Process Excellance Framework

8/16/2019 Process Excellance Framework

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S.No PROCESS NAME

1 Wet Installation of fasteners

2 Application of Fay Sealant


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3 Sealant Mixing


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4 Water Tightness Demonstration process


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5 Mixing of ahesi!e


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" #rotection of F$D sensiti!e Areas


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% Fillet sealing


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& 'DI()#I* +y c,rrent process


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-Drilling./eaming on Metals( De0,rring* Score Mars*Ang,larity


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1 ol oring process


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11 #rotection of omposite oor.0ottom panel


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12 +lectrical 6oning Test process


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13 #aint Mixing


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14 #art maring

15 Application of Ahesi!e


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1" Tor7,e tightening process


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1% +mergency +gress 8atch AT#


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1& 'ics* Scratches* 9o,ges an Dents


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1- Aloine Application


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2 A#: Drain )ea Test


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21 +ngine(Drain )ea Test


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22 a0in 8eating 8ose #ress,re Test


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23 Flight ontrol a0le Alignment test process


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24 #rimer Mixing


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25 8yra,lic System )ine Fl,shing #rocess


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2" 8yra,lic #ress,re #roof Test process


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2% Mo!ement of panels an ca0in from ;ig to ;ig


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2& Application of #rimer


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2- Installation of IDs

3Drilling./eaming on omposites( De0,rring* ScoreMars* Ang,larity


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31 #ainting


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32 Wire )ocing process

33 Saging process

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35 Mo!ement of ca0in to Shipping Fixt,re an tr,c

3" T,0e Installation process

3% #aint Stripping of Metal < omposite parts

ontrol < 8anling of Air(conitione room an itse7,ipment for paint


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KEY CHARACTERISTICS

1= #ersonnel competency2= :sage of primer or sealant for et installation of fasteners as per /o,ter . MA#)3= Sealant recors4= :se of appro!e cleaners < F$D free conition

5= ae7,ate s7,ee>e o,t Sealant or primer nee to 0e extr,e into the hole an aro,n the s,rfa"= inspectors itness ,sage of sealant or primer=%= #ost cleaning an protection against F$D&= $perator an inspector sign o? after et installation of fasteners ith rele!ant oc,mentation=-= 8anling of expire seal or primer an post cleaning of the e7,ipment=1= ,sage of primer or sealant ithin its pot life=11= ##+ Aherence

1= #ersonnel ompetency

2= #roper s,rface preparation3= ##+ ompliance4= F$D free from chips* 0,rrs* ,st an oil=5= ,sage of appro!e cleaners"= ,sage of lint free cloth an iping in single irection=%= re7 sealant is ran as per MA#) an @is,al ai re7,irement ith the sealant recor&= sealant etails Segment* A$S no* W=$ 'o* a0in no* Shift* an DateB are entere in the sealant-= sealant is applie ith a roller or 0r,sh to form a ,niform thicness of approximately =1 inchepattern across the s,rface to 0e coate1= sealant is sprea to a ,niform thicness ith a spreaer or roller= :se eno,gh sealant to o0tainthicness an a S7,ee>e o,t for a Cllet forming11= ae7,ate sealant s7,ee>e o,t from the mating s,rface eges=12= application of the temporary fastener if the permanent fasteners are not installe ithin the a13= +xcess sealant s7,ee>e o,t shall 0e faire to form a Cllet not less than 1.& inch ie14= 'o F$D * 9A#* :n(e!en thicness* locally ,nco!ere area=15= clean of any ,nante sealant ith a sol!ent ampene cloth hile sealant is soft= Do not appamage the seal an create a possi0le lea=1"= recoring of the application complete time in the sealant recor sheet ith sign an stamp= Acompleteness an o?er to inspection=


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1= :se of prescri0e sealant as per the stanar.proce,re=2= en!ironmental conition ,ring preser!ation < mixing=3= mixing en!ironmental conition /8( Max "

Temp( 1&=33 to 2-=44 egree elsi,s4= mix ratio as per the man,fact,rer instr,ction I =e Weight ratio 0ase to acceleratorB

5= :se same 6atch of 0ase < catalyst ,ring the mixing="= mixe sealant conition to 0e in ,niform colo,r < stea free conition=%= tracea0ility of the 6atch < )ot of the sealant=&= A!aila0ility of the mixing of the recor in form TAS) 2 13=-= ##+ ompliance1= one 0atch sealant < catalyst not mixe ith the other 0atch sealant < ahesi!e=11= All the speciCe test 0een performe ,ring the sealant process 12= Daily F$D chec aherence < a!aila0ility of recor=13= the shelf (life of the sealant 0efore the mixing as pee the $=14= Instr,ments cali0ration control15= Free>er temperat,re control in oring an non(oring ho,rs

1"= #ersonnel competency an aareness on sealant mixing as per SS &"4* T$#(2(%1%= Aareness on MSDS1&= /ecor maintenance1-= 'on(conformance hanling in Sealant mixing2= A!aila0ility of the T$# proce,re at the sealant itchen21= Shelf life +xtension proce,re an rele!ant comm,nication ith the s,pplier=22= Test specimens preparation as per T$#* Test recors ,peeping ith specimen23= Accelerate c,ring of Test specimen* Temperat,re control for accelerate c,ring24= 8arness recors for the specimen


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1= Appro!e < #ro!e Test e7,ipment2= optional assem0lies installe on the ca0in f,selage 0efore ater tightness test=3= ,mmies are installe on the ca0in f,selage 0efore ater tightness test=4= Am0ient ,i temp is maintaine 0eteen 4EF to 1EF=5= Fl,i ,se for the test is Fresh ater 2=3 gpm for ca0in . 2=12 gpm for Drip panB ith a o rat

"= test ,ration is 2mins for ca0in an 3 mins for Drip pan=%= test is carrie o,tsie then steay in !elocity of (% nots is maintaine=&= or relate to the ca0in is complete an there are no F or open ' or D/= -= A satisCe irele!ant optional assem0lies are installe=1= Water Tightness e7,ipment ga,ges are cali0rate11= lightening arrangement insie the ca0in for A is s,Gcient12 = all the open areas of the ca0in are close= 0oth the ens of the f,selage are co!ere= all the apoints of M/# an the area of M96 Drip pan are co!ere=13= Testing Cxt,re positioning is as per the proce,re= ,pper no>>les shall 0e approximately "% inc14= Spray pattern from the no>>les sho,l 0e satisfactory to A= Any ,nsatisfactory spray patternno>>le=15= test performe in presence of the A from start to en=

1"= ater press,re at the no>>les shall 0e a sim,late rainfall rate of 45 to & inches per ho,r for1%= 1 min,tes ell time is alloe folloing the sh,t o? of ater s,pply an then A inspect th1&= all the leaages are ientiCe an recore=1-= all the leaages o0ser!e are repaire as per SS&"32= no of leaages are more than 5 then retest performe an if no is less than 5 then local test p21= local test a pocet to co!er the entire leaage area is mae ,sing the polythene co!er an SM22= local test pocets are Clle ith ater an ept on hol for 15 to 2 min an o0ser!e for leas23= report of the ater tightness test is s,0mitte to SA= Is the test report incl,es all the locatiothose leas=24= post cleaning of ca0in is carrie o,t after remo!al of all the co!ers an temporary seals=25= perioic maintenance of the test e7,ipment is carrie o,t2"= test ,i is perioically chece for contamination an replace


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1= ontrolle #reser!ation < mixing Temp 25 egreesB=2= /ecei!ing inspection stamp ith Date of Mfg an Date of +xpiry3= A!aila0ility SS&"4 . T$#(2(11 . MSDS at the Ahesi!e mixing area4= ali0rate Mixing +7,ipment5= #ersonnel competency"= ali0erate Weighing Scale%= ##+ ompliance&= IentiCcation* Tracea0ility of the Ahesi!es* promoter < leaners at Mixing area=-= Shelf (life Tracing.+xtension per $=1= Mix ratio as per Man,fact,rer instr,ction.S$#11= Same 6atch Mixing of Accelerator an 6ase ith 6atch nos recor12= :niform Mixing of parts A < 6 ith ,niform colo,r an homogeneity=13= ientiCcation on mixe ahesi!e ith Date* Time of mixing an +xp etails on a la0el an aGx14= A!aila0ility Ahesi!e Mixing /ecor Sheet of latest /e! an itnesse 0y the inspector=15= F$D control ,ring mixing1"= lean as yo, go

1%= Mixing area ell !entilate1&= #ost mixing cleaning ,sing appro!e cleaners1-= Daily F$D chec aherence < a!aila0ility of recor at the mixing area2= ty mixe is less than 45 9rams=21= hanling of +xpire material at mixing area=


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"= F$D pre!ention Wor instr,ctions speciCc for each man,fact,ring area=%= #erioic selfHassessments of each man,fact,ring area in accorance ith ritten checlists&= Management re!ie of the F$D #re!ention #rogram on a reg,lar 0asis to assess the e?ecti!enee!ience of F$D inspection=-= :sage of #areto an.or tren charts to s,mmari>e an analy>e assessment Cnings an ientifythese charts at or centers to gi!e res,lts to the operators an management=1= A!aila0ility of M System for reporting F$D incients to management* in!estigating root ca,s

11= existence of a metho for formally notifying Siorsy Aircraft of eli!ery of pro,ct non or so0;ects12= Inspection oc,mentation m,st contain a F$D chec13= F$D control o!er its s,ppliers an !enors14 = $rgani>ation control o!er Transient personnel an +n!ironmental conitions for controlling F$15= ontrol o!er )ost items*instr,ment* ga,ge an part proce,re=1"= protection of F$D sensiti!e areas ,ring Transportation of panels or ca0in from one segment t1%= F$D chec 0y 0oth pro,ction an inspection prior to transportation an resting of the ca0in1&= Foams rappe aro,n all s,pports of Dolleys* sis an stans nees to 0e free from F$D otof the sins of )oer T,0=1-= )essons learnt on F$D ,e to past incients an action taen against them= +ns,re iGc,lt toacc,m,lation of 0,rrs an e0ris=2 = protection Tro,gh areas of )oer panel ,sing 3 layers to a!oi ents at 24 segments to a!oi21 = ,stomer complaints on F$D an action taen against them=22= entry to F$D critical areas is restricte an no F or from the pre!io,s stages is 0eing carriof the area manager an relate ,ality inspector of that area=23= en caps are pro!ie to 8yro line inlets an o,tlets* 8eating 8oses* Tee* +l0o an :nions o24= Installs connectors for a0les an Wire 8arness nees to 0e protecte ith +lectro Static Disc25= Drip pan* M96 6,sh areas* Sponson 6,sh areas of Frames* Spherical 6,sh areas of Sponsonagainst F$D=2"= F$D chec 0efore eli!ery of the ca0in 0y pro,ction* Inspection an c,stomer team=2% = F$D control at Stores* sealant . Ahesi!e mixing area* paint 0ooth* #$S area an ## itting2&= perioic performance re!ie of all the or centers=

2- = ,stomer comments* concerns an complaints on F$D if any an action taen against them=3 = material ,se for pacaging of the ca0ins or its are free from F$D=


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1= #ersonnel competency an aareness on Fillet sealing re7,irements as per SS &"42= application of the Cllet sealant as per the speciCcation SS&"43= a!aila0ility of the rele!ant oc,ment for the sealant an compliance of all characteristics=4= ae7,ate cleaning < F$D free conition of the sealant application area 0y operator an concer5= :sage of appro!e e7,ipmentJs as per SS &"4 an T$# proce,re"= #reparation for Fillet sealing

A= leaning1=F$D cleaning2=,sage of appro!e cleaners3= :sage of )int free cloth4= leaning performance as per T$#5= Witnessing of the inspector after cleaning=% :sage of the appro!e sealant as per MA#) an /o,ter& /ecoring the etails of the sealant ith A$S no* Shift* W=$ '$* A. no* Date* Application time operator an inspector=-= Application of the Fillet seal ,sing the g,n as per T$# proce,re i=e Angle an irection control=1 = proper Cllet seal ith is maintaine ,ring the application= All the 0,00les are faire properl11 hec for ,niform appearance= If any efect notice after the sealant has c,re* shall 0e c,t o

12 the croing re7,irements are maintaine If the thicness of the top plate or o?set is the lessthe top plate or o?set 0y =15 to ="LB13 For the 0,tt gap Cll 0y o?setting of =15 to ="L14= Cllet seale area has to 0e free from the !is,al efects15= #ost cleaning an protection against F$D1"= $perator an inspector sign o? after Fillet seal application ith rele!ant oc,mentation=1%= /eor in Fillet seal an relate oc,mentation=1&= 8anling of expire Fillet seal an post cleaning of the e7,ipment=1-= Fillet seal #ot life control at or centers2 =/epetiti!e pro0lems in Fillet seal an action taen to control them21= Aherence of ##+ ,ring Fillet seal application=22= nolege of efects in Fillet seal to operators* S,per!isors an Inspectors=23= +?ect of Temperat,re an h,miity on Fillet seal application=


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a= )e!el of ,aliCcation0= #ersonal ,ties an responsi0ilitiesc= )imitations= Training programe= /ecertiCcation /e7,irementsf= /e7,irements for experienceg= /e7,irements for examinations

h= /ecors an oc,mentation practicesi= Materials ;= +7,ipment35 )e!el III personnel a!aila0le for )#I3" an o,tsie agency ,tili>e for performing the )e!el III f,nctionsIf an o,tsie agency is ,tili>e* has the employer oc,mente the s,ita0ility3% the folloing 5 le!els of 'DI personnel a!aila0lea= Trainee0= )e!el Ic= )e!el II= )e!el IIIe= Instr,ctor

3& a training co,rse o,tline for each le!el in place3- the training co,rse appro!e 0y )e!el III4 the training co,rse o,tline aress* for each le!el the folloingNa= #rinciples0= #ro,ctsc= +7,ipment= $perating proce,rese= Techni7,esf= SpeciCcation coesg= Training ho,rs41 the re7,ire training ho,rs for le!el I* II an III for each metho as per the c,stomer re7,ireme42 e!ience of pre!io,s training from a pre!io,s employerO If yesa= The training is oc,mente0= The training has 0een !eriCe


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cB the rill g,n ithran from the hole ith rill motor still r,nning an stoppe after coming o,B the appropriate cleco selecte an hole is loce ith cleco 0y ,sing cleco pliereB the rilling contin,e in the similar ay as etaile a0o!e for the remaining holes of the !is,alfB the rille holes are ha!ing s,rface Cnish of 25 micro inches AA'oteN iB Install a rill stop if there is a o0str,ction 0ehin the part 0eing rilleiiB :se a g,ie 0,sh hen rilling at the c,r!e s,rface to g,ie the hole normal to the s,rface=iiiB :se a 0ac,p s,pport of oo or Al,min,m to a!oi the mo!ement of the thin stac ,p parts

i!B If the rilling is one on a sin hole rilling to 0e starte from centre to o,tar=- Step DrillingN the progressi!e or step rilling folloe if the hole si>e larger than =125 inches to 0e rille in TiAl,min,m'oteN For rilling =5 inches in Al,min,m a start rill of P4 folloe 0y rill si>e of =25* =3%1 #ost DrillingNaB the shop air isconnecte from the rill motor0B the parts isassem0le for e0,rring an cleaningcB all the holes cleane ,sing the chip chaser if it is impractical to isassem0le the partsB all the holes self inspecte 0y the operator an InspectoreB the inspectors ,sing the cali0rate pin ga,ge for inspectionfB the rele!ant operations signe an stampe 0y operators an inspectors

gB the clean as yo, go folloe 0y operator11 /eaming $perationNaB the reamer of appropriate material an si>e selecte0B the reamer c,tting teeth free from F$DcB the re7,ire /#M as per the material set in rill motorB the reamer ch,ce into the rill motor an tightene properlyeB the reamer c,tting ,tes ippe in 6oe l,0e c,tting ,ifB the reamer positione perpenic,lar to the s,rface 0y ,sing the g,ie 0,shgB the reamer passing to f,ll length of the holehB the shop air isconnecte an reamer man,ally taen o,t 0y rotating in anticlocise irectioniB the reamer cleane an ippe again in 6oe l,0e an a0o!e steps repeate for remaining hole

;B the holes e0,rre ,sing the appropriate tool an cleane for 0,rrB the holes chamfere as per the g re7,ire tolerances =15(=3 /ai,s for Titani,m an =12 /eame 8oles InspectionN


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B the hole col ore 0y act,ating the p,ller ,nit so that manrel is ithran thro,gh the sleeB the act,ation of the p,ller ,nit is contin,e ,ntil the manrel is clear of the str,ct,refB the slee!e remo!e from the hole an iscare'oteN /e ,se of the slee!e is not permitte=gB the col ore hole !eriCe ith com0ination ga,gehB the a0o!e col or proce,re repeate for other holes hich are reay1 oloring 8ole Finish characteristicsN

aB the hole pro,ce 0y coloring is of ho,rglass shape ith en of the hole corresponing to tthe manrel entry en of the hole0B 'o 6,cling or oil canning of the material a;acent to the hole after col expansion'oteN A0o!e conition is accepta0le only if the hole is Clle ith a fastener installe ith s,Gcient0,cling=cB the 0ore of the hole free of im0ee particles* aing* tearing* foling an cracing'oteN the presence of a shear iscontin,ity shall not 0e ca,se for re;ection of a col expane holB the iameter of each hole shall 0e !eriCe 0y a traine operator 0efore an after col expansiohas 0een accomplishe an that Cnal imension an alignment is in accorance ith the re7,ireeB the col oring hole is ha!ing o,t of plane istortion S,rface ,psetB'oteN The a0o!e conition is accepta0le as long as the installe fastener meets the re7,irementsfB the 0ore of the hole is ha!ing axial rige corresponing to the position of the split in the slee!e

'oteN A0o!e conition is accepta0le=gB the shear iscontin,ities notice after col expansion'oteN A0o!e conition is accepta0lehB separation of the faying s,rfaces 0eyon =5 inches folloing col expansion of a stac ,p oiB the !eriCcation ga,ge is not pass thro,gh the stac ,p ,e to spring 0ac in m,lti material stac'oteN hen col expaning m,lti(material stac ,p the col expansion ill not 0e the same in eac11 Final /eamingNaB the Final si>e reamer appropriate to the fastener iameter is selecte an loae onto rill g,n0B the colore hole reame 0y ,sing the c,tting ,i an g,ie 0,sh at re7,ire /#M for the'oteN )oer /#M nees to 0e ,se for any reaming operationcB the reamer cleane to remo!e 0,rrs after reaming itho,t remo!ing from the holeB the g,n t,rne o? an reamer p,lle o,t 0y rotating in anti clocise irection to a!oi scoreeB the hole s,rface Cnish of "3 micro inches AA is maintaine itho,t any score marsfB the hole is normal to the s,rface


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transportation=2 +ns,re the sins are taen after !is,al inspection for the Dents after receipt from ##= hec forfrom Stores* ## to pro,ction area3 +ns,re Thic foams are ,se for protection against core for tool roppings are any other impact4 Aherence to lean As Qo, 9o 0y the employees an ens,re that the panel is ent free5 +ns,re the proper training to operators for the hanling of loer panel sins against Dents an i" +ns,re the ro,ters an !is,al ais of 244 segments ha!e pre!enti!e or instr,ctions for protec

% +ns,re the aily chec 0y the area operators an inspectors for the Dents on Sins of loer panany=& +ns,re ,ring Final shaeon that no ents exist on the sins on 0oth exterior as ell as interiattache along ith the /o,ter an attach the same along ith the Tra!eller=- +ns,re the protection of F$D sensiti!e areas ,ring Transportation of panels or ca0in from one s1 +ns,re the F$D chec 0y 0oth pro,ction an inspection prior to transportation an resting ofolleys=11 +ns,re Foams rappe aro,n all s,pports of Dolleys* sis an stans nees to 0e free froms,rface of the sins of )oer T,0=

12 8a!e the panels inspecte for Dents 0y the inspector of next stage an tae the sign o? in thesheet in the similar manner at each stage of Transportation to other segments till Cnal ispatch=

13 +ns,re the proper care taen ,ring clear coat painting at paint 0ooth on the interior of )oer14 +ns,re ,ring clear coat inspection for the ents if any= hec on the exterior s,rface also=15 +ns,re 6efore integration 24 inspector checs for Dent chec sheet from pre!io,s stages aninterior an exterior of the panels=1" +ns,re the preparation of the panel ith 2 layers of protection on the panels as speciCe on thprotection are free from Dent ca,sing materials= +ns,re that operators are not stepping on the int1% +ns,re after panels integration Wooen Floor 0oars are place on the loer panel to protect aSame protection nee to 0e folloe till Cnal shaeon=1& +ns,re the entry to F$D critical areas is restricte an no F or from the pre!io,s stages isnolege of the area manager an relate ,ality inspector of that area=1- +ns,re the )oer panel interior an exterior sins are free from Dents ,ring shaeon at eafor the same ,ring Daily F$D checs at these segments= +ns,re that F$D chec happens itho,ttro,gh areas nees to remo!e to a!oi Dents=2 +ns,re )oer panels are free from Dents 0efore o?ering the ca0in to c,stomer team for Cnal 0


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2= #ersonnel competency on s,rface preparation an +lectrical 0oning meas,rement= Also for pro3= /emo!al of protecti!e or ecorati!e Cnishes < F$D* remo!al of oil* grease* epoxy an sealants f 4= :se of appro!e cleaners an iping cloth ,se for remo!al of oil* grease otherise !apo,r eg5= leaning of sol!ent ipe ry ith lint free cloth 0efore it e!aporates"= Apply orrosion protection after 0oning meas,rement%= Installation or assem0le in accorance ith re7,irements of applica0le installation raings= &24 ho,rs after completion of orrosion #rotecti!e treatment=

-= attaching harare to achie!e 0one connections speciCe on the applica0le engineering ra1= #rotecti!e Cnishes on the harare is not remo!e ,ring installation11= Intermeiary ashers re7,ire in attaching harare stac ,p hen 0oning 0eteen issimil12= Crst an secon terminal l,gs on a st, shall 0e installe ith the topsie ,p= When 3 or moreCrst to l,gs shall 0e in!erte= The thir an s,0se7,ent l,gs shall 0e installe top sie ,p to pre13= meas,rement of 0on shall 0e in accorance ith engineering raing= The test shall meas,rmating s,rfaces ,sing milli(ohm meter= If the esire !al,es are not met then the steps repeate14= +n!ironmentally expose electrically 0one assem0lies an.or installations shall 0e seale toseale shall 0e slightly larger in iameter than the cleane area= Sealing shall 0e complete notmagnesi,m components* an not more than % ays after installation for all other materials=15= hen protecti!e coating is 0een remo!e from the metallic s,rfaces* the complete connectioa s,ita0le protecti!e to,ch(,p Cnish * ithin 24 ho,rs after inspection=

1"= s,rface preparation* harare installation an meas,rement are as per the instr,ction gi!en i0y operators an inspectors=1%= on,cti!e coatings or Cnishes shall not 0e remo!e 0eca,se they ha!e s,ita0le con,cti!ityre7,ire only cleaning or egreasing to meet 0oning an.or gro,ning re7,irements* i=e= tin platiAloineB1&= remo!al of on,cti!e oating from Metallic S,rfaces only hen eCne on engineering rai1-= If the assem0ly raing oes not specify a resistance limit* the re7,irement shall 0e 1 milli2= con,cti!e coating on connectors is not remo!e=21= Saning is prohi0ite on screene composite parts in hich the al,min,m ire mesh.copper f an protecte 0y copper tape masing22= 6oning harare shall 0e 3.1" inch P1B minim,m hoe!er* P& may 0e ,se here clearaith a 1 AM# c,rrent ret,rn shall 0e K inch minim,m an a 2 AM# ret,rn re7,ires 5.1" inch23= +lectrical components meas,rements shall 0e taen an recore ith airframe harness connconnectors mate* ,e to installation location shall 0e taen an recore as connectors mate=


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+ns,re the aherence of the ##+ 6,tyl /,00er or Teon 9lo!es* 8alf face respirator e7,ippe itf,ll(face respirator e7,ippe ith organic !apo,r cartrigesB ,ring application as speciCe 0y ma% @iscosity /e7,irements after mixingIs the max= @iscosity of the paint coatings shall 0e 3 Sec thro,gh P4 For c,p* immeiately after%O& IentiCcation* Tracea0ility an Storage of #aint componentsNAre the IentiCcation* Tracea0ility of the #aint components* Thinners< leaners at Application are

Are the conitions for the storage shall 0e a aily am0ient air temperat,re that is maintaine at 5- Is the paint after mixing < storage at room temperat,re in a close container cons,me ithin i1 Are the facilities ,tili>e for cleaning* priming < painting pro!ie protection from in* rain an11 Is there a close room ,tili>e hich can control the ,st entry* lighting to pro!ie normal !isi08,miity of 35 to %5O12 Is the Aircraft* Ma;or component or part temperat,re shall 0e at least "EF an in e7,ili0ri,m prior to application of any coatingsO leaning prior to #aint ApplicationN13 leaning 9eneralNIs the s,rface to 0e coate clean an free of oil* ,st* a0rasi!e poer etcO14 Is the cleaning an s,rface treatment of aircraft* ma;or assem0lies an parts prior to painting opaint ahesion an CnishO15 Are non(a0rasi!e 0r,shes or other cleaning ais ,se if there is contamination or other soils thoperations itho,t scratching or marring the s,rfaceO leaning of Metal s,rfacesN1" Is there any cleaning or sc,Gng of anoi>e or chemical con!ersion treate metal s,rfaceO'oteN Sc,Gng of anoi>e or chemical con!ersion treate metal s,rface is not permitte=1% leaning of existing exterior coatingsNAre the existing exterior coatings s,ch as epoxy primer or aircraft paint* prior to prime or paint cleSS&%52* SS-1%.5" an SS-1%."&1 or alaline cleaners in accorance ith SS-1%.22O1& Is 2 grit or Cne san paper or light to mei,m hite or /e scotch0rite ,se for Sc,Gng or sother soils that cannot 0e remo!e ith simple han ipe operations an to pro!ie optimal ahe1- Is the scotch0rite a0rasi!e pa ette ith sol!ent or cleaner as an ai to clean the s,rface an

2 Is the sc,Gng or saning limite to primer gla>e an not extening onto 0are metal or anoi>e21 leaning of existing Interior coatingsN


42/58

4 +ns,re part maring of etail le!el an assem0ly le!el is ,se for ientiCcation 0oth 0y itting tthat it is clear an protecte at i?erent stages of Assy=5 +ns,re pro,ction* M+ an ,ality team are ha!ing the competency o!er the Siorsy re7,irem/e7,irements=" +ns,re appropriate part maring metho as prescri0e in +ngineering Dg is calle o,t 0y M+ i0oth pro,ction an ,ality=% +ns,re the e7,ipment ,se for part maring is in line ith the re7,irements of SS &%-&* MI)(M(&

StencilB=& +ns,re the personnel in!ol!e in part maring are aare of permanent part maring an non pein SS&%-& an rele!ant ro,ters=- +ns,re !i0ration peen or Dot peen marers are meeting the /ai,s < Diamon or ar0ie Tip reso,rce as speciCe in SS &%-&=1 +ns,re min part Thicness re7,irement of =25 inches are met for #art maring 0y @i0ration pexcee =" inches for !i0ration peen an =3 inches for ot peen=11 +ns,re ,sage of Aloine an clear coat after @i0ration peen maring as prescri0e in @is,al ai12 +ns,re for /,00er stamping characters are p,t in a straight line an pre c,t stamps are ,se f 13 +ns,re the characters height of 1.3 to 3.& inches is maintaine for /,00er stamping=14 +ns,re the ,sage of the appro!e in as eCne in SS &%-& an it is p,rchase from the so,rc

15 +ns,re the Tag an 6ag metho is folloe here it is not possi0le to mar as per the /o,ter o0ag an it is tie s,ita0ly to part ith Tag clearly reaa0le=1" +ns,re the D/ no is mare an 8oles here Fasteners are installe at )ater stages of assy atas per the instr,ctions gi!en in D/ . /o,ter1% +ns,re the D/ /epair parts are mare ith appropriate no as instr,cte in the D/ or /o,ter ,1& +ns,re the 'ame plates are mare ith appropriate Assy no* Sl no* MF/ coe* Aircraft moel*Inspector an SA/ or / or D/ as re7,ire 0y that assy= +ns,re Aloine an clear coat is ,se1- +ns,re +ngineering Assy no ,pon completion of it is /,00er stampe an MF9 Assy no is stamthe Dg an ro,ter re7,irement= Tag metho is ,se for small parts of si>e U inch V 2 inch /ectan2 +ns,re the part marings 0y /,00er stamp are clear an reaa0le= For reor on part maringcleaners=21 +ns,re the iring harness installation parts.assem0lies shall 0e ientiCe ith ientiCcation Ta',m.name* Draing .#hoto 0oo 'o an Aircraft e?ecti!ity=22 +ns,re 8anriting irectly on the part shall only 0e ,se hen a0sol,tely necessaryB= A met

1= #ersonnel ompetancy2= S,rface preparation3= ##+ ompliance4= Free from F$D*chips* 0,rrs* ,st an oil=5= #roper leaning N lint free cloth an iping in single irection=%= For 'M#.#ainte ahesion a0rasion 0efore applicationN 0rea gla>e only&= Ahesi!e recor-= ell !entilate area to a!oi toxic !apo,rs of the cleaners an ahesi!es

1= #rimer or promoter Application < ,ring11= Ae7,ate Fillet ahesi!e s7,ee>e o,t from mating s,rface eges=12= :se of Ahesi!e ithin its pot life=13= ero !is,al efects N F$D* Air 0,00les* 9A#* :n(e!en s7,ee>e o,t < ,nco!ere areas=14= Application Time15= ontrolle temperat,re < time1"= +xpire Ahesi!es hanling.isposal at or centers1%= proper rolling to a!oi e0oning=


43/58

1 +ns,re the Tor7,e /e7,irements are folloe as speciCe in SS-3=2 +ns,re M+ ro,ter an @is,al ai are in line ith the re7,irements of SS-3 < Dg re7,irement3 +ns,re the a!aila0ility of Training to operators an Inspectors on Tor7,eing as per SS-34 +ns,re the operators an inspectors are clearing the test after the Training ith ,alifying mar5 +ns,re the Tor7,e at Shop oor is performe either 0y Tor7,e certiCe operator or Tor7,e certiC

" +ns,re the operators an inspectors are aare of the ,sage of Tor7,e rench% +ns,re the cali0rate Tor7,e renches are ,se for Tor7,eing= +ns,re the operators an inspectany on the tor7,e renches 0ase on the cali0ration certiCcate ,ring the Tor7,eing process=& +ns,re the operators an inspectors are aare of the tolerance to 0e consiere for the tor7,ein- +ns,re the self(locing n,ts remo!e for any reason after tor7,eing are not re,se1 +ns,re the o!er Tor7,e fasteners are not re,se ,ner any circ,mstances=11 +ns,re after the Tor7,eing instr,ment ID no is entere in the ro,ter or FI/ ith Act,al Tor7,e !certiCe operator or certiCe inspector=12 +ns,re hene!er the ',t sie is not accessi0le operators are gi!ing Tor7,e at 6olt sie ith 113 +ns,re in the a0sence of Tor7,e !al,es in the 6.# g M+ is calling o,t the Tor7,e !al,es in /oSS-314 +ns,re the loa re7,irements of Tension or shear are ecie 0y +ngineering hile calling the

15 +ns,re only Tightening of the fasteners are folloe for the scres of si>e 0elo P1 or the loa1" +ns,re the Mating threas of the fasteners are free from 0,rrs* chips < F$D prior to Tor7,eing=1% +ns,re the operators are selecting the Mean Tor7,e !al,e for the fasteners an for the castella

Tor7,e=1& +ns,re ,ring the Tor7,eing no o!er Tor7,eing or :ner Tor7,eing sit,ation arise1- +ns,re the Tor7,e rench is hanle lie a elicate instr,ment* alays store in a protecti!e c2 +ns,re the folloing for Series Fastener Tor7,eing= Diametrically tor7,e all fasteners to minim,21 +ns,re one pitch of the threas of 6olt protr,sion o,t of ',t after Tor7,eing=22 +ns,re Tor7,e Striping carrie o,t as per the re7,irements of SS-3=23 +ns,re hen the aapter changes the e?ecti!e length of the rench Tor7,e correction taen in24 +ns,re hen applying the speciCe assem0ly tor7,e* the operator shall not apply excessi!e ax


44/58

1 Are the pro,ction an Inspection personnel aare of the p,rpose of this testO2 Are they ha!ing training* competency to perform this testO3 Is there any etaile proce,re from M+ etailing the re7,irementsO Is there any speciCc g focapt,re in the proce,reO4 Is the test proce,re ha!ing c,stomer appro!alO5 Is the test on First ca0in FAIB itnesse 0y the c,stomerO" Does the temperat,re an h,miity conitions re7,ire 0y the tests are maintaine an recore

% Are the instr,ments* ga,ges ,se for the test are cali0rate an c,rrentO& Is there any ro,ter from M+ for this test for e!ery ca0in till 1% an then once in e!ery % to 1t,alityO- Are the +mergency Door )8 an /8 ,se for this test are cleare from pre!io,s stageO1 Are the Assy 'o* a0in no* MF/ coe an inspection stamp are ritten on themO11 Are all the parts re7,ire for this test is installe onto ca0in as per 6.#* TAT#(% or !is,al ai .12 Does the concerne ,ality inspector itnessing all the se7,ence of operations as etaile in13 Is the s,rface preparation for electrical 0oning carrie o,t on ca0in as ell as +mergency Doo14 Are the !al,es chece an recore 0y #ro,ction an ,ality inspectorO15 Are the /,00er seals (1% < (1&B of appropriate lengths are ,se for the testO1" Are the gaps of to =1 inches maintaine 0eteen the ens of (1% < (1& after assem0ly a1% Is the #,sh p,ll ga,ge locate on the 8anle as shon in TAT# at interior as ell as exterior of

1& Is the ga,ge p,she normal to hanle arm hile the hanle is rotateO1- Is the force applie to rotate the hanle is less than 5 )0fO2 Is the istance 0eteen corner of the hatch sin an c,t sin of f,selage hanleJs f,ll stroe colimit min 1=2inchesBO21 Is the p,sh o,t force at the corner of the hatch after hanle is f,ll rotate is less than 5 )0fO22 Are the tests performe 0y applying force at exterior* interior of the oor hanle at 0oth )8./823 Are there any operators a!aila0le at o,tsie of the ca0in near +mergency Door to hol the ooga,geO24 Are the tests satisfactory to #ro,ction an inspectorO25 Are all the parts isassem0le an chece for any physical amagesO2" Does the protecti!e Cnishes applie at the areas of electrical 0oning checO2% Are all the rele!ant ro,ters signe 0y #ro,ction < ,alityO2& Are the parts co!ere properly an hane o!er to #$S areaO


45/58

11 Are the pro,ction operators folloing the instr,ctions gi!en in the ro,ter for reor of scratch12 Is the appro!e paint stripper ,se for remo!al of paint . #rimerO13 Are the operators aare of not ,sing the poer tools for Sc,Gng especially on TiO14 Is the san paper ,se for sc,Gng is of grit si>e as inicate in the ro,terO15 Is the grease ,se along ith the san paper if speciCe on ro,ter only for Ti parts sc,GngO1" Is the operators sc,Gng till the epth of efect an spreaing the area either in 1N1 or 1N2 0l1% Are the operators an inspectors ens,ring the thicness at the sc,?e area at fre7,ent inter!al

excee the tolerance limits of thicnessO1& Are there any 'Js raise for o!er sc,Gng 0eyon tolerance limits of 6.#O1- Are the pro,ction s,per!isors an ,ality inspectors in conc,rrence ith M/6 A team taingof efectO Are they treating the iscrepancy as the opport,nity for impro!ementO2 Are the operators an inspectors folloing the 1N1 or 1N2 or 1N3 6lening ratio re7,irementsthro,gh D/ repairO21 Are the inspectors ens,ring the thicness after sc,Gng an taing appropriate action after me22 Are the cleaning operations post sc,Gng is one ,sing appro!e cleanersO23 Are the s,rface Cnish re7,irements as per 6.# maintaine post sc,GngO24 Is )#I performe at the area of sc,Gng as per the D/ re7,irementO25 Is the #ost cleaning after )#I is carrie o,t 0y pro,ctionO2" Are the protecti!e Cnishes reapplie as per ro,ter instr,ctionO

2% Is the /eor operations* Thicness meas,rements an s,rface Cnish re7,irements are recorone on the ro,terO2& Do the recors attache to concerne ro,ter or FI/ along ith ra0 sheet or '.D/O2- Is the e?ecti!eness of A taen 0eing monitore 0y pro,ction* ,ality an A teamO Is thereA re!isite for those casesO $nly for the ases of Dents3 Are the inspectors ,sing the acceptance re7,irements on Dents as per SS-2& on metallic part31 Are the inspectors raising 'Js for the cases relate to Dents hich are exceeing the Spec re732 Are the Dents repaire as per the /epair instr,ctions gi!en in D/O33 Are the planishing tools re7,ire for repair of Dents at conto,re areas are prepare 0y #ro,c34 Are the /epair Do,0lers* Filler coins prepare ,sing the material as per the D/ ispositionO35 Is the )#I performe if re7,ire 0y D/ ispositionO3" Is the repair or performe after )#I as per D/ isposition ,ner the g,iance of S,per!isor a3% Is any special team ientiCe for oing s,ch repairs an are they ha!ing re7,ire competencyO


46/58

1= #ersonnel ompetency2= Intene :seN Aloine as per conitions eCne3= MixingN ,sing ty as eCne4= ontrolle Temp mixing conitions5= MSDS Aareness

"= Shelf )ife Aherence of Three months%= Storage of con!ersion coating sol,tions in a ell(seale polyethylene* stainless steel* or aci repreparation or expiration ate* name of the sol,tion an appropriate ha>ar arnings=&= no con!ersion coating ret,rning to its storage container-= #roper Disposal of ,n,se sol,tions or expire sol,tions as per local irecti!e an reg,lationsO1= ##+ ompliance11= :se of appro!e chemical con!ersion to,ch ,p sol,tions12= /eay to :se application #ensN /T: Aloine P&%1 an Aloine P1132 T$:8('(#/+#X Applicith +8 < S epartment=13= /ecei!ing inspection stamp ith Date of Mfg an Date of +xpiry14= :se of pens ithin their shelf life perio

15= AloineP&%1 an Aloine P1132 sol,tions ept in same container of T$:8('(#/+#X Applica15= Application proce,reN F$D lean1"= :se of Appro!e cleaner1%= Application of con!ersions coating sol,tions 0y 0r,sh* sponge* ipe* spray or immersion1&=ontrolle temperat,re for application of chemical coating sol,tion maintaine1-= part s,rfaces are ept et ith the sol,tion for the time perio2= /insing < Drying methos folloe for the Aloine sol,tions other than P&%1 an P1132O 21= /e7 appearance in the form of colo,r itnesse


47/58

Is there any speciCc Dg for the testOAre all the re7,irements are capt,re in the proce,reODoes the latest re! controlle copies of Dg an TAT# are a!aila0le at the point of ,seOIs the proce,re ritten 0y M+ is ,nerstana0le to operators an InspectorsO& Is the test proce,re TAT#(" latest /e! is ha!ing c,stomer appro!alO- Is the test on First ca0in FAIB itnesse 0y the c,stomerO1 Does the /oom temperat,re re7,ire 0y the test is maintaine an recore in the rele!ant ch

11 Are the instr,ments* ga,ges ,se for the test are cali0rate an c,rrentO12 Does the 2= to 5= #SI9 Cltere ry compresse air is a!aila0le for ,sing as the test ,iO13 A#: om0,stor Drain )ine )ea TestNDoes the e7,ipment set ,p re7,ire for the test carrie o,t 0y pro,ction an itnesse 0y inIs the set ,p as per the rele!ant ca0in re7,irements as speciCe in the TAT#O14 Does the o,tlet of t,0e installation is pl,gge ,sing r,00er pl,g as shon in Fig 1 an 1A of TA15 Does the Air #ress,re Cxt,re* #ress,re ga,ge are pl,m0e to the +l0o on )8 sie ,pper sinpage no %O1" +ns,re application of /eg,late Air press,re of 2 to 5 #SI9 to the t,0e installation= Also ens,reisolate the A#: rain system from the air press,re test Cxt,re=1% +ns,re the press,re is maintaine for 5 mins= 'o loss of press,re is alloe ,ring this perio=1& +ns,re ,ring test any loss of press,re is o0ser!e then apply )ea(Tec sol,tion to the connectileas as per the proce,re lai on 0y M+= Test to 0e re(performe after Cxing the lea for the sa1- Does the Dismantling of the Test e7,ipment is carrie o,t as per the state proce,reO2 om0ine Drain )ine )ea TestNDoes the e7,ipment set ,p re7,ire for the test carrie o,t 0y pro,ction an itnesse 0y inIs the set ,p as per the rele!ant ca0in re7,irements as speciCe in the TAT#O21 Does the Tee inlets on :pper Sin are pl,gge ith 2 nos of A'-2-(" ap AssyODoes the T,0e inlet hich sho,l 0e connecte to A#: hyra,lic start acc,m,lator an one o,tlet22 Does the Air press,re Cxt,re an press,re ga,ge are connecte to the :nion on sie ,pper si23 +ns,re application of /eg,late Air press,re of 2 to 5 #SI9 to the t,0e installation= Also ens,reisolate the A#: rain system from the air press,re test Cxt,re=24 +ns,re the press,re is maintaine for 5 mins= 'o loss of press,re is alloe ,ring this perio=

25 +ns,re ,ring test any loss of press,re is o0ser!e then apply )ea(Tec sol,tion to the connectileas as per the proce,re lai on 0y M+= Test to 0e re(performe after Cxing the lea for the sa


48/58

12 Does the 15 #SI9 Cltere ry compresse air is a!aila0le for ,sing as the test ,iO13 +ngine om0,stor Drain )ine )ea TestNDoes the e7,ipment set ,p as shon in Fig 5 page no 14 of TAT#(5 re7,ire for the test carrieinspectorOIs the set ,p as per the rele!ant ca0in re7,irements as speciCe in the TAT#O14 Does the o,tlet of t,0e installation is pl,gge ,sing r,00er pl,g as shon in Fig 5 of TAT#(515 Does the Air #ress,re Cxt,re* #ress,re ga,ge are pl,m0e to the +l0o on )8 sie ,pper sin

5 page no 14O1" +ns,re application of /eg,late Air press,re of 15 #SI9 to the t,0e installation= Also ens,re theisolate the +ngine rain system from the air press,re test Cxt,re=1% +ns,re the press,re is maintaine for 5 mins= 'o loss of press,re is alloe ,ring this perio=1& +ns,re ,ring test any loss of press,re is o0ser!e then apply )ea(Tec sol,tion to the connectileas as per the proce,re lai on 0y M+= Test to 0e re(performe after Cxing the lea for the sa1- Does the Dismantling of the Test e7,ipment is carrie o,t as per the state proce,reO2 Does the a0o!e test steps repeate for the /8 sie +ngine com0,stor rain lineO21 Sc,pper Drain )ine )ea TestNDoes the e7,ipment set ,p re7,ire for the test carrie o,t 0y pro,ction an itnesse 0y inIs the set ,p as per the rele!ant ca0in re7,irements as speciCe in the TAT#O22 Does the 2 inlets on :pper Sin of the left han t,0e installation are pl,gge ith 2 nos of /,023 Does the Air press,re Cxt,re an press,re ga,ge are connecte to the left han o,tlet t,0e onFig %* page 1" of TAT#(5O24 +ns,re application of /eg,late Air press,re of 15 #SI9 to the t,0e installation= Also ens,re theisolate the +ngine rain system from the air press,re test Cxt,re=25 +ns,re the press,re is maintaine for 5 mins= 'o loss of press,re is alloe ,ring this perio=2" +ns,re ,ring test any loss of press,re is o0ser!e then apply )ea(Tec sol,tion to the connectileas as per the proce,re lai on 0y M+= Test to 0e re(performe after Cxing the lea for the sa2% Does the Dismantling of the Test e7,ipment is carrie o,t as per the state proce,reO2& Does the a0o!e test steps repeate for the /8 sie Sc,pper rain lineO2- +ngine Drain )ea TestNDoes the e7,ipment set ,p re7,ire for the test carrie o,t 0y pro,ction an itnesse 0y in

no 1%O3 Does the o,tlet of the )eft han tan on )oer Sin is pl,gge ith /,00er pl,gO


49/58

& Is the test proce,re TAT#(4 latest /e! is ha!ing c,stomer appro!alO- Is the test on First ca0in FAIB itnesse 0y the c,stomerO1 Does the /oom temperat,re re7,ire 0y the test is maintaine an recore in the rele!ant ch11 Are the instr,ments* ga,ges ,se for the test are cali0rate an c,rrentO12 Does the 1% < %5 #SI9 Cltere ry ompresse 'itrogen is a!aila0le for ,sing as the test ,i13 a0in )eft 8an 8eating 8ose #ress,re TestNDoes the e7,ipment set ,p re7,ire for the test carrie o,t 0y pro,ction an itnesse 0y in

Is the set ,p as per the rele!ant ca0in re7,irements as speciCe in the Fig 1 page " of TAT#(4O14 Does the to hose ens Which are normally connecte to the +;ectorsB are cappe ,sing to4O15 Does the #enetration ,ct on sie ,pper sin is connecte ith #ress,rise 'itrogen 6ottle* /e,sing the Aaptor an o,pling as shon in Fig 1 of TAT#(4O1" +ns,re application of /eg,late 'itrogen press,re of 1% #SI9 to the hose installation= Also enscompletely o? to isolate the heating hose system from the 'itrogen 6ottle=1% Does the press,re is maintaine for 15 minsO Does the press,re ga,ge !al,e at the start an e'o press,re loss is alloe ,ring the perio=1& +ns,re #ress,re ga,ge inicates any loss of press,re=+ns,re application of )ea(Tec sol,tion to the connecting Cttings an caps to ientify leaage=After ientiCcation* Cx the lea as per the proce,re eCne 0y M+ an repeat a0o!e steps ,ntil n'itrogen press,re for 15 mins=1- Does the e7,ipment set ,p ismantle an same test repeate on /8 sie as shon in Fig 2 #a2 ocpit 8eating 8ose #ress,re TestNDoes the e7,ipment set ,p re7,ire for the test carrie o,t 0y pro,ction an itnesse 0y inIs the set ,p as per the rele!ant ca0in re7,irements as speciCe in the Fig 3 page & of TAT#(4O21 Do the 8ose en an Q(Fitting t,0e ens hich are normally connecte to cocpit are pl,gge

TAT#(4O22 Does the #enetration ,ct on sie ,pper sin is connecte ith #ress,rise 'itrogen 6ottle* /e,sing the Aaptor an o,pling as shon in Fig 3 of TAT#(4O23 +ns,re application of /eg,late 'itrogen press,re of %5 #SI9 to the hose installation= Also ens,o? to isolate the heating hose system from the 'itrogen 6ottle=

24 Does the press,re is maintaine for 15 minsO Does the press,re ga,ge !al,e at the start an e'o press,re loss is alloe ,ring the perio=


50/58

14 Is there any improper clearance 0eteen the ca0le < other partsO Determination of Misalignment of the a0le to the p,lley15 Is a tension 15Y15 l0s applie to the ca0le 0y t,rning the han heel of the test Cxt,reO1" Is the ',t shon as # of Cg 1 of TAT# a;,ste to maintain the 7,arant stopper Assy at the neca0leO1% Is the ca0le chece for slacO1& Is the ca0le sitting properly in the groo!e of the p,lleyO

1- Is the misalignment of the ca0le =r=t p,lley at 12 locations ,sing the alignment tester as sho2 Is the egree of misalignment of the ca0le at each p,lley is less than 2Z except at STA 4"2O21 Is the misalignment is less than 1Z at locations 11 < 12 i=e at aft of STA 4"2 frameO22 Misalignment is [ than /e7 !al,eNIs the Tension completely remo!e from the ca0le an folloing parameters checeiB #osition of p,lleyiiB #layiiiB #ath of the ca0lei!B Deformation of the ca0le!B Tist of the ca0le'oteN If any of the a0o!e factors are the ca,se for the misalignment Cx the same an repeat the t!al,es=23 Is the misalignment of the ca0le to the ,arant is chece at the locations 13 < 14 as shonIs the meas,re misalignment is less than 2ZO24 Are the Misalignment !al,es are recore 0y pro,ction operator an ,ality inspectorO Determination of the clearance 0eteen the ca0le an other parts=25 Is the tension of 15 Y 15 l0s is applie to the ca0le 0y t,rning the han heel of test Cxt,reO2" Is the clearance 0eteen the ca0le an the airframe str,ct,re is meas,re ith !ernier caliper'oteN If the clearance is not istinct* meas,re the clearance at e!ery 12Z=2% Is there a clearance of =25 inches or greater 0. the ca0le an the nearest part ith the exceIs there a clearance of =1- inches or greater meas,re at the etail S* Fig & of page 1&OIs the clearance 0eteen the ca0le an the electrical iring* t,0es hyra,lic* f,el* l,0rication angreaterO

2& learance is \ than /e7 !al,eNIs the tension completely remo!e from the ca0le an folloing parameters checeO


51/58

!B Is the pot life after mixing an storage at room temperat,re in a close container is 4 ho,rsO12 =Is the mixe primer transferre to plastic to,ch ,p it or spray g,n 0ase on re7,irementOIs the plastic container to,ch,p its shelf life nonrenea0leO13 Is the mixing person maes the ientiCcation on the mixe primer ith Date* Time of mixing aexterior s,rface of the mixe c,p=14 Are the primer mixing recors maintaine in the form TAS) 2 2 #rimer Mixing recor sheretrie!a0leO

'oteN As per SS &521 inspection recors shall 0e a!aila0le to the p,rchaser for a min of 1 years f 15 +ns,re F$D control is taen care 0y the operator ,ring mixing an clean as yo, go is folloe1" +ns,re the post cleaning of the +7,ipment ,sing the appro!e cleaners1% #rimer coating Test panels preparationNAre the samples for tests selecte at ranom from each 0atch a complete ,nopene itO

Are the test panels prepare ,ner la0 conitionsO

Are the imensions for test panels shall 0e approximately =2 inch th* " inch length an 3 inch

Are the test panels mae of Al,min,m alloy 224(T3 temper conforming to SA+(AMS((A(25.4O

Is the alloy composition < pre(treatment of test panel is in accorance ith Ta0le I of MI)(#/F(233

Are the panels treate ith con!ersion coating to pro,ce coatings conforming to MI)(DT)(5541 l

Are the panels passing Water(6rea cleanliness criteria as per ASTM F 21 0efore primer application

Is the test panel if it is eoxii>e T3 Tempere SA+(AMS((A(25.5B immerse in corrosion reremo!e an rinse ith istille aterOBIs the primer coating applie ithin 1 hr= after preparation of the panel as escri0e a0o!eO

Are the primer coatings prepare an applie as follosNiBThoro,ghly mix each component separatelyiiB Sloly po,r component 6 into component A hile stirring the mixt,re to achie!e the man,fact,iiiB Dil,te the amixe primer coating* if necessary* ith thinner conforming to MI)(T(&1%%2* Type I


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24 +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI925 +ns,re that ,i is alloe to circ,late for 15mins or more=2" +ns,re that !al!e positions are meeting as per 0elo position ta0le=

T+/MS FI9:/+ 11 @A)@+ ':M6+/ @A)@+ 1 @A)@+ 2 @A)@+ 3] )$S+ $#+' )$S+^ $#+' )$S+ )$S+

_ )$S+ )$S+ $#+'2% +ns,re that a0anon is more than 2 cc ,i from the line=2& /AM# AT:AT$/ #/+SS )I'+ B+ns,re that ,shing cart line is connecte to port 3T /amp act,ator press B an ret,rn hose to p2- +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI93 +ns,re that ,i is alloe to circ,late for 15mins or more=31 +ns,re that a0anon is more than 2 cc ,i from the line=32 TAI) /$T$/ S+/@$ /+T:/' )I'+B+ns,re that pl,gs are reconnecte to o,tlets of ,shing cart=33 +ns,re that pl,gs is connecte as per the setch Fig3=4 B34 +ns,re that the Clter ,nits are goo in conition as per the Cltration re7,irement=

35 +ns,re that !al!e of ,shing cart is opene an pointe o,t as per the setch=3" +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI93% +ns,re that press line an ret,rn line is isconnecte from the ,shing cart=3& +ns,re that the pl,gs are protecte from ,st an contamination=3- /AM# AT:AT$/ /+T:/' )I'+ B+ns,re that ,shing cart line is isconnecte from port 4T an connecte to press,re hose to port4 +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI941 +ns,re that ,i is alloe to circ,late for 15mins or more=42 +ns,re that contamination test is meeting the re7,irement e!en if the test is repeate=43 6/+A)I'++ns,re that pl,gs are connecte as per Cg,re & an Cg,re "4- +ns,re the Clter ,nitJs conitions are goo=5 +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI951 +ns,re that ,i is alloe to circ,late for 15mins or more=


53/58

+ns,re that #ress,re hose is connecte to #ort 1T laning gear +xtenB an ret,rn hose to port24 +ns,re that !al!e of ,shing cart is opene an pointe o,t as per the setch=25 +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI92" +ns,re that ,i is alloe to circ,late for 15mins or more=2% +ns,re that !al!e positions are meeting as per 0elo position ta0le=

T+/MS FI9:/+ 11 @A)@+ ':M6+/ @A)@+ 1 @A)@+ 2 @A)@+ 3

] )$S+ $#+' )$S+^ $#+' )$S+ )$S+_ )$S+ )$S+ $#+'

2& +ns,re that a0anon is more than 2 cc ,i from the line=2- /AM# AT:AT$/ #/+SS )I'+ B+ns,re that ,shing cart line is connecte to port 3T /amp act,ator press B an ret,rn hose to p3 +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI931 +ns,re that ,i is alloe to circ,late for 15mins or more=32 +ns,re that a0anon is more than 2 cc ,i from the line=33 TAI) /$T$/ S+/@$ /+T:/' )I'+B+ns,re that pl,gs are reconnecte to o,tlets of ,shing cart=34 +ns,re that pl,gs is connecte as per the setch Fig3=4 B35 +ns,re that the Clter ,nits are goo in conition as per the Cltration re7,irement=3" +ns,re that !al!e of ,shing cart is opene an pointe o,t as per the setch=3% +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI93& +ns,re that press line an ret,rn line is isconnecte from the ,shing cart=3- +ns,re that the pl,gs are protecte from ,st an contamination=4 /AM# AT:AT$/ /+T:/' )I'+ B+ns,re that ,shing cart line is isconnecte from port 4T an connecte to press,re hose to port41 +ns,re that the hyra,lic o an press,re is set o!er 49#M at 1Y1 #SI942 +ns,re that ,i is alloe to circ,late for 15mins or more=43 +ns,re that contamination test is meeting the re7,irement e!en if the test is repeate=

4- 6/+A)I'++ns,re that pl,gs are connecte as per Cg,re & an Cg,re "


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11 D+T 355 < 8(#late chec after panel mo!ementNIs location of all D+T locators =r=t frames ,sing tooling pins chece 0y segment inspectorOIs the D+T355 < 8(plate loae onto panel an locing of all the pins =r*t Frames* D+T 355 < 8(plAre the pins locing se7,ence is in iagonally opposite se7,enceOAre all the pins entering freely an chece 0y segment inspectorOIs the pitch meas,rement 0eteen frames recoreOIs the gap chec at Sta 4"2 0eteen frame an heaer plate recoreO

'oteN 1= After itnessing a0o!e checs inspector can gi!e clearance for performing or at FA22= If the panel or of 0oth FA1 < 2 one on the same ;ig then a0o!e checs can 0e ignore an f 12 #anel Transfer from 241 FA2 to #:NDoes the operators ha!ing nolege an sill for panel transfer from 241 FA2 to #: as per A$S 213 Manatory or completion #rior to TransferNDoes all the A$SJs or complete for 241 FA(2 an all the A$SJs are 0o,ght 0y Seg ,ality inspDoes 2 nos P3 holes rille onto Frame at Sta 4"2 frame are rille as per A$S 2411(-24 ith tDoes the pitch 0ars remo!e an pitch meas,rement 0eteen Frames meas,re an recore 0yIs the 9ap chec meas,re an recore 0y segment inspector 0eteen Frame at Sta 4"2 an 8eDoes D+T(355 an 8(plate positione =r=t panel an all the pins are entering freely at 1& placesOAre the D+T(355 an 8(plate ,ninstalle after pin checingOIs there any A$S or open ,e to '.D/* $pen ra0s* non(a!aila0ility of fasteners or parts an f

,alityOIs the Tra!eller form ClleOIs F$D chec one 0y #ro,ction < ,alityOIs the Final shaeon complete 0y segment inspectorO14 Is the role an responsi0ility of personnel ,ring panel transfer isc,sse among the team me15 $,tsie Fitting installationNIs the Drilling of P3 holes at & places on Frames at Sta 35 an 3-- complete as per A$S 2411(Do all the holes e 0,rreOAre all the fasteners ,ner $,tsie Ctting 6racet are installeOAre D+T 23(1 at STA 35 an D+T 23(1- at STA 3-- remo!e to facilitate installation of $,tsie CAre the o,tsie Ctting 6racets installe ,sing appropriate pins* asher an n,tsOAre the #ins an ',ts are tightene properly an is there any play in asher after tighteningOIs the orientation of asher correctOIs the o,tsie Ctting 6racet installation chece 0y InspectorO


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Inspection /e7,irements after primer applicationN21 the thicness meas,rements performe ,sing a con!entional non(estr,cti!e meas,ring e!icaccorance ith ASTM 6244 or e7,i!alentthe a!erage ry Clm thicness !al,es meeting the re7,irements as speciCe in Ta0le I < II of SS&522 the amixe primer coatings applie to a !ertical s,rface are ha!ing any Sag* r,n or strea atto =- mil23 rie Clm ha!e smooth* ,niform s,rface free of grit* sees* craters* 0listers an other irreg,lari

24 any orange peel a!y appearanceB hen !iee from at least "ft istance25 amixe primer coatings tac free ithin 5 ho,rs an shall ry har ithin & ho,rs2" any e!ience of lifting or any other Clm irreg,larity after top coating the amixe primer coatin'oteN olor i?erence 0eteen appro!e primers of i?erent !enors is not the ca,se for re;ectiopreceence o!er aesthetics.cosmetics= 6r,sh To,ch ,p for the fasteners on Interior sie of the ca0in except )ongeron assy )8 < /8 at W2% Dg .Aos(/o,ter calling for et installation of fasteners ,sing #rimer or To,ch ,p on Assy . Inst2& the holes free of 0,rrs* F$D* chece an cleare 0y Segment Inspector2- the holes to,che ith #rimer an fastener installe3 primer S7,ee>ing o,r all aro,n the attache or inserte harare'oteN The 0,l of s7,ee>e o,t material may 0e remo!e after installation hoe!er a !isi0le amo,as e!ience that the et installation performe=

31 the fasteners cleane ith appro!e cleaners an free of F$D32 the fasteners installation self(chece 0y operator an cleare 0y Segment inspector for propeheight* S ,shness* Spinle 0rea o? epth in case of 0lin ri!ets* set mars on heas33 6r,sh primer to,ch or Spray g,n To,ch ,p carrie o,t on the hea an tail sie for all the interfasteners are installe on the sin34 proper masing one to a!oi o!erspray on pre!io,sly prime or painte areas35 the applie primer protecte against F$D 0efore it gets c,re3" the primer to,ch for the fasteners free of F$D* /,ns an thicness !ariation an entire s,rface'oteN Transl,cent appearance is alloe as long as =" inch min thicness is met=3% the primer to,ch ,p self(inspecte for a0o!e efects an cleare 0y segment inspector3& the rele!ant operations in the ro,ter close 0y operator an inspector3- the clean as yo, go folloe an expire primer ispose as per the state proce,re Mist oat ,sing primer prior to 9lossy coat or painting at Interior or exterior of Aircraft or Ma;or As4 the s,rfaces to 0e mist coate* age more than 24 ho,rs an ha!ing glossy appearance


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3 +ns,re the cali0ration stat,s for )aser tracer an other ;igs an instr,ments ,se for ID meas4 hec for the laser locations position on aft sie for ID points on top ec an on gro,n or rigi5 +ns,re the at,m points are taen ith respect to ig $#TJs or M96 holes=" hec for the locing pins are perfectly on proper tightene conitions=% If M96 holes are taen as a at,m then ens,re that locing conitions are mae except M96 pla& hec the appropriate metho is 0eing ,se for selection of the at,m points= +ither rt to ;ig- +ns,re that selection of at,m is as per the ID plan appro!e 0y Siorsy=

1 +ns,re that the meas,rement s,rfaces are properly cleane ith cloth 0efore taing the laserIf Dat,m is Wrt to ;ig

11 +ns,re that at least & to 1 accessi0le ;ig $T# points are selecte for taing the meas,rement=12 +ns,re that minim,m of 0est 3 Ct points are consiere an the points are ithin =2` !ariat13 +ns,re the proper alignment 0efore the meas,rement is starte=If Dat,m is Wrt to M96

14 +ns,re that at least & to 1 points are selecte for taing the meas,rement=15 +ns,re that hole no 1 an " is taen for esta0lishment for at,m after alignment also chec for"=Meas,rement ith T #/$6+L

1" +ns,re that plane of respecti!e s,rface is taen 0efore taing the act,al point= Meas,rement ith Aapter an SM/

1% +ns,re that exact si>e of the aapters is chece as per the raing 0efore ,sage=1& +ns,re that SM/ is ,se along ith the aapters to chec the act,al location of the point= ross checing the Dat,m1- +ns,re that at,m is cross !eriCe for the all the pre(eCne conitions lie 6reas* +xternal ilaser change=2 If e!iations are o0ser!e ,e to a0o!e mentione case the ens,re that meas,rements to 0eonce again=21 +ns,re that ID meas,rements are as per ID plan co!ering all the 1422 +ns,re all the 13 areas are co!ere ,ring ID meas,rement as mentione in T$#(%(1%=23 +ns,re all the 13 parameters are ini!i,ally chece ith respect to the appropriate metho

ga,ges #in ga,ge* Feeler ga,geB24 +ns,re that the laser report an ata sheets is recore ith all meas,re !al,es an ,ner th


57/58

Is the tape then remo!e in one a0r,pt motion an test area examine for any paint amage or r

51 Is there any remo!al coating exceeing 1.1"th of an inch in length an ith in ry or et tape'oteN /etesting may 0e performe after an aitional c,re cycle=52 Is the test panel retaine ith proper ientiCcation of 0atch no* ate* ca0in no* =o 'o* inspecti53 Are the rele!ant operations in the ro,ter close 0y operator an inspectorO /eor of #ainte S,rfacesN

54 Is there any scratch or ahesion fail,re peel o?B or thicness !ariation* r,ns* sags* ro,gh s,rfas,rfacesO55 Are the s,rfaces Degrease as per SS&423 to remo!e oil or grease if any on the s,rfacesO5" Is the appro!e paint stripper T,rco +A"-3 as per SS&%&" applie at the iscrepant area 0y mtape or Al,min,m tapeO5% Is the person ahering to ##+ ,ring paint stripper applicationO5& Is the stripper alloe to stay on the iscrepant area for the re7 ell time as speciCe 0y th5- Is theStripping time less than 24 ho,rs for room temperat,re strippers an & ho,rs for hot strip" Is the s,rface chece after 2 ho,rs after application* for 0,00ling an harnessO"1 Is m,ltiple applications ens,re if no 0,00ling or softening is e!ienceO"2 Is the 0,00les scrape ,sing plexiglass or ooen scrapersO'oteN Metallic scrapers or ire 0r,shes not permitte for scraping=

"3 Is the area thoro,ghly rinse ith hot or col ater ,ntil traces of stripper are remo!eO"4 Is the s,rro,ning area ,nmase an remase again ith ne masing tape or Al,min,m ta"5 Is the area rie ith force air 1 ho,r after ater rinsingO"" Is the area cleane ,sing the appro!e cleaners remo!e all the oil* grease* irt* F$D etc=*O"% Is the Aloine applie if the 0ase metal is exposeO"& Is the primer applie as per the proce,reO"- Is the paint or topcoat applie as per the 6.# re7,irement after primer c,ringO% Is the mas remo!e an inspecte 0y paint inspectorO oating* on,cti!e an Anti(Static application to Fi0er laminate s,rfaces as per SS&51%N%1 Are the 8$(Shiel con,cti!e coatings Type 1 proc,re as per SS&51% from the appro!e so,%2 Are the Milli ohmmeters as speciCe in SS spec are a!aila0le for the meas,rement of resistanc%3 Are the C0er laminate s,rface lightly sane an then cleane ,sing SS-1%.24 or SS-1%.5%4 Application of primerNAre the s,rfaces prime ith one coat of MI)(#/F(&55&2 epoxy primerO


58/58

Are the parts are relate to electrical system ith harare closely space < in close geometricaIs the ire locing meant for shear applications to permit operation or act,ation or emergency eIs the ire installe s,ch that it can 0e easily 0roen hen re7,ire in emergency sit,ationOAre only external snap rings loce ,sing single ire methoO'oteN 'o locing re7,ire for Internal snap rings=1" Do,0le Wire MethoNIs the harare installe in closely space geometric pattern hich sec,re hyra,lic or air seals* h

areas of cl,tch mechanisms an s,perchargers has to ,se Do,0le ire locing methoO1% Are the parts shall 0e loc ire s,ch that it is in tension hen the parts ten to looseO'oteN Safety ire sho,l alays 0e installe so as to mae the ',t or 6olt TI98T+'L itself hen tsafety ire sho,l come aro,n top of hea of the 0olt.n,t an 0ac onto the sec,ring ,nit so thairection=1& Is the loc ire installe an tiste so that the loop aro,n the hea stays on an oes notlea!e a slac loopO1- Is the care taen ,ring installation so that loc ire is tight 0,t not o!er stresse in 0oth the'oteN $!erstressing eaens it an co,l ca,se it to 0rea ,ner !i0ration or loa=2 Is the safety ire passe thro,gh the iametrically opposite hole an then rappe aro,n halcase of Internal Wrenching 6oltsO21 Is a pigtail of K to inch 3 to 5 tistsB mae at the en of iring an it is 0ent 0acO22 Is the safety ire ne ,pon each application irrespecti!e of the methoO23 Is the astellate ',t Tor7,e to loest range an ire loce if the hole in St, or 0olt or screIs the tor7,e tightening contin,e for next "E angle of the ',t if the hole oes not aligns ith lo'oteN Do not o!er tor7,e or ,ner tor7,e=24 Is Dia =2 inches ire locing ,se on +lectrical onnectors hich ,se threae co,pling ringsfasten the ini!i,al parts of the pl,g togetherOAre all the electrical connectors ire loce ini!i,allyO'oteN Do not loc ire one connector to another ,nless necessary=25 +ns,re no ire locing re7,ire if the rille hea 0olts or scres installe in to Self locing ',2" Are the ire locing carrie o,t as shon in the pict,res on Sheet 5 < " of T$# proce,re T$#(Are the ire locing mae opposite as shon in the pict,res of sheet 5 < " if left hane threas

2% Is there in any 'ics or ins after ire locing hich is the ca,se for re;ectionOIs ire c,t an re ire locing carrie o,t in s,ch casesO

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