Premier Avionics Control Manual Rev-7 for... · premier avionics, llc quality control manual . faa approved repair station no. 7pmr634b . premier avionics, llc. fort wayne international

Premier Avionics, LLC

QUALITY CONTROL MANUAL

FAA APPROVED REPAIR STATION NO. 7PMR634B

Premier Avionics, LLC.

FORT WAYNE INTERNATIONAL AIRPORT

11007 WEST PERIMETER ROAD

FORT WAYNE, INDIANA 46809 1-260-747-4810

MANUAL CONTROL NO.: ________

ASSIGNMENT: _______________


ISSUE DATE: 1/12/2014

REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE I

TABLE OF CONTENTS

Section Heading Page No.

TABLE OF CONTENTS ………..……………………………………………………….. I-II

INTRODUCTION …………………………………………………………………………. III

MANUAL CONTROL AND REVISION PROCEDURE……………………………….. IV

RECORD OF REVISION…..…………………………………………………………….. V

LIST OF EFFECTIVE PAGES…………...……………………………………………… VI-VII

SECTION I: INSPECTION AND QUALITY CONTROL SYSTEM……….…………. 1.1 Receiving/Incoming Parts, Materials and Shelf Life..……………….... 1.2 Hardware, Equipment, and Materials...………………………………… 1.2 Preliminary Inspection………………………………………………….… 1.3 Hidden Damage Inspection…………………………………………….... 1.3 In Process Inspection…..…………………………………………….….. 1.3 Suspected Unapproved Parts Reporting……….…………………………. 1.3 Malfunction and Defects Reporting…………………………………..…. 1.4 Parts and Unit Storage/Segregation….………………...…………….... 1.4 Record of Specialized Inspection, Test and/or Calibration……….….. 1.4 Record of Inspections…………………………….……………………… 1.4 Continuity of Inspection Responsibility..……………………………….. 1.5 Final Inspection and Approval for Return to Service…………………. 1.5 – 1.6 Calibration Work by Outside Vendors…..……….……………………... 1.6 Control of Precision Tools and Test Equipment……...……………..… 1.7 In-House Calibration Procedures…………………………………….…. 1.7 Shop Standards………………………………………………………..….. 1.7 Test Equipment Calibration Requirements………………………….…. 1.8 Troubleshooting Using Test Equipment…………………………….….. 1.8 Procedures for Performing Maintenance and Alterations for Air

Carriers under Parts 121, 125, 129 and 135.……………..…………… 1.9 Performance of Maintenance at a Location Other Than the Repair

Station……………………………………………………………………… 1.9 – 1.10 Current Technical Data………………………………………….……….. 1.10 Corrective Action for Deficiencies found in the Repair Station…...…………. 1.11 Proficiency of Inspection Personnel……………………………………………. 1.11


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE II

TABLE OF CONTENTS (continued) Section Heading Page No.

SECTION II: FORMS AND STAMPS……………………………………………………. 2.1 Forms…………………………………………………………………….… 2.2 Repair Station Stamps……………………………………………….…... 2.2 Log Book Entry Form………………………………………………….…. 2.3 Training Form: Training Records Form.…………………………….….. 2.4 Training Form: Employee Orientation and Initial Training Records

Form….…….………………………………………………………….….. 2.4.1 Training Form: Personnel Training Needs Assessment Form….….... 2.4.2 – 2.4.3 Training Form: Repair Station Needs Assessment form……………... 2.4.4 – 2.4.5 Training Form: Initial and Annual Recurrent Training Program Items. 2.4.6 Training Form: Employee RSM and QCM Questionnaire Form….…. 2.4.7 Work Order Discrepancy Sheet (Form)………….………………….…. 2.5 Certificate of Calibration (For in House Calibrations) Form….…….… 2.6 Parts Tags………….…………………………………………………..…. 2.7 - 2.9 Log Entry/Return to Service Sticker.................................................... 2.9.2 Altimeter Correction Card…………………………………………….…. 2.10 VFR Testing Log Book Entry Form……………………………………... 2.10.1 Transponder Test Worksheet Form (Mode A/C)................................. 2.10.2 Transponder Test Worksheet Form (Mode S).................................... 2.10.3 Compass Correction Card…………………………………………….…. 2.11 Altimeter Inspection Decal…………………………………………….…. 2.11 Purchase Order Form………………………………………….………… 2.12 Supplemental Weight and Balance/Data and Equipment List Form… 2.13 Packing Slip Form...……………………………………………….……... 2.14 8010-4 Malfunction Report Form……………………………………….. 2.15 Blank Page for future use.................................................................... 2.16 Parts Inspection Rejection Form…………..……………………………. 2.17

SECTION III: PRIMARY TEST EQUIPMENT & CALIBRATION INTERVALS….… 3.1 Primary Test Equipment Calibration Intervals…………………….…… 3.2 Test Equipment in House and Rented Policies……………………….. 3.3 Record of Precision Test Equipment Calibration……………………… 3.3 Calibration Intervals and Corrective Action for Errors………………… 3.3 SECTION IV: CONTRACT MAINTENANCE AND VENDORS……………………… 4.1 List of Contract Maintenance Providers..………………………………. 4.2 List of Vendors……………………………………………………………. 4.3 – 4.4


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE III

INTRODUCTION

1. This Quality Control manual has been prepared in accordance with Federal Air Regulations, FAR Part 145 and outlines the policies of Premier Avionics, LLC.

2. This manual details the internal inspection systems of Premier Avionics, LLC. It does not contain detailed inspection standards or instructions for a particular airframe, powerplant, propeller, instrument, radio, accessory, etc.

3. Documentation incorporates the Repair Station’s inspection system including

the continuity of the inspector’s responsibilities, as well as samples of inspection forms, and their use. Procedures for inspection of Incoming Materials, - the preliminary inspection of the product involved for hidden damage are also included as applicable.

4. The manual will refer when necessary to the appropriate Manufacturer’s

Standards for the repair and overhaul of the article involved.

5. All maintenance, repair and alteration work shall be performed in accordance with the standards prescribed in FAR 43. Premier Avionics, LLC. shall utilize and maintain in current order, manufacturer’s service manuals, instructions, and service bulletins related to the articles undergoing repair or alteration. No work will be initiated unless the above information is available to company personnel.

6. It shall be the responsibility of the General Manager to maintain this manual in a current condition at all times. Any changes or revisions will be forwarded to the proper FAA Representative.

7. Copies of this document are provided for all supervisory and inspection personnel who must be thoroughly familiar with it’s contents. Facility copies are also available for company personnel so that they may become familiar with related procedures for which they are responsible.


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE IV

MANUAL CONTROL AND REVISION PROCEDURE

1. Each manual (Repair Station Manual, Quality Control Manual and Training Manual), will have a control number and an assignment entry on the manual cover page. All related Inspection Personnel, General Manager/Accountable Manager, and the FAA shall maintain a current Revision of the Repair Station manual. In addition, shop personnel will keep one copy of the Repair Station manual in the Avionics shop for use. A master list containing the manual number, location and revision status will be kept in the General Manager/Accountable Manager’s office at all times.

2. As manual revisions become necessary, the General Manager/Accountable

Manager will create and review each page of the revision. Each revised page and the list of effective pages will then be submitted to the FAA in either hard copy or electronic media type. The Revision will be sent along with a letter stating the changes that were made. After a period of 30 days, if the FAA has not returned the letter, a phone call shall be made to the FAA in regards to why this letter has not been returned. Upon acceptance from the FAA, sufficient copies will be made and distributed for each manual holder.

3. Each Revision page will contain the Revision date located in the bottom right

hand corner of the page along with the revised section of the manual highlighted by an underline. Upon receipt of a revision, each manual holder will be responsible for inserting the revised pages into the manual, record the revision on the manual revision page and return the acknowledgement form recognizing the change to the General Manager/Accountable Manager indicating the holder has revised the manual.

4. Should procedures be performed that do not comply with applicable FAR’s, the

Repair Station will make contact with all applicable customers within 24 hours to remedy this problem. If contact cannot be made with a customer, the Repair Station shall contact the FAA to inform them of this problem.

5. A list of effective pages will be issued with each revision so that each manual

can be checked and maintained in current order.


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE V

RECORD OF REVISION Manual No. _______________ Manual Holder ___________________

PROCEDURE:

(1). Retain this record in the manual to permanently reflect all manual changes. (2). Upon receipt of revisions, insert revised pages in the manual and enter the data in the appropriate block on the record of revisions. (3). All personnel are expected to suggest revision requirements, when need is apparent, to the General manager/Accountable Manager. Revision Number

Revision Date

Insertion Date Performed By Purpose of Revision

ORIGINAL ISSUANCE

ORIGINAL ISSUANCE

ORIGINAL ISSUANCE

ORIGINAL ISSUANCE ORIGINAL ISSUANCE

1 10/6/11 10/7/11 To make required changes

mandated by FAA for new part 145 requirements. This is a complete manual revision.

2 11/4/11 2/3/12 To add VFR Log Book Entry form to forms used

3 3/14/12 3/28/12 To add Transponder worksheet and Training form

4 6/19/12 7/20/12 To update ratings, capabilities

and update equipment calibration list

5 10/24/12 10/30/12 To add a Log Entry/Return to Service Sticker to Forms

6 10/4/13 10/27/13 Updated numerous items to

update manual to comply with current Regulations.

7 1/12/14 To update form to reflect current FAA form 8130


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE VI

LIST OF EFFECTIVE PAGES

SECTION PAGE NO. DATE REVISION

NO. SECTION PAGE

NO. DATE REVISION NO.

Table of Contents I – II 1/12/14 7 Shop Standards 1.7 10/6/11 1

Introduction III 10/6/11 1 Test Equipment Calibration Requirements

1.8 10/6/11 1 Manual Control and Revision Procedure IV 10/4/13 6 Troubleshooting Using

Test Equipment 1.8 10/6/11 1 Record of Revision V 1/12/14 7 Contract Maintenance 1.8 – 1.9 6/22/12 4

List of Effective Pages VI-VII 1/12/14 7

Procedures for Performing Maintenance and Alterations for Air Carriers Under Parts 121, 125, 129 and 135

1.9 10/6/11 1

Section I: Inspection And Quality Control System

1.1 10/6/11 1 Performance of

Maintenance at a Location Other Than the Repair Station

1.9 – 1.10 10/4/13 6

Receiving/Incoming Parts, Materials and Shelf Life

1.2 10/6/11 1 Current Technical Data 1.10 10/6/11 1

Hardware, Equipment, and Materials 1.2 10/6/11 1 Corrective Action for

Deficiencies Found in the Repair Station

1.11 3/14/12 3

Preliminary Inspection 1.3 10/6/11 1 Proficiency of Inspection Personnel 1.11 3/14/12 3

Hidden Damage Inspection 1.3 10/6/11 1 Section II:

Forms and Stamps 2.1 10/6/11 1 In Process Inspection 1.3 10/6/11 1 Forms 2.2 10/6/11 1 Suspected Unapproved Parts Reporting

1.3 10/4/13 6 Repair Station Stamps 2.2 10/6/11 1 Malfunction and Defects Reporting 1.4 10/4/13 6 Log Book Entry Form 2.3 10/6/11 1 Parts and Unit Storage/Segregation 1.4 10/6/11 1 Training Records Form 2.4 10/4/13 6

Record of Specialized Inspection, Test, and/or Calibration

1.4 10/6/11 1 Employee Orientation and Initial Training Records form

2.4.1 10/6/11 1

Record of Inspections 1.4 10/6/11 1 Personnel Training Needs Assessment Form

2.4.2-2.4.3 10/6/11 1 Continuity of Inspection Responsibility

1.5 10/6/11 1 Repair Station Needs Assessment form 2.4.4-2.4.5 10/6/11 1

Final Inspection and Approval for Return to Service

1.5–1.6 10/4/13 6

Calibration Work by Outside Contractors 1.6 10/6/11 1 Control of Precision Tools and Test Equipment

1.7 10/6/11 1

In-House Calibration Procedures 1.7 10/6/11 1


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE VII

LIST OF EFFECTIVE PAGES (Continued)

SECTION PAGE NO. DATE REVISION

NO. SECTION PAGE

NO. DATE REVISION NO.

Initial and Annual Recurrent Training Program Items

2.4.6 10/4/13 6 Section IV: Contract Maintenance and Vendors

4.1 10/6/11 1 Employee RSM and QCM Questionnaire Form

2.4.7 10/6/11 1 List of Contract Maintenance Providers

4.2 10/4/13 6

Work Order Discrepancy Sheet (Form)

2.5 10/6/11 1 List of Vendors 4.3-4.4 10/6/11 1 Certificate of Calibration (For in House Calibrations) Form

2.6 10/6/11 1

Parts Tags 2.7-2.9 1/12/14 7 Log Entry/Return to Service Sticker 2.9.2 10/24/12 5 Altimeter Correction Card 2.10 10/6/11 1 VFR Testing Log Book Entry Form 2.10.1 11/4/11 2 Transponder Test Worksheet Form (A/C) 2.10.2 3/14/12 3 Transponder Test Worksheet Form (S) 2.10.3 3/14/12 3 Compass Correction Card 2.11 10/6/11 1 Altimeter Inspection Decal 2.11 10/6/11 1

Purchase Order Form 2.12 10/6/11 1 Supplemental Weight and Balance/Data and Equipment List Form

2.13 10/6/11 1

Packing Slip Form 2.14 3/14/12 3 8010-4 Malfunction Report Form 2.15 10/4/13 6 Blank Page for future use 2.16 10/24/12 5 Parts Inspection Rejection Form 2.17 10/6/11 1 Section III: Primary Test Equipment & Calibration Intervals

3.1 10/6/11 1

Primary Test Equipment Calibration Intervals

3.2 6/22/12 4

Test Equipment in House and Rented Policies

3.3 10/6/11 1

Record of Precision Test Equipment Calibration

3.3 10/6/11 1

Calibration Intervals and Corrective Action for Errors

3.3 10/4/13 6


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE 1.1

SECTION I

INSPECTION AND QUALITY CONTROL SYSTEM


REVISION NO.: 7




Receiving/Incoming Parts, Materials and Shelf Life All incoming materials will be checked by a qualified Inspector when received from manufacturers, supply houses and applicable vendors. He / She will determine that they conform to purchase orders, manufacturer specifications, drawings or dimension and specifications. Parts shall be checked for shipping damage, deterioration, corrosion, rust and other defects. Qualified Inspectors will have access to required applicable current technical data so that they may determine whether items are found to be acceptable to current regulations. The Repair Station uses two different stamps in records. The “Incoming Parts / Material” stamp is used to approve and date all incoming parts / equipment and is applied to packing slips. The stamp is illustrated in Section II on page 2.2 of this manual. A record of all rejected articles will be made on the Parts Inspection Rejection Form located in the repair facility. Rejected articles will be properly tagged and segregated from acceptable articles. These items will be segregated and secured in the General Manager/Accountable Managers office. When incoming parts or materials are received, the cure date of the material having shelf life shall be noted, and the older stock shall be used first, provided it is not beyond the manufacturer’s specifications. Incoming parts will be checked for any contamination that might have happened in shipping. Parts will be properly shelved to avoid any cross contamination of those parts and/or materials. In an event of contamination, such parts and/or materials will be segregated from the system and either returned to the sender or disposed of appropriately. Various types of data used to accept incoming parts or materials are as follows: (1) Verification that the parts received were produced under some type of FAA approved process with traceability. (2) Documented Airworthiness release or approval for return to service record by an appropriately certificated entity. (3) Parts produced for which a replacement time, inspection interval, or related procedure is specified in the Airworthiness Limitations section must have been permanently marked with part number and serial number (or equivalent) under FAR Part 45 subpart B. (4) Review of shipping tickets, packing slips, purchase orders, other PAH documents or markings identifying the approved manufacturer of that part / material. (5) FAA Form 8130-3: Airworthiness Approval Tag. (6) FAA-PMA marking in accordance with section 45.15. (7) FAA TSO markings in accordance with Sections 21.603 and 21.607. Hardware, Equipment, and Materials All parts, materials and supplies shall be stored and segregated properly to assure the preservation of these articles or parts. To assure they are not compromised and/or subjected to deterioration or shelf life expiration in accordance with manufacturer’s storage requirements. Only acceptable parts and supplies shall be issued for a job. When a part is deemed as unserviceable, the part will be destroyed by cutting, crushing or any other means required to make certain that the item can no longer be used for any means of return to service.


REVISION NO.: 7



INSPECTION AND QUALITY CONTROL SYSTEM (continued)

Preliminary Inspection This inspection is annotated, when completed, by a qualified Inspector on the Work Order Discrepancy Form. As part of the Preliminary Inspection process, proper documentation will be verified, life limits, AD’s and Service Bulletins as applicable. All articles undergoing maintenance will be inspected by a Repair Station Inspector to determine state of preservation (functional test if appropriate) and noting any non conformities. Any 8130-3 or traceability documentation will be kept with either the work order/aircraft repair that proves that the part is a qualified/approved component to be used in aircraft repair. The results will be noted on the Parts Inspection Rejection Form found on page 2.17 of this manual prior to returning the article to the vender. If a component is found to be damaged, that component will be removed and segregated with a Red Reject tag (Found on page 2.8 of this manual). All maintenance and alterations determined necessary, will be performed in accordance with methods, techniques and practices acceptable to the Administrator.

Hidden Damage Inspection This inspection is annotated, when completed, by a qualified Inspector on the Work Order Discrepancy Form. All articles that have been involved in an accident will be given a searching inspection by a Repair Station Inspector for hidden damage. This inspection will include areas adjacent to damaged structure and / or components. The result of this inspection will be recorded on appropriate work order forms, which will accompany the article until released to service. If a component is found to be damaged, that component will be removed and segregated with a Red Reject tag (Found on page 2.8 of this manual). All maintenance and alterations will be performed in accordance with methods, techniques and practices acceptable to the Administrator. In Process Inspection This inspection is annotated, when completed, by a qualified Inspector on the Work Order Discrepancy Form. A Repair Station Inspector will perform an in process inspection after disassembling and cleaning, during build-up and assembly. This will include tests and calibration when appropriate. The results will be entered on the work order discrepancy sheet and work order invoice, and will remain with the article until release to service. If a component is found to be damaged, that component will be removed and segregated with a Red Reject tag (Found on page 2.8 of this manual). All maintenance and alterations will be performed in accordance with methods, techniques and practices acceptable to the Administrator. When any shelf life items are required to be used, the cure date of the material having shelf life shall be verified prior to use. Suspected Unapproved Parts Reporting If during the various internal inspection steps set forth in Premier Aviation’s Inspection System find that a Suspected Unapproved part has been found, that part shall be immediately removed from the Installation/Repair facilities normal storage area and segregated to a holding area so that the item or items actual condition can be determined by the Chief Avionics Inspector. The item or items that were suspected must not be returned to normal production use until the Inspector has released those items to a Return to Service condition. If such item or items have been found to been Unapproved in a Defective state, then the Inspector shall fill out the appropriate information on a Malfunction and Defect report. Information pertaining to the Malfunction and Defect report are contained in the Malfunction and Defects Reporting section found on page 1.4 in this manual.


REVISION NO.: 7




(continued)

Malfunction and Defects Reporting This Repair Station will report to the FAA within 72 hours after it discovers any serious defect in, or other recurring un-airworthy condition of, an aircraft, avionics equipment or avionics appliance, or any component of any of them. The report will be made by visiting the FAA website and completing an SDR (Service Difficulty Report) using the online form for reporting such M&D information. This form will be completed in full as required by the online form questions. This form has online help instructions on how to complete the form correctly. In any case, where the filing of a report under the preceding paragraph might prejudice the Repair Station, it will be referred to the Administrator for determination as to whether it must be reported. If the defect or malfunction could result in an imminent hazard to flight, the Repair Station will use the most expeditious method it can to inform the Administrator.

Parts and Unit Storage/Segregation (a) All parts or units under the control of the repair station will be segregated, identified and classified. Classifications are: serviceable, repairable, and rejected. Any part or unit classification may be segregated and identified by appropriate tagging, and secured in the Accountable Managers office for disposition. Samples of tags utilized at this facility can be found on page 2.7 and 2.8:

Red: Reject Green: Repairable Yellow: Serviceable- May Include maintenance release

Work Order - A company work order identified by number, customer’s name, date and identity of part(s) that will be utilized. This form will contain a description of all work to be accomplished in sufficient detail to be readily understood. Space will be provided for the identification of the certified person performing or supervising the work and the inspector approving the work. A sample work order can be found on pages 2.5.

Record of Specialized Inspection, Test and / or Calibration Specific notations, attesting accomplishment, will be made on appropriate printed work forms for recording specialized inspection, testing and / or calibration of a component or aircraft. Record of Inspections Where a record of the inspection by dimensions, tests or calibration is required by the manufacturer’s technical data such a record will be made on the appropriate form properly identified with the work order. It must also be dated and signed by the repairman performing the inspection, tests or calibration and / or the inspector as appropriate. A sample form may be found on page 2.6 of this manual.


REVISION NO.: 7




Continuity of Inspection Responsibility

In the event that any technician is unable to perform any inspection or continue with an in progress installation for reasons such as; sickness, vacation, unavailable for work, etc., it will be the responsibility of the technician to start and finish such inspection. This will ensure that no inspection is partially done and missing data from such inspection. In the event that a particular project has been started by any delegated technician, that technician will complete that project for final inspection. The technician performing the work may pass delegation and responsibility back to the Chief Avionics Inspector, Avionics Inspector, or Inspector so long as proper communication between both parties allows information and full details as to what status such project is at and what is required to complete such project. If direct communication between the parties is not possible, then the technician that will continue the project will determine as to what work has been done and what remaining work needs to be done to complete the project. Premier Avionics currently does not work in multiple shifts. A shift log is not utilized by our company.

Final Inspection and Approval for Return to Service

This inspection is annotated, when completed, on the Work Order Discrepancy Form. Prior to approval for return to service, the Chief Avionics Inspector will audit the records “package” as identified by the work order, to determine that all work has been inspected as required for compliance with this inspection system and applicable FAR. When approval has been given to the above audit, either the Chief Avionics Inspector or the individual authorized in the official roster and individual summary of employment will approve the article for return to service. This approval will be accomplished as appropriate to the work done, the article involved, the records available with the article, and the instructions of the customer. Care will be exercised to comply with FAR Part 43 in every case. Whenever the aircraft records (log) are available, record of work accomplished will be entered in that record otherwise the records will be rendered to the customer. This does not waive and FAR Part 145 records requirements. Neither will FAR Part 43 or FAR Part 91 be considered waived by FAR Part 145 records requirements. Articles such as appliances, accessories, and individual parts or components will not have an individual record to which an entry may be added. However, the installation of these items on an aircraft constitutes an aircraft maintenance or alteration, and records must be made accordingly. Personnel shall check to see that manuals utilized for the return to service process are of the most current revision available to them. Routinely, major repair approvals will be handled in accordance with Section 43.9 and/or. A maintenance release is completed as part of the work order form at the time of approval for return to service. At the request of the customer (to be indicated on


REVISION NO.: 7




Final Inspection and Approval for Return to Service (cont) the work order when originated) FAA Form 337 will be completed instead of the maintenance release approval for return to service in accordance with the procedure in paragraph (a) of FAR Part 43, Appendix B. In all cases where major alterations are involved, FAA Form 337 will be completed per FAR 43.9 and FAR 43, Appendix B. The authorized supervisor in whose work area the repair of alteration is accomplished will be responsible for establishing that the repair or alteration was made in accordance with the requirements of FAR Part 43 and will sign the conformity statement of FAA Form 337. Authorized personnel responsible for the approval for return to service of aircraft will indicate such approval by signing the approval for return to service of FAA Form 337. The original FAA Form 337 will be inserted in the aircraft record with 1 copy forwarded to the appropriate FAA Flight Standards District Office, within 48 hours, and one copy retained with the aircraft work order. It is the responsibility of the person authorizing return to service to assure that the aircraft flight manual is properly revised following any alteration or modification to the aircraft and that the weight and balance record and aircraft equipment list have been amended as necessary. Aircraft components, appliances, and other items, as authorized by the Repair Station specifications, will be returned to service through the use of a maintenance release pre-printed on the FAA Form 8130-3 described in Section II, page 2.9 of this manual. The authorized supervisor under whose jurisdiction the work is accomplished will be responsible for the release of units in the category. No aircraft may be released for return to service until the work order and other records have been reviewed for completeness and final acceptance cleared by inspection. Particular attention shall be accorded the status of applicable airworthiness directives. All applicable Inspections shall be signed off on the lower section of the Work Order (found on page 2.5 of this manual) as each Inspection has been performed during the job process. Maintenance and Repairs are accomplished in accordance with approved and acceptable data. Major alterations will be recorded on an FAA form 337 as approved. All Maintenance will be recorded in accordance with FAR 43.9 and/or 43.11 of the FAR’s as applicable.

Calibration Work by Outside Vendors When test and / or calibrations are performed by outside contractors they will be required to provide the records as outlined above. Specific information on precision tools and test equipment is on file in the office of the Avionics shop. Included in this file is the name of the item, manufacturer, part number, serial number, last calibration, date and next calibration due date. The maximum interval for calibration is one year. Any extension of calibration interval must be approved by their FAA Flight Standards District Office, 5800 Nimtz Parkway, South Bend, IN, 46628.


REVISION NO.: 7



PAGE 1.7


Control of Precision Tools and Test Equipment

Precision tools, gauges, pressure gauges, ohmmeters, voltmeters, electronic equipment used in the Repair Station operations are subject to periodic checks and calibration in accordance with appropriate Repair Station procedures. All Repair Station personnel, before using test equipment, are responsible to check that the testing unit has a current calibration label attached. Periodic reviews of calibrated test equipment records are accomplished to verify calibration due dates and to ensure no equipment is used beyond the calibration due date. Any piece of equipment found in the Repair Station without a current calibration label attached shall be given to the Chief Inspector for recalibration. In-House Calibration Procedures

Premier Avionics retains the Manufacturers Technical documentation to facilitate specific limited In-House Calibrations. Instruments will be calibrated by the Chief Avionics Inspector, and/or designee for Premier Avionics, LLC., Repair Station No. 7PMR634B.

a) Calibrate and adjust per manufacturer’s current technical data specific to the following calibrations:

• Fluke 75 Multimeter • TIC CES-116A b) All calibrations must be performed using Shop Standards as referenced below. If a

Shop Standard is used to perform maintenance, the Shop Standard will be re-calibrated before it can be used as a Shop Standard.

c) Records of calibration will be recorded on a Premier Avionics, LLC., calibration log located into the Calibrations Book located in the Avionics shop manager’s office. A certificate of calibration for In-House calibrations must be completed, including technical data and shop standards used. An example of this form can be found on page 2.6 of this manual.

Shop Standards

Shop standards used to calibrate test equipment must be traceable to the National Institute of Standards and Technology.

1) Shop Standards will not be used for test equipment and shall be used for calibration purposes only. If a Shop Standard is used to perform maintenance, the Shop Standard will be re-calibrated before it can be used as a Shop Standard.


REVISION NO.: 7




Test Equipment Calibration Requirements

Test equipment shall be calibrated at periodic intervals established on the basis of stability, purpose, degree of usage and/or impact shock. One year shall be the maximum calibration interval, or other procedures approved by the Administrator. Each piece of test equipment will be labelled. The label will identify the unit by manufacturer, model, and serial number. The attached label must indicate the last calibration date and next calibration date due. During the first week of each month, the Chief Avionics Inspector will review the Test Equipment Calibration history file. The test equipment requiring calibration will be given to the Chief Avionics Inspector as appropriate. It will be the responsibility of that person to issue repair requests to Repair Station shops or outside contractors as necessary for the calibration of the units and attachment of updated calibration labels. After calibration, the test unit will be checked for proper labelling and the equipment calibration history file will be updated and returned to the Avionics Manager for final acceptance. At no time will any person be permitted to perform work on aircraft or components using test equipment which is out of calibration. The test equipment labels will be checked by supervisors at random to assure that equipment in use is in calibration. This includes personnel test equipment owned by employees. If at any time a piece of test equipment inadvertently exceeds its calibration due data, it will immediately be removed from service until a calibration check has been performed. Standards used to calibrate test equipment is traceable to the National Institute of Standards and Technology or an approved foreign country’s standards by certificate from the testing facility. All test equipment due, will be removed from service and sent for calibration within 14 days of due date.

Troubleshooting Using Test Equipment

Prior to using test equipment for Return to Service a technician will make certain that the equipment is in calibration. Test equipment used as reference aids will be labelled For Reference Use Only or Removed from Service and will not be used for Return to Service.


REVISION NO.: 7




Procedures for Performing Maintenance and Alterations for Air Carriers under Parts 121, 125, 129, and 135.

Premier Avionics only provides Avionics services to Part 91 and Part 135 operators. Work performed on Part 135 aircraft will be done in accordance with the Air Carriers program and maintenance manual as applicable. Premier Avionics shall maintain a current drug testing program approved by the FAA as part of the requirements of Air Carrier programs. Premier Avionics shall maintain all current in house performance requirements as approved by the FAA for work to be performed for Air Carrier programs. The General Manager/Accountable Manager or Chief Avionics Inspector will be responsible for overseeing the work and ensuring that the Air Carriers Inspection and/or Maintenance program is available as applicable to facilitate work performed. Premier Avionics does not perform RII Inspections. If a RII is required, then Premier Avionics will rely on the Air Carrier to provide qualified RII Inspectors for the project. Performance of Maintenance at a Location Other Than the Repair Station Premier Avionics will provide maintenance service for its customers on an on-call basis at a location away from the Repair Station. Premier Avionics can only provide this service for work, which the Repair Station is rated. The General Manager, Chief Avionics Inspector, or in their absence, a Repairman, are authorized to initiate a work order for such work. The General Manager or Chief Avionics Inspector will be responsible for assigning the personnel necessary to perform the work and appoint a person to be in charge of the work force. If neither the General Manager or Chief Avionics Inspector are available to appoint a person for the project, a qualified Repairman may perform the work themselves and are responsible for the work performed and the associate documentation required for the work performed. The Chief Avionics Inspector will assign the inspector(s) responsible to inspect the work and assure that all required forms and work are completed as necessary. The Chief Avionics Inspector will assign one inspector with the responsibility for returning the article to service. The Accountable Manager and/or the Chief Avionics Manager is responsible to ensure that the article to undergo maintenance 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 or


REVISION NO.: 7




Performance of Maintenance at a Location Other Than the Repair Station (cont) Chief Avionics Inspector will be responsible for providing all the necessary Chief Avionics Inspector requirements for the accomplishment of the maintenance being performed. The General Manager or Chief Avionics Inspector will establish a system of communications best suited between the technician and the Repair Station. All personnel assigned to accomplish work away from the Repair Station shall accomplish the specific function of work in the same manner as when performed at the Repair Station. Prior to leaving to such location for work to be performed, the responsible manager shall make sure that all equipment required to perform such work will be taken to such location. All off sight work to be performed, in accordance with acceptable and/or approved methods and procedures. If required for the task to be performed, the location may be required to provide access to: electrical outlets, heated hanger, adequate lighting and other possible items required to perform the task at that location. When the work has been completed the log book entry appropriate to the work performed, will be rendered to the customer. Personnel that are performing work away from the Repair Station, have access to the Repair Station Manual and Quality Control Manual online. The manuals can be found via www.premieravionics.net using online access. Current Technical Data Premier Avionics will provide current technical publications, AD’s, Service bulletins and other pertinent items that provide proper approval for return to service information for its employees so that they can provide proper and legal repairs and alterations to aircraft. These may be provided in various means. They will be provided by hard copy, or electronic media (CD, DVD, internet) as means of keeping up to date information as necessary for proper return to service information. The General Manager/Accountable Manager is responsible for maintaining data in a current condition.


REVISION NO.: 7

http://www.premieravionics.net/




Corrective Action for Deficiencies found in the Repair Station Any deficiencies found at the Repair Station or when providing off site repairs, will be immediately noted and reported to the Chief Avionics Inspector so that the item can be addressed and corrected. When such item has been determined to be in need of attention, it shall be reported to the General Manager/Accountable Manager or Inspector for immediate corrective action. If the deficiency has been determined to have affected any aircraft or component that has been returned to service, the General Manager/Accountable Manager shall take immediate action to contact the owner/pilot or person responsible for maintaining such aircraft or component. If immediate contact cannot be made with such person for immediate corrective action, then the General Manager/Accountable Manager shall contact the local FSDO so that the aircraft can be located and the corrective action may be completed. If the deficiency is due to an installation or repair problem, then action will be taken to correct the installation or repair problem. At that time, the Inspector will determine if recurrent training will be required for the technician that performed the work to the aircraft or if the problem was due to other issues (such as lighting, heating, etc.) that item will be corrected. Measures will be taken to make sure that any deficiencies are not systemic. Proficiency of Inspection Personnel Premier Aviation will comply with applicable regulations under our Initial and Recurrent Training Program that covers various current training on regulations and being familiar with the current FAR’s under the current manual. Proficiency training covers items such as techniques, practices, tools, rules and regulations, aids, Inspection equipment, current manufacturer’s available training programs and on the job training. Current technical data will be provided to the technician by various means. They will be provided by hard copy, or electronic media (CD, DVD, internet) as means of keeping up to date information as necessary for proper return to service information. An OJT trainer is qualified by showing previous training qualifications in the area that they are providing training on or a technician can provide this training for final completion of their training on a project/component/system while under the direct supervision of a previously approved OJT trainer.


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SECTION II

FORMS AND STAMPS


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FORMS AND STAMPS

FORMS The forms described in this section are for the use of this Repair Station for the continuity and documentation of work performed. Each form will be described as to its use and the personnel responsible for its completion. REPAIR STATION STAMPS The Repair Station uses two different stamps in records. The “Incoming Parts / Material” stamp is used to approve and date all incoming parts / equipment, and is applied to packing slips. The “Superseded” stamp is applied to old Aircraft Weight and Balance data sheets when a current data sheet is created for the aircraft. The stamps are illustrated below: Incoming Parts/Materials Stamp Superseded Data Stamp

INCOMING PARTS/MATERIAL INSPECTION COMPLETED

DATE: ___________________________

___________________________________________________________

INSPECTOR INITIALS

PREMIER AVIONICS, LLC FAA REPAIR STATION 7PMR634B

SUPERSEDED

DATE:


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FORMS AND STAMPS CONTINUED LOG BOOK ENTRY FORM This form is used when the aircraft records are not readily available. The form has a peel-off glued backing and will be inserted in the aircraft records when they become available. The Chief Avionics Inspector will be responsible for the completion of this form. As shown below, the N#, Tach, Hobbs or total time, (as appropriate) and date will be inserted on the top line. The middle section will contain a description of the work performed. On the bottom the person filling the log entry out will sign and record the work order # assigned to the task performed.

A V I O N I C S L O G B O O K E N T R Y N 12345 TIME 1234.5 DATE 12-02-02

REMOVED PN; SN;, AND INSTALLED PN;, SN;, IN AIRCRAFT. SYSTEM WAS RAMP CHECKED AND FOUND TO RAMP CHECK GOOD.

SAMPLE

Aircraft and/or components above were repaired and inspected in accordance with current federal aviation regulations, and was/were found airworthy for return to service. Signature: __________________________ Work Order: ______________ Premier Avionics, LLC 11007 W. Perimeter Road • Fort Wayne, IN 46809 • Tel: 260-747-4810 • Fax: 260-747-4810 • CRS: 7PMR634B


REVISION NO.: 7



FORMS AND STAMPS (CONTINUED)

TRAINING FORM: TRAINING RECORDS FORM This form may be used to record all updates in training status of all employees. The General Manager/Accountable Manager will maintain this form and a copy of this form will also be placed in the employee’s permanent record. The employee’s name will be placed on the top of the form. The following information will be entered in the lower section of this form: What type of training was performed, on what date and hours of training performed, the person’s name in charge of the training and what equipment or new procedure was involved in the training session.

PREMIER AVIONICS, LLC TRAINING RECORDS FORM

NAME:____________________ POSITION:__________________________

OJT

SS START DATE

SUBJECT STOP DATE

HOU

RS

INST

TRAINEE

INFORMATION


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PAGE 2.4.1


TRAINING FORM: EMPLOYEE ORIENTATION AND INITIAL TRAINING RECORDS FORM This form is used when hiring a new employee. The General Manager or person that the General Manager has authorized for interviewing and hiring will complete this form during the interview process. The new employee for consideration will provide an application, copy of their drivers license, social security card, a completed W-4 form and copy of any previously held Repairman Certificate (if applicable), and a tour of the facility will be performed. Before performing aircraft sensitive activities, the employee will perform a drug test. The employee will then have a training records folder started, review of shop basic safety practices and the employee will familiarize them self with the Repair Station manual, and Quality Control Manual. After the employee has had the opportunity to read the Repair Station and Quality Control manuals, the employee will complete the RSM and QCM questionnaire form found on page 2.45 of this manual. Within the first 90 days or prior to any installation or repair work being performed, the employee will show that they understand installation manuals, and common wiring basics and practices prior to performing installation projects.


REVISION NO.: 7


QUALITY CONTROL MANUAL PAGE 2.4.2


TRAINING FORM: PERSONNEL TRAINING NEEDS ASSESSMENT FORM (Page 1) This form is used when evaluating an employee for a new task that the Repair Station needs the employee to perform. If that task has not yet been performed by that employee and it is felt that the employee requires assessment to perform that task, this form is used to determine if that employee is qualified at the present time, or if the employee requires additional training from another qualified person prior to the work being performed by the employee being assessed. Page 2 of this form can be found on page 2.4.3 of this manual.


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TRAINING FORM: PERSONNEL TRAINING NEEDS ASSESSMENT FORM (Page 2) This is page 2 of the Training Needs Assessment form. Page 1 of this form can be found on page 2.42 of this manual. When using this form, indicate the employee name, title, date, training item or task that is being taught and the Inspector or qualified trainer that is providing the training for this task on the top of the page. A brief answer for the questions presented on the form will then be completed based upon the use of this form and the applicability of each question to the employee receiving the training.


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TRAINING FORM: REPAIR STATION NEEDS ASSESSMENT FORM (Page 1) This form is used when the Repair Station requires additional ratings or specialized equipment in which the Repair Station needs to self assess itself and capabilities to perform a specialized task for which it is currently not rated for or has the equipment to support that item that it is planning to work on.


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TRAINING FORM: REPAIR STATION NEEDS ASSESSMENT FORM (Page 2) This is page 2 of the Repair Station Needs Assessment form. Page 1 of this form can be found on page 2.4.4 of this manual.


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TRAINING FORM: INITIAL AND ANNUAL RECURRENT TRAINING PROGRAM ITEMS This form is used for maintaining Premier Avionics recurrent training program requirements for new employees and current employee initial and recurrent training program needs. Each employee will complete Initial and Recurrent Training as indicated in the form below. If a Recurrent Training item has not been completed for any reason within the required date indicated, that employee will complete that task prior to any work performed under that task.

INITIAL AND RECURRENT TRAINING PROGRAMS FREQUENCY FORM

PREMIER AVIONICS

CRS# 7PMR634B

# Training Topic Initial As Applicable

Refresher Required

Initial date completed

Recurrent completed

1 Repair Station Manual Review X 12 months 2 Company Organization and job functions X 3 Quality Control Manual Review X 12 months 4 Work Order documentation X 5 Drug testing/or review of policy for employees X 6 Calibration procedures X 7 Review of 91.411 and 91.413 procedures 12 months 8 Review of forms used and procedures for completing

those forms X 12 months

9 Human Factors Training X 12 months 10 Part 43.9 and Part 43.11 Regulation Review X 12 months 11 Test Equipment Familiarization X 12 months 12 In House Calibration Procedures (*This training required

prior to use of test equipment used for Return to Service) X *

13 Training Manual Review X 12 months 14 Review of Tools and Technical Data Resources X 12 months 15 FAR 91.411 / 91.413 / RVSM Maintenance Training

Course (*This training course is required prior to any employee performing their initial RVSM for RTS information and annually for any employee who is responsible for RVSM RTS information as refresher.)

X 12 months for RTS Personnel

16 Incoming Inspection X 12 months As applicable

17 Preliminary Inspection X 12 months As applicable

18 Hidden Damage Inspection X 12 months As applicable

19 In-Process Inspection X 12 months As applicable

20 Final Inspection X 12 months As applicable

21 Approval for Return to Service X 12 months As applicable


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TRAINING FORM: EMPLOYEE RSM AND QCM QUESTIONNAIRE FORM This form is used when hiring a new employee. The person that is interviewing the new employee will use this form to determine if the new employee has read and understands the Repair Station and Quality Control Manuals and their content.


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WORK ORDER DISCREPANCY SHEET (FORM)

When a work order is initiated, this form will be completed to indicate the discrepancies or maintenance required on a particular aircraft, appliance, or component. The Chief Inspector is responsible for the content or this form. The person performing the work will initiate the form and assign item numbers to each discrepancy / maintenance action. He/or she will also complete the spaces provided for date, work order number, aircraft information, etc. In the upper right hand section of the form is pertinent aircraft data information. The Make, Model, and serial number will be completed in this section along with the time for the aircraft, which is completed in the respective block and what type of time data that it is, which can be circled in that block. The work performed or reference to a log entry, invoice or 337 shall be made indicating what type of work was performed. Upon the completion of a particular item the technicians will enter the corrective action on the appropriate line and sign off the discrepancy using his initials. Each type and/or inspector will then inspect the work and sign the form in the space provided using his initials. The form also contains a return to service statement with space provided for Inspectors signature. Space for an inspector’s initials for preliminary, hidden damage progressive and final inspections are also included and will be initialled by the Inspector prior to approval for Return to Service. This form will be placed in a rack in the General Manager/Accountable Manager’s office after the job is completed. The Chief Inspector will be responsible for the completion of all items on this form.

DATE:

PREMIER AVIONICS, LLC.

11007 WEST PERIMETER ROAD FORT WAYNE, IN 46809

TEL: (260) 747-4810

CRS# 7PMR634P

Work Order No NAME: PAGE: OF A/C REG.

ADDRESS: TACH: HOUR:

CITY: A/C SN:

STATE, ZIP: IN MAKE: PHONE/E-MAIL: MODEL:

ITEM # SQUAWK HOURS LABOR TECH INSP

WORK PERFORMED:

PARTS USED

ITEM: PN:

ITEM: PN:

SN: SN:

ITEM: PN:

ITEM: PN:

SN: SN:

ITEM: PN:

ITEM: PN:

SN: SN:

ITEM # SQUAWK HOURS LABOR TECH INSP

WORK PERFORMED:

PARTS USED

ITEM: PN:

ITEM: PN:

SN: SN:

ITEM: PN:

ITEM: PN:

SN: SN:

ITEM: PN:

ITEM: PN:

SN: SN:

Preliminary inspection ______ Hidden damage inspection ______ In-progress inspection _____ Final inspection ______ Aircraft and / or components above was repaired and inspected in accordance with current federal aviation regulations, and was found airworthy for return to service. Pertinent details of the repair are on file at this agency. Inspector’s Signature: ______________________ Date: ____________

INSTRUCTIONS: (1). Once a Work Order No. has been assigned, complete all sections as outlined in procedure: SECTION III: Forms and Stamps-page 3.5., Work Order Discrepancy Form – IPM Revision 0. (2). Submit to the General Manager upon completion.


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CERTIFICATE OF CALIBRATION (FOR IN HOUSE CALIBRATIONS) FORM

This form is used to record information on (in-house) calibrated test equipment used within the Repair Station. It is the responsibility of the Chief Inspector to maintain this form up to date. This form is used to record the make, model, serial number, nomenclature, date calibrated, who certified the item, the title of the person certifying, procedure used, and equipment used to certify the item. The top of the form will be filled out in full. The procedure of how the item was calibrated will be indicated in the procedure area of the form. Finally, a list of the equipment used to calibrate the item shall be indicated on the lower portion of the form.

Premier Avionics, LLC CERTIFICATE OF IN-HOUSE CALIBRATION

Premier Avionics, LLC hereby certifies that the equipment listed below meets or exceeds it’s Minimum Performance Specifications.

MAKE: DATE CALIBRATED:

MODEL: NOMENCLATURE:

SERIAL NO: FCC No.: CERTIFIED BY: TITLE: (Signature) CRS No: 7PMR634P Procedure:

The Unit Bears a Calibration Sticker Dated: _______________________________ Calibration Equipment Used:

MODEL TYPE CALIBRATION

DATE MODEL TYPE CALIBRATION

DATE

CALIBRATED BY:

DATE: NEXT CALIBRATION DATE:

SAMPLE CALIBRATION STICKER


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PARTS TAGS

Three different color tags are used for the identification of parts.

1. Yellow Tag Attached to parts, which have received final inspection and are approved for return to service. A maintenance release is printed on the reverse side. An inspector will be responsible for the completion of this tag. On both the front and back of this form, the date, work order #, and Inspectors signature shall be filled out. On the front of the form, the customers name, and tail # shall be filled out. In addition, the equipment’s part number, serial number and description shall be indicated. Finally, the technicians signature shall be recorded if the technician is not the same name as the inspector.

Date: Work Order: The aircraft component and/or appliance identified on the other side was repaired and inspected in accordance with current Regulations of the Federal Aviation Administration and is approved for return to service. Pertinent details of this repair are on file at this repair station under

Customer: Tail Number: Part No: Serial No.:

Description: Technician: Work Order No.: Date:

Inspector: Signed: Premier Avionics, LLC

11007 West Perimeter Road– Fort Wayne, IN 46809 Telephone: (260) 747-4810

for Premier Avionics, LLC. FAA Repair Station #: 7PMR634B

2. Green Tag -Will be attached to parts requiring repairs or test and will include a description of work to be performed. Inspectors are responsible for the completion of this tag. On the front of this form, the date, and work order # shall be filled out. In addition, the customer’s name, and tail #, the equipment’s part number, serial number, description and reason for removal shall be indicated. Finally, the technicians signature shall be recorded in the lower section. The lowest section of the form is not a required item to be filled out on this form.

Date:

Work Order:

Customer: Tail Number:

Part No: Serial No.:

Description:

Reason For Removal: TSN TSO CYSN CYSO Technician:

P/N Installed: S/N Installed:

Warranty Non-Warranty

Premier Avionics, LLC 11007 West Perimeter Road – Fort Wayne, IN 46809 (260) 747-4810

FAA Repair Station #: 7PMR634B


REVISION NO.: 7



FORMS AND STAMPS (CONTINUED) PARTS TAGS (CONTINUED) 3. Red Tag -Will be attached to rejected parts, pending final disposition. An inspector will be responsible for the completion of this tag. The tag requires the items part number, serial number and reason for removal. In addition it requires a signature of the person filling out the form. The section above the signature is not a required item to be filled out on this form.

REJECT P/N: S/N:

Reason for Reject:

TSN TSO CYSN CYSO

Technician: Premier Avionics, LLC

11007 West Perimeter Road – Fort Wayne, IN 46809 Telephone: (260) 747-4810


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FORMS AND STAMPS (CONTINUED) PARTS TAGS (CONTINUED) 4. FAA Form 8130-3 Airworthiness Approval Tag - May be used in place of the above

listed “Yellow TAG” to identify airworthy parts. The form has been filled out with an example of required information below.


REVISION NO.: 7




Log Entry/Return to Service Sticker This form is used for return to service for an individual item in which repair or testing has been performed. This log entry/sticker can be applied directly to the component that has been inspected or repaired when the use of a yellow tag or 8130 can’t be, or is impractical to be applied directly to the unit. The Inspector signing off the work shall complete the following items on the form: A short description of the work performed, the part number and serial number of the component, the work order number and the date the work was completed and the Inspector will sign the form on the bottom. This form will serve as the return to service form for the component that was inspected or repaired.

The aircraft component identified below was repaired, tested and/or inspected in accordance with current Federal Aviation Regulations and was found airworthy for return to service. Work Performed:

________________________________________________ Pertinent details of the repair are on file at this agency under: PN ________________ SN _______________

WO# ____________ DATE _______________

Inspector ______________________________

Premier Avionics, LLC 11007 West Perimeter Road

Fort Wayne, IN 46809 CRS# 7PMR634B


REVISION NO.: 7




ALTIMETER CORRECTION CARD This form is used during certification of the altimeter and static system per FAR 91-411 and Part 43 Appendix E. This form shall be filled out with the information obtained from the applicable testing procedures required by the FAA. Each of the altitude points will be recorded with the actual altitude data seen during the test. This form will also indicate the baro. Scale error test, hysteresis, after effect and case leak as required by the FAA. Finally, the altimeter, blind encoder, and transponder checked will be indicated with the applicable information filled out in the blanks. In addition the altitude system was tested to shall be filled out. The form shall be dated with the technicians initials, signature and applicable work order assigned to the work performed.

Premier Avi on ics, LLC. N# __________________ ALTIMETER, STATIC AND TRANSPONDER CERTIFICATE

CERTIFIED ALTIMETER PER FAR 43, APP. E (b) TO ________________________________ FT. TO COMPLY WITH FAR 91.411. CERTIFIED STATIC SYSTEM PER FAR 43, APP. E (a) TO COMPLY WITH FAR 91.411. CERTIFIED AUTOMATIC PRESSURE ALTITUDE REPORTING SYSTEM PER FAR 43, APP. E (c) TO COMPLY WITH FAR 91.411. CERTIFIED TRANSPONDER PER FAR 43, APP. F TO COMPLY WITH FAR 91.413.

This aircraft and/or component identified above was repaired and inspected in accordance with current Federal Aviation Regulations and was found airworthy for return to service. Pertinent details are on file at this agency under the following work number.

Date: ________________ Tech. ________________ W.O __________________ Signed _________________________________________________

PREMIER AVIONICS, LLC. • CRS# 7PMR634B • PH: (260) 747-4810 • 11007 WEST PERIMETER ROAD • FORT WAYNE, INDIANA 46809


REVISION NO.: 7




VFR TESTING LOG BOOK ENTRY FORM This form is used during certification of the Transponder and Encoder system per FAR 91-413 and Part 43 Appendix F. This form shall be filled out with the information obtained from the applicable testing procedures required by the FAA. The technician performing the test will record the Tail Number, date and work order number on the form as appropriate. In addition the Transponder and/or Encoder along with its appropriate serial number, will be recorded on the form. The form shall be completed with the technician’s initials and signature on the bottom of the form.


REVISION NO.: 7




TRANSPONDER TEST WORKSHEET FORM This form is used during certification of the Transponder and Encoder system per FAR 91-413 and Part 43 Appendix F. This form shall be filled out with the information obtained from the applicable testing procedures required by the FAA. The technician performing the test will record the Tail Number, Aircraft Serial Number and applicable Transponder Model and Serial number information on the form as appropriate. This data will be placed with the final Work Order documentation and kept on file with the 91.413 data testing information


REVISION NO.: 7




TRANSPONDER TEST WORKSHEET FORM This form is used during certification of the Transponder and Encoder system per FAR 91-413 and Part 43 Appendix F. This form shall be filled out with the information obtained from the applicable testing procedures required by the FAA. The technician performing the test will record the Tail Number, Aircraft Serial Number and applicable Transponder Model and Serial number information on the form as appropriate. This data will be placed with the final Work Order documentation and kept on file with the 91.413 data testing information


REVISION NO.: 7




COMPASS CORRECTION CARD This form is used when performing a compass swing. True compass direction information shall be entered in each section tested showing the true bearing, not the error in the applicable data section below.

0 30 60 90 120 150

180 210 240 270 300 330

Altimeter Inspection Decal This decal is used for identifying an altimeter that has been tested by Premier Avionics, LLC. The information to be filled out includes the following: The altitude that the altimeter has been tested to, the part number and serial number of the altimeter, the work order and date of the test performed, and the Inspectors name indicated on the last line of the decal. When this information has been completed, the decal shall be placed on the altimeter that has been inspected. This form may be used to if needed to cover an existing decal from an earlier test, but this form is not required to be installed on the altimeter.


REVISION NO.: 7




PURCHASE ORDER FORM

This form is a computer-generated form used by the Repair Station for the purchase of parts required for completion of a work order when the manufacturer requires a purchase order number for purchase of equipment. This is a white, single page form to be turned into General Manager for tracking purposes. The General Manager is responsible for the completion of this form. This form is generated by the internal data within our financial software program.


REVISION NO.: 7




SUPPLEMENTAL WEIGHT AND BALANCE DATA AND EQUIPMENT LIST FORM The Supplemental Weight and Balance Data and Equipment List form is used whenever an aircraft is weighed or its weight and balance data must be updated after installation or removal of equipment. This is a computer-generated form. One copy is entered in the aircraft flight manual. A copy is filed in the Repair Station records. The General Manager or Chief Inspector is responsible for the completion of this form. Top of the form is filled in with the aircraft data. Below the removed and installed equipment are listed with applicable part number and serial number information. The items weight, arm, and moment are entered into the spreadsheet. The new data is then calculated based upon the old aircraft data entered on weight, arm, moment, and useful load. Finally, the person completing the form must sign the form on the bottom in the signature block.


REVISION NO.: 7




PACKING SLIP FORM This computer-generated packing slip form is used for tracking purposes when items are shipped out of the shop for various reasons. It is a single page, white form used to record the location the item was shipped to, type of shipping method, date sent, serial and part numbers, and date and initials of person packing the item(s) for shipping. This is not a required form, but is used when items should be tracked by serial number.

March 19, 2012

Ship to: Garmin AT, Inc. Description of Contents: Model 820 S/N 01032811. Rec. inop. Please repair and return. Call if there are any problems. Thank you, Premier Avionics, LLC 260-747-4810 Contacts: Brian Paugh General Manager Eric Faulkner Avionics Manager

Premier Avionics, LLC 11007 West Perimeter Road Fort Wayne, IN 46809 Phone: 1-260-747-4810 Fax: 1-260-747-4810 Email: [email protected] or [email protected] Avionics CRS# 7PMR634B


REVISION NO.: 7




8010 - 4 MALFUNCTION REPORT FORM If a defect or malfunction is found which could result in an immediate hazard to flight, the local Aviation Safety Office shall be notified immediately. In any event the Station shall file a “Malfunction or Defect Report”, FAA Form 8010-4 within 72 hours after a defect or malfunction has been found. In cases where filing such a report might result in a situation prejudicial to the Station’s interests, each case in question shall be reported to the local responsible flight operations and airworthiness Inspector. This form can be found on the FAA website and instructions on how to complete this form can be found as part of the online form.


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This page is blank for future use.


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FORMS AND STAMPS (CONTINUED) PARTS INSPECTION REJECTION FORM This form is used to record all rejected parts during preliminary, hidden damage, progressive and final inspections. This form will be maintained by the Chief Avionics Inspector and kept in the repair facility. The item, part number, serial number and reason for rejection are to be completed. The corrective action to the problem, date corrective action was taken and employee’s initials are to be entered on the form.


REVISION NO.: 7



SECTION III

PRIMARY TEST EQUIPMENT & CALIBRATION INTERVALS


REVISION NO.: 7



Primary Test Equipment Calibration Policies

Test Equipment Calibration List A list of Test Equipment currently owned, and being utilized by this Repair Station is available for Inspection at our facility. A copy of the List of Test Equipment and Calibration Intervals is located in the General Manager/Accountable Managers office. It lists the test equipment used by our facility requiring calibration and the time frame required between calibrations for each piece of equipment. Test Equipment Calibration Requirements

Test equipment shall be calibrated at periodic intervals established on the basis of stability, purpose, degree of usage and/or impact shock. One year shall be the maximum calibration interval, or other procedures approved by the Administrator. Each piece of test equipment will be labelled. The label will identify the unit by manufacturer, model, and serial number. The attached label must indicate the last calibration date and next calibration date due. During the first week of each month, the Chief Avionics Inspector will review the Test Equipment Calibration history file. The test equipment requiring calibration will be given to the Chief Avionics Inspector as appropriate. It will be the responsibility of that person to issue repair requests to Repair Station shops or outside contractors as necessary for the calibration of the units and attachment of updated calibration labels. After calibration, the test unit will be checked for proper labelling and the equipment calibration history file will be updated and returned to the Avionics Manager for final acceptance. At no time will any person be permitted to perform work on aircraft or components using test equipment which is out of calibration. The test equipment labels will be checked by supervisors at random to assure that equipment in use is in calibration. This includes personnel test equipment owned by employees. If at any time a piece of test equipment inadvertently exceeds its calibration due data, it will immediately be removed from service until a calibration check has been performed. Standards used to calibrate test equipment is traceable to the National Institute of Standards and Technology or an approved foreign country’s standards by certificate from the testing facility. All test equipment due, will be removed from service and sent for calibration within 14 days of due date.


REVISION NO.: 7



TEST EQUIPMENT IN HOUSE AND RENTED POLICIES

1. Equipment currently owned, and being utilized by this Repair Station have been listed

above on page 4.2. If equipment other than what is listed above is required, this facility shall either utilize an approved outside facility rated for this equipment or shall rent such equipment as required to perform such repairs or Return to Service requirements.

2. If outside sources are used for Return to Service requirements, such facility shall provide

all necessary log book entries as required for Return to Service requirements. 3. If equipment has been rented to provide Return to Service requirements, copies of that

equipments most recent Certificate of Calibration report shall be given to this facility. If such equipment has been verified to been properly functioning and in current calibration, that piece of equipment can be used for Return to Service.

Record of Precision Test Equipment Calibration

Calibration of all test equipment will be checked at regular intervals in accordance with acceptable standards. All precision test equipment shall bear a calibration sticker. Records of calibration will be recorded on a Premier Avionics calibration log located in Calibrations Records Book located in the Avionics shop. A Certificate of calibration for In-House calibrations must be completed, including technical data and shop standards used. An example of this form is found on page 2.6 of this manual.

Calibration Intervals and Corrective Action for Errors

Test equipment used for “Return to Service” will be calibrated as per intervals listed in section 3.2 of this Manual. Prior to use of a piece of test equipment, the person using the equipment will verify that the equipment calibration is current prior to using that test equipment for “Return to Service” use. If a piece of equipment is found to be out of calibration, that item will be tagged as “For Reference Use Only” and will not be used for “Return to Service”, until it has been calibrated and has a current calibration tag showing the date of calibration. When a piece of test equipment has been calibrated, Premier Avionics will view the calibration documentation and determine if that piece of equipment was found to be “Out of Tolerance” to determine if any potential items “Returned to Service” require further attention or recall. If it is determined that items were “Returned to Service” using the test equipment in question that could have caused potential errors with “Return to Service” test results, Premier Avionics will contact any customers that might have been affected by using that equipment. If it is found that errors have been made using that equipment, the local FSDO will be notified of such potential issues. Calibration intervals for test equipment can be found on page 3.2 of this manual. Any changes to the calibration interval must be approved by the local FSDO prior to any change.


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SECTION IV

CONTRACT MAINTENANCE AND VENDORS


REVISION NO.: 7



LIST OF CONTRACT MAINTENANCE PROVIDERS

Company Name Address Phone

This page is for future use. Premier Avionics currently does not use Contract Maintenance Providers. Outside Maintenance work is done by facilities authorized to return their work to service.


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LIST OF VENDORS


ATEC INC. CRS# XI7R807J

1750 Westcourt Road Denton, Texas 76207

1-800-553-2233

Century Labs 2802-G Congressional Parkway Fort Wayne, IN

260-471-1673

Mid-Continent Instrument Co, Inc. (CRS#OL2R061L)

9400 East 34th Street North Wichita, KS 67226

1-800-821-1212

Duncan Aviation (CRS# JGVR194F)

P.O. 3066 Omaha, NE 68103-0066

1-800-228-4277

Duncan Aviation (CRS# EBVR450D)

15745 South Airport Road Battle Creek , MI 49015-8688

269-969-8400

Metro CRS# JY2R943K

2135 Airport Rd. Oakland County Int’l Airport Waterford, MI 48327-1207

248-666-3670

JKM Calibration 4000 East Bristol Street Suite 3-221 Elkhart, IN 46514

877-434-6122

Tel-Instrument 728 Garden Street Carlstadt, NJ 07072

201-933-1600

Aero Standard 720 Valley Ridge Circle Suite 21 Lewisville, TX 75057

877-521-2600

Universal Avionics (CRS# UZNR483N)

3260 East Universal Way Tucson, AZ 83756

520-295-2300

ASI (Avionics Specialist, Inc. (CRS# PK4R443M)

9400 East 34th Street North Wichita, KS 67226

1-800-821-1212

Avidyne Corporation (CRS# 1VAR161B) *Instrument and radio repair

710 North Drive Melbourne, FL 32934

321-821-5224

Elliot Aviation (CRS# KX5R005N) *Instrument and radio repair

13801 Pioneer Trail Eden Prairie, MN 55347

952-944-1200

Elliot Aviation Des Moines, Inc. (CRS# JEMR166F) *Instrument and radio repair

2800 McKinley Avenue Des Moines, IA 50321

515-285-6551

Elliot Aviation of Omaha, Inc. (CRS# MGOR426G)

3636 Wilbur Plaza Omaha, NE 68110

402-422-6789

ISSUE

DATE: 1/12/2014 REVISION NO.: 7



LIST OF VENDORS (cont.)


Elliot Aviation of the Quad Cities (CRS# CGHR812C)

6601 74th Avenue Milan, IL 61264

309-799-3183

Garmin International, Inc. (CRS# G6XR582Y)

1200 East 151st Street Olathe, KS 66062

913-397-8200

Garmin AT, Inc. (CRS# JC6R634N)

2345 Turner Road SE Salem, OR 97302

503-581-8101

PS-Engineering, Inc. (CRS# P34R133O)

9800 Martel Road Lenoir City, TN 37772

865-988-9800

S-TEC Corporation (CRS# FF2R818K)

One S-TEC Way Mineral Wells, TX 76067

940-325-9406

Century Flight Systems, Inc. (CRS# FD2R816K)

3010 FM 1195 Mineral Wells, TX 76067

940-325-2517

Muncie Aviation (CRS# AJVR135C)

5201 North Walnut Street Muncie, IN 47308

1-800-289-7141

Mayday Avionics (CRS# YXXR3887Y)

P.O. Box 888316 Grand Rapids, MI 49588

616-957-4920

Lafayette Avionics (CRS#KH2R952K)

1632 Aviation Drive West Lafayette, IN 47906

765-743-3828

L-2 Communications (CRS#NN2R037L)

5353 52nd Street SE Grand Rapids, MI 49512

616-949-6600

Millennium International (CRS# M7XR967N)

1825-2 Southwest Market Street Lee’s Summit, MO 64082

816-524-7777

Precision Dial (CRS# P19R0190)

7240 West K L Avenue Kalamazoo, MI 49009

269-375-5601


REVISION NO.: 7

Documents

Premier Avionics Control Manual Rev-7 for... · premier avionics, llc quality control manual . faa approved repair station no. 7pmr634b . premier avionics, llc. fort wayne international