Structural Testing Systems’ records.

2. DESCRIPTION

Form # 10 will be printed on Company Letterhead, with provisions for the Vendor / Sub-contractor to provide applicable company information.





PROCEDURE FOR COMPLETING VENDOR/ SUB-CONTRACTOR AUDIT

STS FORM # 10

1. Company Name Enter Vendor’s Company Name

2. Address, City, State, Zip Enter Vendor’s street, city, state and zip

3. Phone Enter Telephone number of Vendor

4. Fax Enter Fax number of Vendor

5. FAA Repair Station Number Enter FAA Repair Station number of Vendor

6. Name of Contact / Title Enter Vendor’s Contact Name and Title

7. Contact Phone / Fax Enter Vendor’s Contact phone and fax number

8. Email Enter Vendor’s Contact email address

9. Auditor Enter Name of STS Auditor

10. Date Enter date STS Audited the Vendor

11. Self Audit Checklist Vendor shall check applicable boxes

12. Number of Personnel & Levels Enter # of NDT Personnel qualified to each Level

13. Self Audit Checklist Vendor shall check applicable boxes

14. Auditor’s Signature / Title Enter Signature and Title of STS Auditor





SAMPLE COPY OF STS FORM # 10





SAMPLE COPY OF STS FORM # 10 (Cont’d)





SAMPLE COPY OF STS FORM # 10 (Cont’d)





STRUCTURAL TESTING SYSTEMS AUDIT PROGRAM, STS FORM # 11

1. PURPOSE

To take corrective action on any deficiencies to remedy any undesirable situation related to the repair station. These deficiencies can be two types and are only addressed if the deficiency is committed by a person authorized to perform work for the Repair Station.

2. DESCRIPTION

Form # 11 will be printed on Company Letterhead, with provisions for Type I and Type II deficiencies to be annotated as applicable. A copy of any additional forms to accompany STS Form # 11 will be stapled to the back of the form, and will be held in the Structural Testing Systems Audit file as a permanent record of compliance.





PROCEDURE FOR COMPLETING STRUCTURAL TESTING SYSTEMS AUDIT PROGRAM

STS FORM # 11

1. Auditor Name Enter Auditor Name

2. Date Enter Date form is completed

3. Discrepancy Found By Enter Discrepancy Found By Name

4. Type I Enter if Type I Discrepancy

5. Type II Enter if Type II Discrepancy

6. Notify the CHDO Enter if CHDO is to be notified

7. Notify Owner Operator Enter if Owner Operator is to be notified

8. Recall Un-airworthy product Enter if Un-airworthy product is recalled

9. Report to SUPs Program Office Enter if reported to SUPs Program Office

10. Letter sent to Applicable Agency Enter if Letter is sent to Applicable Agency

11. Description of Discrepancy Enter Description of Discrepancy

12. Root Cause of Discrepancy Enter Root Cause of Discrepancy

13. Corrective Action Enter Corrective Action for Discrepancy

14. Open Discrepancies Found Enter if Open Discrepancies are Found

15. Applicable Agency Notified Enter if Applicable Agency is notified

16. Audit Follow-up Required Enter if Audit Follow-up is Required

17. Next Audit Follow-up Date Enter Next Audit Follow-up Date (if applicable)





SAMPLE COPY OF STS FORM # 11

Structural Testing Systems Audit Evaluation for Discrepancies and Corrective Action

Auditor Name: 1 Date: 2

Discrepancy Found By (Name) : 3

Mark appropriate areas with an “X” if applicable: Annotate “N/A” if Not Applicable

TYPE I Discrepancy: 4 TYPE II Discrepancy: 5

(Critical: If Type II, notify the applicable agencies in 24 Hours. Attach verification of Notification to Audit Form)

Notify the CHDO: 6 Notify Owner Operator: 7

Recall any Un-airworthy product: 8____ Reported to the (SUPs) Program Office: 9

Letter Sent to applicable Agency: 10

1. Description of Discrepancy: (Lines 1thru 3: May be responded to on Company Letterhead and attached if needed)

11 2. Root Cause of Discrepancy 12 3. Corrective Action: Response not to exceed 30 days 13

SIX MONTH AUDIT REVIEW: (Check appropriate Box and Attach verification of Notification to Agencies as required)

Open Discrepancies Found: Yes No (14)

Applicable Agency Notified: Yes No N/A (15)

Audit Follow-up Required: Yes No ALL DISCREPANICES RESOLVED _______ (16)

Next Audit Follow-up Date (if applicable): (17)

STS Form #11