TABLE OF CONTENTS

Page
COVER SHEET 1

TABLE OF CONTENTS 2-3

INTRODUCTION 4

RSM/QCM RECORD OF REVISIONS 5

RSM/QCM MANUAL CONTROL SYSTEM 6-8

REPAIR STATION MANUAL 9

SECTION I – ORGANIZATION 10 - 17

SECTION II – PERSONNEL/REPAIR STATION ROSTER 18 – 19

SECTION III – OPERATIONS – HOUSING, FACILITIES, EQUIPMENT,

DATA AND MATERIALS 20- 30

SECTION IV – CAPABILITY LIST 31 - 32

SECTION V – APPROVED TRAINING PROGRAM REVISIONS 33 – 34

SECTION VI – WORK AT OTHER LOCATIONS 35 - 36

SECTION VII – MAINTENANCE OF 14 CFR PART 121, 125, AND 135

AIRCRAFT AND FOREIGN CARRIERS OR PERSONS UNDER 14 CFR
PART 129 37 - 38

SECTION VIII – CONTRACT MAINTENANCE 39 - 40

SECTION IX – RECORDS 41- 42

QUALITY CONTROL MANUAL 43

SECTION I – INSPECTIONS 44 - 47

SECTION II – CONTINUITY OF MAINTENANCE AND INSPECTION

RESPONSIBILITIES 48 - 49

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 TABLE OF CONTENTS Page

SECTION III – REPAIR STATION INSPECTION PERSONNEL 50- 51

SECTION IV – TECHNICAL DATA 52 - 54

SECTION V – TOOLS/EQUIPMENT CALIBRATION 55 - 57

SECTION VI – DISCREPANCIES/CORRECTIVE ACTION 58 - 59

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 Title: Introduction

These manuals have been prepared in accordance with the current Code of Federal Regulation (CFR)
and the policies of Leach International North America and set forth the requirements and policies of this
Repair Station, which are to be observed by all employees. Observance of this procedure will assure
compliance with the requirements of 14 CFR Part 145 of the Code of Federal Regulation. This
compliance is required to obtain and retain a Federal Aviation Administration Repair Station Certificate.

Leach International North America is physically located at 6900 Orangethorpe Avenue in Buena Park,
CA 90620. The mailing address is 6900 Orangethorpe Ave, Buena Park CA 90620. The telephone
number is 714 739-0770.

Note: The corporate names of Leach International-North America (LINA), and Leach International
function as Leach International’s Repair Station No. FJ3D503L. These terms for the repair station are
all interchangeable as utilized in this document.

These manuals explain the operation of the Repair Station and the internal inspection system in detail,
including continuity of inspection responsibility.

The general repair, overhaul, or alteration of products will be performed in accordance with the current
CFR, manufacturer’s data, drawings, specifications, and bulletins, or other technical data approved or
accepted by the FAA for the particular product.

This repair station will not repair or alter any item for which it is not rated, and will not repair or alter
any article for which it is rated if it requires technical data, equipment, materials, facilities, or trained
personnel that are not available.

The technical library, this Repair Station Manual (RSM) and Quality Control Manual (QCM) are
required for the operation of this repair station, and will be maintained in a current status at all times.

All Repair Station Personnel on the RSM/QCM organizational chart, responsible for the repair station
effort, will be provided immediate intranet access to controlled electronic copy of these manuals. Repair
Station Management is responsible for seeing that all supervisory and inspection personnel have access
to and thoroughly understand the manuals’ contents, and adhere to their provisions.

The performance of any repair, alteration, or required inspections for an air carrier or commercial
operator having a continuous airworthiness program under 14 CFR, Part 121, 125, or 135 will be
performed in accordance with the requirements of 14 CFR Part 145.

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REPAIR STATION MANUAL / QUALITY CONTROL MANUAL
Title: RSM/QCM Record of Revisions

Rev. No. Rev. Date Rev. No. Rev. Date Rev. No. Rev. Date
N/C 04-21-80
A 01-18-84
B 02-03-84
C 01-20-87
D 11-27-91
E 01-11-92
F 02-03-92
G 02-08-94
H 03-04-94
J 11-08-95
K 01-30-97
M 05-10-98
N 04-20-00
P 05-18-01
R 03-08-02
S 07-18-03
T 01-30-04
U 04-15-05
V 05-24-05
W 09-27-05
X 02-01-08
Y 09-02-08
AA 09-16-08
AB 10-30-09
AC 02-19-10
AD 04-25-11
AE 12-19-11
AF 04-10-13
AG 1/29/14
AH 09/26/14
AJ 09/02/15

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REPAIR STATION MANUAL / QUALITY CONTROL MANUAL
Title: RSM/QCM Control System

ACCESS TO THE RSM/QCM MANUALS

The RSM and QCM will be available by access to the company intranet and on the company web site
(www.esterline.com). If the website copy is unattainable, please email [email protected] to
obtain a copy by email. Hard copies may be printed but are considered uncontrolled. Repair station
personnel must verify that any hard copy they are using is of the current revision before initiating any
repair station activities. This may be accomplished by verifying the revision available on the company
intranet. CHDO is provided by the hard copy. Obsolete hard copies shall be either destroyed or removed
from repair station to prevent usage.

RSM/QCM AUDITS
The Manager, MSC/Supervisor, Repair Station will perform an audit of the company intranet and
website monthly to verify that the posted manuals are current. A record of the audit will be made
documenting the revision posted on the intranet website, the revision available at Quality Management
Systems, the revision posted on the internet website, the name of the Manager, MSC/Supervisor, Repair
Station and the date performed will be documented on form MSC-032 (See Forms Manual 512-0010-
000-000). The audit record will be maintained in the RSM/QCM information binder retained in the MSC.
Records of these audits will be retained for minimum two years.

RSM/QCM REVISION SECURITY

The Manager, Quality Systems will assure that the current manuals are available on the company intranet
in secure PDF file format.

FAA REVISION NOTIFICATION

Any changes to Repair Station and Quality Control Manual will go through the Quality Management
Systems process and the final draft will be sent to FSDO by Manager, Quality Systems for FSDO review.
After FSDO’s review and acceptance the final draft will complete the process to be formally released.
The FSDO will be notified by email that the revision has been released and a hardcopy for review will
be provided via U.S. Mail within 5 business days. Upon receiving the Acceptance letter from FAA, it
will be placed in front of final released document and the Manager, Quality Systems/Designee shall
remove the obsolete version from the Intranet and company website and post the new revision. .

APPROVED RSM/QCM TRAINING

Training will be provided to personnel requiring access to this manual to assure they can access all
relevant sections of the manual and competency shall be demonstrated by observing their ability to do
so. The training shall be performed at the workstation to assure that the software is available to view the
manual. Records of this training shall be maintained within Human Resources department as described
in the FAA Approved Repair Station Training Manual (RSTM) 512-0006-003-000. Repair Station
Management is responsible for seeing that all personnel under their supervision have access to the
RSM/QCM and adhere to its provisions.

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Title: RSM/QCM Control System
RSM/QCM REVIEW
Repair Station Management and personnel responsible for Repair Station effort, must read the procedure
and periodically review its contents in order to maintain familiarity with its current provisions. Any
repair station personnel who, in the performance of their duties, identifies a needed change in these
manuals shall contact the Manager, Quality Systems. The Manager, MSC/ Supervisor, Repair Station
will have these changes and revisions found necessary incorporated into the manuals, produced in final
form, and delivered to the Manager, Quality Systems for coordination with the FAA FSDO. The
Manager, Quality Systems will approve and sign the RSM/QCM.

The RSM/QCM will be revised in its entirety under a single revision letter and date. All pages will carry
the same revision date. Asterisks or bars will be placed in the margins of changed paragraphs to identify
changes. Change notifications will be documented and stored to indicate the changes and nature of the
changes. In cases where the manuals and FAR undergoes major changes, requiring extensive changes to
the RSM/QCM, it is permissible to annotate “complete revision” and forego the asterisks or bars. A
change notification record should be documented to indicate the nature of the complete revision.

REFERENCED PROCEDURES
Procedures referenced in the RSM/QCM, and any procedures referenced in those procedures essential
to the operation of the repair station, shall be provided to the FSDO for review. Revisions to these
referenced procedures shall also be provided to the FSDO within 5 business days. Any revisions
determined to be noncompliant to the FARs by the FAA will require immediate revision to attain
compliance with the FARs.

LIST OF REFERENCED PROCEDURES FOR FSDO REVIEW

QAD 00037 Procedures used in FAA Approved Repair Station No. FJ3D503L and
Manufacturing Operations
QAD 00039 Back-Up Responsibilities
QAD 00046 Steps for Personnel Entering into Repair Station (RS)
512-0006- EASA Supplement
512-0006-001-000 Capability list for FAA approved repair station no. FJ3D503l, Leach
International North America
512-0006-002-000 Repair Procedure
512-0006-003-000 Repair Station Training Program Manual FAA Approved RS
512-0010-000-000 Repair Station Forms Control Manual
512-0024-000-000 Material Service Center Procedure
512-0026-000-000 Training
550-0006-000-000 Electrostatic Discharge (ESD) Control Procedure
552-0245-000-000 Procedure for Documentation and Control of Test Equipment/Acquisition
Software
ENG 003 Document and Data Control
FAC 000 Preventive Maintenance.
OPR 012 Stockroom Material Handling Procedure
OPR 015 Router and Operation Maintenance
OPR 017 Production Handling of Work-in-Process
QAI 303 Control of Age Sensitive Materials
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REPAIR STATION MANUAL / QUALITY CONTROL MANUAL
QAP 1.8 Stamp Control
QAP 2.1 Documentation Control
QAP 2.3 Data Retention/Data Control
QAP 5.7 Receiving Inspection Procedure
QAP 3.15 In-process and Final Inspection Procedure
QAP 4.1 Equipment Control and Calibration
QAP 6.1 Control and Review of Nonconforming Material
QAP 6.3 Corrective and Preventive Action
QAP 6.1.3 Control of Scrap Material
QAP 7.5.1.004 Maintain BOM in Syteline

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Repair Station Manual

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REPAIR STATION MANUAL

SECTION I

ORGANIZATION

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Title: SECTION I – ORGANIZATION
ORGANIZATION CHART

(See Repair Station Roster for actual names.)

Note: (*) Denotes those persons in management authorized to act on behalf of the repair station.
All personnel holding a Part 65 Airman Certificate (repairman) report to the Repair Station
Supervisor for maintenance, inspection, airworthiness, and return to service activities

Solid lines represents the oversee relationship on directing the work performed under the repair
station/Dotted lines represent administrative reporting functions only.

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Title: SECTION I – ORGANIZATION

DUTIES AND RESPONSIBILITIES

Manager, Quality Systems/Accountable Manager

The Manager, Quality Systems is responsible for the overall operation of the Repair Station and is the
Accountable Manager.

The Manager, Quality Systems is responsible for providing adequate plant facilities, i.e., equipment,
material, and personnel for operation of the Repair Station in compliance with applicable Code of Federal
Regulation. This includes compliance with design requirements and the procedures specified herein, as
appropriate, to process items received, repaired, replaced or delivered by the repair station.

The Manager, Quality System’s duties and responsibilities are to:

1. Supervise and direct the activities of the Repair Station Personnel as indicated on the
organizational chart. Ascertain that Repair Station work is performed to established
workmanship standards, and applicable specifications.
2. Determine the proper maintenance of all equipment, supplies and services to properly process
Repair Station repair components/items.
3. Provide the final completion of and obtain repairman signatures on the Returned Goods and
Product Analysis forms, and comply with the requirements herein to satisfy FAA Repair Station
Certification.
4. To ascertain that adequate firefighting equipment is available at the repair station.
5. To establish standards to ascertain that adequate safety precautions are observed.
6. To establish procedures to determine the need for original and recurring training of personnel
consistent with the work to be performed.
7. Serve as primary contact with the FAA, unless otherwise delegated.
8. Provide QA personnel and equipment to support the Repair Station operations, and to assure
compliance with the procedures specified herein.
9. To approve and maintain the RSM and QCM in accordance with the requirements of the FAA
Part 145 regulations.
10. Primary responsibility for control of calibration functions, for maintaining shelf-life control and
Scrap parts handling.
11. Assure the proper maintenance of files of complete Repair Station Routers in such a manner that
the file pertaining to a specific repaired item can be readily located for review

12. Submit proper reports of any serious failure, malfunction, or defect via web-site http://av-
info.faa.gov/sdrx/.) in accordance with 14 CFR Part 145 as referenced in the Forms
Manual.

The duties of the Manager, Quality Systems may be delegated to qualified individuals as necessary;
however, such delegation does not relieve the Manager, Quality Systems of these overall responsibilities.

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Title: SECTION I – ORGANIZATION

Manager, Quality Engineering

The Manager, Quality Engineering is responsible to the Accountable Manager (Manager, Quality
Systems) for the overall operation of the Quality Engineering functions.

The Manager, Quality Engineering duties and responsibilities are to:

1. Review MRR (Material Rejection Report) and performs trend analysis to assure appropriate
corrective action is taken to resolve any system major product non-conformance.
2. Supervise the stamp control functions per QAP 1.8

3. Primary responsibility for control of technical data.

4. Coordinates the Supplier Quality functions.

The duties of the Manager, Quality Engineering may be delegated to qualified individuals as necessary;
however, such delegation does not relieve the Manager, Quality Engineering of the overall
responsibilities.

PERSONNEL/TECHNICIANS-(REPAIR STATION)

The Repair Station personnel/technicians are directly responsible to the Manager, MSC/Supervisor,
Repair Station for the following operations. Personnel consist of Operators, and support personnel. They
are responsible to:

1. Perform the repair functions and ascertain that all Repair Station work is performed in compliance
to established workmanship standards, and applicable specifications.
2. Provide continuity of repair sequence and assure completion of such when personnel shift or
assignment changes occur.
3. Ensure that no defective or un-airworthy piece parts are installed in any product or unit released by
the Repair Station.
4. Ensure proper identification of all products.
5. Ensure that rejected and unserviceable products are handled in such a way as to prevent their re-use
as serviceable products.
6. Utilize all practices, standards, and techniques, as approved the repair station, in performing
maintenance in accordance with approved data and the RSM/QCM.

INSPECTION PERSONNEL

The Inspection personnel are directly responsible to the Manager, Quality Engineering for the following
operations:

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Title: SECTION I – ORGANIZATION

1. Perform the Inspection functions and ascertain that all Repair Station work is performed in
compliance to established workmanship standards, and applicable specifications.
2. Ascertain that all in-process and final inspections are properly performed on completed work before
it is released to service, and that the inspection and maintenance records, reports and forms, required
for such release, are properly executed.
3. Provide continuity of inspection, and assure completion of required inspections when personnel shift
or assignment changes occur.
4. Ensure that no defective or un-airworthy piece parts are installed in any product or unit released by
the Repair Station.
5. Ensure proper identification of all products.
6. Ensure that rejected and unserviceable products are handled in such a way as to prevent their re-use
as serviceable products.
7. Make monthly checks on all inspection tools and test equipment located in the In-Process Inspection
and Final Inspection areas to determine that the calibration due date has not been exceeded.

RECEIVING INSPECTION PERSONNEL

The Receiving Inspection personnel are directly responsible to the Manager, MSC/Supervisor, Repair
Station for the following operations:

1. Perform Final Acceptance of all incoming material and supplies.

2. Make monthly checks on all inspection tools and test equipment located in the Receiving and
Verification Inspection areas to determine that the calibration due date has not been exceeded.
3. Ensure proper identification of all products.
4. Ensure that rejected and unserviceable products are handled in such a way as to prevent their re-use
as serviceable products.
5. Provide continuity of inspection, and assure completion of required inspections when personnel shift
or assignment changes occur.

MANAGER, MATERIAL SERVICE CENTER (MSC)/SUPERVISOR, REPAIR STATION

The Manager, MSC/Supervisor, Repair Station is responsible to the Accountable Manager, Manager,
Quality Systems for the operation of the MSC and supervises the repair or overhaul of repairable
components. The Manager, MSC/Supervisor, Repair Station duties and responsibilities are to:

1. Supervise and direct the activities of MSC through the personnel indicated on the organization chart.
Assure the maintenance of all records, supplies and services necessary to properly process MSC items.
2. Assure the proper maintenance of files of complete Material Service Center Routers in such a manner
that the file pertaining to a specific repaired item can be readily located for review.
3. Schedule and prioritize workflow in the Material Service Center.

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Title: SECTION I – ORGANIZATION

4. Review and approve all repair and test data generated for the repair prior to approving 8130-3 tag.
5 Sign and stamp all required Repair Station documentation and Return to Service Tags per 14 CFR
Part 145.
6. Ensure that no defective or un-airworthy piece parts are installed in any product or unit released by
the Repair Station.
7. Ensure proper identification of all products.
8. Ensure that rejected and unserviceable products are handled in such a way as to prevent their re-use
as serviceable products
9. Supervise and direct repair station personnel performing the repair functions. Ascertain that all
Repair Station work is performed in compliance to established workmanship standards, applicable
specifications/approved data, and the requirements of the RSM/QCM/RSTM.
10. Provide continuity of repair sequence and assure completion of such when personnel shift or
assignment changes occur.
11. Act on behalf of the Manager RS/MSC as required supporting the repair station.
12. Perform Final Inspection of all parts being returned to service. Final Inspection Repair Station
personnel must be certified under 14 CFR Part 65.
13. Is responsible for controlling, bonding, issuing, and maintaining logs on the Operations stamps.
14. Responsible for maintaining the repair station roster. Changes to the roster will be incorporated
within 5 days.
15. Responsible for maintaining a historic record of RSM/QCM revisions.
16. The Manager, MSC/Supervisor, Repair Station has been delegated authorization to mark operations
as ‘N/A’ (not applicable) per OPR 017 for routers, on specific returns, when they are not required at
the discretion of the Accountable Manager.
17. The Manager, MSC/ Supervisor, Repair Station is responsible for assuring that the training schedule
is reviewed
and that training is conducted when required

18. Back-Up responsibility for control of Technical data and control of Calibration functions.

The duties of the Manager, MSC/Supervisor, Repair Station may be delegated to qualified individuals,
as deemed necessary; however, such delegation does not relieve the Manager MSC/Supervisor, Repair
Station of these overall responsibilities.

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Title: SECTION I – ORGANIZATION

SUPERVISOR, REPAIRS ADMIN.

The Supervisor, Repair Administrative is responsible to the Manager, Quality Systems for the
administrative functions only and indirectly reports to Manager MSC/Supervisor, RS

1. Oversight the administrative functions for all components and goods.

2. Staff and support required for repair station administrative activities
3. Manage the task of ensuring that repair station personnel comply with 14CFR 121.377 Duty Time
Limitation requirements
4. Perform other administrative duties required within the repair station.

The duties and responsibilities of, Supervisor, Repair admin. is strictly administrative

ENGINEER REPAIRS

The Engineer/RS is responsible to the Manager, MSC/Supervisor, Repair Station for the repair
engineering functions.

1. Defines the sequence of operations by creating, releasing and controlling Repair station routers.
2. Helps perform failure analysis, tolerance studies, and participates in the troubleshooting/root
cause/corrective action process for repair station.
3. Reviews and writes assembly and process procedures for product repair.
4. Documents repair process requirements by creating product repair specifications.
5. Provide engineering evaluation as required on the MSC-002 returned Goods Analysis sheet.

SUPERVISOR, QUALITY CONTROL ADMIN.

The, Supervisor Quality Control is responsible to the Manager, Quality Engineering for the
administrative Quality Control functions.

1. Oversight the administrative functions of all repaired components and goods.

2. Staff and support required by inspection personnel for repair station administrative activities
3. Support Manager, Quality Engineering to ensure that the requirements set forth in FAA Part 43.9,
43.13 and 145 are being met.
4. Ensure the requirements of the Leach International RSM/QCM are communicated to all personnel
and are met.
5. Provide administrative support to the Inspection personnel.

The Duties and responsibilities of Supervisor, Quality Control is strictly administrative.

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Title: SECTION I – ORGANIZATION

MSC COORDINATORS

The MSC Coordinators are directly responsible to Manager, MSC/Supervisor, Repair Station for the
following functions. They are responsible to:

1. Respond to customer e-mail, fax or telephone correspondence and review purchase orders.
2. Receive Repair Station return goods to repair station.
3. Issue returns authorization numbers and generate job orders.
4. Create and distribute for signature, 8130-3 Airworthiness Tags.
5. Ship repaired units back to the customer for Repair Station.
6. Communicate with customers regarding “Beyond Economic Repair” and part disposition issues for
Repair Station.

MSC CLERICAL SUPPORT (MRB COORDINATOR)

1. Receive and inspect packaging of all repair station returned products in the MSC department
2. Unpack repair station returned products and review any non-conformance information supplied
by the customer. Enter information related to new receipts into ERP system
3. Submit documentation and non-conformance information to MSC coordinator
4. Move repair station returned products to initial work stations for processing
5. Performs miscellaneous support functions for MSC department as needed.

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SECTION II

PERSONNEL/REPAIR STATION ROSTER

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Title: SECTION II - PERSONNEL/REPAIR STATION ROSTER

PERSONNEL/REPAIR STATION ROSTER EMPLOYMENT SUMMARIES

REPAIR STATION ROSTER

The listing of personnel responsible for compliance with this procedure is maintained by Manager,
MSC/Supervisor, Repair Station and is available for review. This repair station roster shall list
management personnel, supervisors, Repair Station inspection personnel, and those individuals
authorized to perform final inspection and/or approve an article for return to service (repairmen).
Repairmen alone have the authority to sign off on final inspection and maintenance release. This repair
station roster shall include the name and title, certification type and number and authority and must be
signed or approved by the Accountable Manager. The Manager, MSC/Supervisor, Repair Station will
be responsible for maintaining the repair station roster, which must be revised to reflect the termination,
reassignment, change in duties or scope of assignment, or addition of any personnel. Human Resources
will notify the Manager, MSC/Supervisor, Repair Station when Repair Station Personnel have been on
leave of absence or medical leave for more than 1 year. These personnel will be removed from the Repair
Station. Changes to the repair station roster will be incorporated within 5 working days. Revision of the
repair station roster will be accomplished by issuance of a newly dated roster as applicable. Manager,
Quality Systems will notify FSDO within 5 working days after the release of newly dated repair station
roster. Previous versions of the repair station roster(s) will be maintained for a minimum of 2 years on-
site.

RETURN TO SERVICE AUTHORITY

The approved repairmen are authorized to return to service parts for which the repair station is rated after
alterations, overhauls, and repairs have been completed. Inspection forms and FAA forms must be signed
with each repairman’s full name in ink. A certified repair station that chooses to use repairman to meet
the applicable personnel requirements must certify in a format acceptable to the FAA. Each person
recommended for certification as a repairman is employed by the repair station and meets the eligibility
requirements of part 65.101

EMPLOYMENT SUMMARIES
The employment summaries of all persons on the required repair station roster responsible for
compliance to this procedure are maintained by Manager, MSC/Supervisor, Repair Station and are
available for review upon request. The employment summary must contain enough information on
each individual listed on the repair station roster to show compliance with the experience requirement
of 14 CFR 145.151, which states that repair station personnel must have the training, knowledge, and
experience to perform maintenance, preventive maintenance, or alterations authorized by the repair
station certificate. As a minimum the employee summary must include: 1) present title, 2) total years’
experience and type of maintenance work performed, 3) past relevant employment with names of
employers and periods of employment, 4) scope of present employment, 5) type of mechanic or
repairman certificate held and the ratings on that certificate.

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SECTION III

OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND MATERIALS

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

OPERATIONS

GENERAL OVERVIEW
The repair station tests, repairs, and overhauls products listed in the FAA approved Capability List. For
a complete list of repairable products see the capability list, 512-0006-001-000, maintained by Quality
Assurance. The document is available at the company web site (www.esterline.com) as a PDF file. The
center of repair station operations is located in the MSC. Parts initially received at the receiving dock
are brought to the MSC in their original packaging and placed on the receiving shelf. Items too large or
heavy to be placed on the receiving shelf may be placed next to the shelf on the floor. MSC personnel
open the packaging, check for identification and damage, review all accompanying paperwork, and enter
the parts into the system. Routers are generated for each receipt and the part(s) is (are) routed to the shop
floor for preliminary visual inspection, preliminary inspection (functional test), analysis, and repair.
Certified Repairmen perform final inspection by inspecting repaired parts and reviewing paperwork to
ensure parts are acceptable for return to service. A certified repairman will then approve the item for
return to service by signing a FAA form 8130-3, Authorized Release Certificate. The parts are returned
to the MSC for out-processing and then moved to the shipping area for packaging and shipment. The
instruction 512-0006-002-000 (Repair Procedure for Returned Goods requiring return to service tag
8130-3) details the repair station’s operations which describes how the maintenance is to be performed,
where it would start, and how it progresses through the entire repair cycle for an approval for return to
service.

PRODUCTS RECEIVING POLICY

Products returned to the MSC, for repair are received as noted below.

Products in warranty, which can be economically repaired, will be authorized for repair and processing
in accordance with the router. The letter “R” will suffix date codes applied on the repaired products. The
suffix letter “T” will signify tested only and found acceptable upon return.

Products deemed not economically repairable, or out of warranty, will be withheld from further
processing pending MSC, and/or customer disposition.

GENERAL TEST REQUIREMENTS

All functional checks, and repair, overhaul, and test shall be performed in accordance with the latest
revision of the technical data and requirements, in the sequence planned on the specific repair station
router.

Repair Station personnel will be trained to be familiar with the methods, procedures and equipment
required to assure conformance to requirements and airworthiness of articles processed.

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

OPERATIONS

WORK ORDER
The MSC will enter receipt by Returned Material Authorization Number (RMA) in the MSC Database.
A file containing customer documentation received will also be established. All available information
about the returned goods are entered into the MSC database. This includes the FAA Repair Station
number, RMA number, customer name, date of receipt, Purchase Order number (if applicable), part and
model numbers, warranty information, etc. The MSC database is used to generate a MSC Analysis form,
MSC-010 (See Forms Manual), which accompanies the parts throughout processing. A MSC Router or
Overhaul Router is prepared by the MSC that identifies the progressive steps necessary to verify the
reason for return and to perform any repair necessary to repair the part. As a supplement to the routers,
detailed repair instructions are contained in the FAA approved document 512-0006-002-000, Repair
Procedure. Generic MSC Routers are available for each product line and a specific Overhaul Router is
available for the 9207-10296 primary trim relay. Repair Station routers are printed on light green paper
stock to facilitate identification. The returned goods and associated paperwork are issued to the
appropriate work center to begin processing.

RECORD OF WORK
The MSC Analysis form, MSC Router or Overhaul Router (as applicable), and all other documentation,
generated to provide a record of all work performed by the repair station, will be maintained for a period
of at least ten years in accordance with QAP 2.3. The records are maintained in the MSC onsite two
years minimum. Thereafter records will be archived and stored at a commercial offsite document storage
facility for the remainder of the required years.

PRELIMINARY INSPECTION
Products received in the MSC for repair will be given a preliminary inspection per section I of the QCM.

INSPECTION FOR HIDDEN DAMAGE

The preliminary inspection will not be limited to the failure identified by the customer, but includes a
thorough and searching inspection for hidden damage in all visible areas of the subject product per
section I of the QCM.

PROGRESSIVE INSPECTION
Progressive Inspection of products received in the MSC for repair will be performed per section I of the
QCM.

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

OPERATIONS

REPAIR, ALTERATION AND OVERHAUL ACCESSORIES AND APPLIANCES

The MSC Analysis form, the MSC Router or Overhaul Router, and the associated test data for each
product provide a complete record of work accomplished. The specific revisions of drawings and
procedures used in the repair or alteration of product are those revisions in effect at the date noted on the
MSC Router next to the specific operation. All components used in the repair shall be recorded on the
MSC Trace Log, MSC-003 (See Forms Manual), which shall remain with the repair documentation to
provide traceability of materials used.

HANDLING OF PARTS/PRODUCTS
All items or products undergoing repair or alteration in the repair station shall have the product parts
segregated and in containers in order to assure that all parts of the same unit(s) are kept together. Suitable
trays, bags, and protective covers (as required) are to be provided to the shop areas to assure maximum
protection of all products. During handling of parts, if for any reason, a person believes any part is not
an approved part, (SUP - suspected unapproved part), it should be reported to
management/supervision for reporting per section III of the RSM. Reasons for suspicion of non-approval
may include findings such as a different finish, size, color, improper (or lack of) identification,
incomplete or altered paperwork, or any other questionable indication. Personnel handling aviation
articles always need to exercise caution not to damage the articles. Parts labeled as ESD sensitive shall
be handled in accordance with 550-0006-000-000, Electrostatic Discharge (ESD) Control Procedure.

TAGGING AND IDENTIFICATION OF PRODUCTS

The documentation accompanying the products shall identify the status of the products at all times. Parts
and Products in the Stock Room shall be labeled for identification per OPR 012, Stockroom Material
Handling Procedure. The MSC Router or Overhaul Router allows identification of the last operation
completed, the current operation, and that performance of all of the prior operations was found
acceptable for product in work-in-process. Nonconforming material shall be recorded as documented
QAP 6.1, Control and Review of Nonconforming Material.

PRODUCT FINISHING
Plating, painting, and finishing are accomplished in areas segregated from the assembly areas.

PRESERVATION OF PRODUCTS
Products are preserved in accordance with acceptable industry standards. To afford suitable protection
against humidity, extreme temperature, dust, rough handling or other damage, product will be preserved
by wrapping in suitable containers, plastic bags, and/or rigid boxes containing suitable shock absorption
materials.

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

OPERATIONS

SHELF LIFE
The Manager, Quality Systems is responsible for Shelf Life Control and the Repairman are back-up for
this function. Age sensitive material shall be inspected and processed in accordance with the material
specification temperature storage requirements and QAI 303, Control of Age Sensitive Materials.
Material shall be received, verified, logged, labeled and properly stored and monitored as documented
in QAI 303 Control of Age Sensitive Materials. First-In-First-Out (F.I.F.O.) system for issuance of all
age-sensitive material shall be used. When material is issued to the Repair Station, the Repair Station
personnel shall monitor the age sensitive material for correct storage and expiration date. Stores and
Repair Station personnel shall assure that any age sensitive material being transferred from the original
container and distributed into smaller quantities, has a shelf life label installed on the smaller container.
Quality Control inspection shall verify the accuracy of the age sensitive label being transferred.
Repairman/designee shall contact QC personnel for inspection acceptance stamp. The shelf life label
shall contain the following information as a minimum:
a) Part number
b) Trace number
c) Shelf Life expiration date
d) Inspection Acceptance Stamp
For action on purging and proper disposition of expired age-sensitive material, QAI 303 Control of Age-
Sensitive Material procedure shall be followed.

HARDWARE AND EQUIPMENT STORAGE

To ensure stock control, segregation and identification, so that personnel will be able to locate
parts/products and determine adequacy of the stock and to protect parts/products against deterioration
and contamination, the following system will be used. Part number, trace number, and age control date
will identify material parts and supplies. Special boxes, containers and preservation measures shall be
utilized to preclude damage, deterioration or loss.

Materials, parts and supplies shall be stored in a restricted warehouse area and issued only upon a
properly executed material requisition.

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

OPERATIONS

RELEASE TO SERVICE
The MSC Analysis Form will be completed by Repair Station personnel as listed on Repair Station
roster. The product shipping documentation, identified as repaired and serviceable, will be processed
and forwarded together with the MSC Router or Overhaul Router, a completed 8130-3 Airworthiness
Approval Tag (See Forms Manual) signed by an FAA Certified Repairman for each item and a copy of
the MSC Analysis form to Shipping Inspection for acceptance and delivery.

The MSC Router or Overhaul Router, together with the MSC Analysis Form, Shipping, and Customer
documentation, will be maintained on file in this Repair Station for a period of not less than two (2) year
onsite (see section IX for off-site storage requirements).

MECHANICAL RELIABILITY REPORTS

The Manager, Quality Systems will notify the relevant air-carrier as deemed appropriate, when work is
being accomplished for an air carrier and a defect is found, as described under the Forms Manual. The
air carrier will be notified in order that the air carrier may issue a Mechanical Reliability Report.

RESPONSIBILITY FOR SUBMITTING REPORTS

When work is being accomplished for an air carrier and a defect as described under the Malfunction or
Defect Report is found, the air carrier will be notified as described below in order that the air carrier may
generate a Mechanical Reliability Report.
The Manager, Quality Systems or designee shall submit the report within 96 hours after the discovery
of any serious failure, malfunction, or defect (Malfunction or Defect reports, via website http://av-
info.faa.gov/sdrx/.in accordance with 14 CFR 145) of any unit or product undergoing work by this
station. If the defect or un-airworthy condition could result in an imminent hazard to flight, the most
expeditious method available will be used to inform the FAA.

PARTS SUBSTITUTIONS

Not applicable to the repair or alteration of the products produced by Leach.

DUTY TIME LIMITATIONS

Within the United States, each certificate holder (or person performing maintenance or preventive
maintenance functions for it) shall relieve each person performing maintenance or preventive
maintenance from duty for a period of at least 24 consecutive hours during any seven consecutive days,
or the equivalent thereof within any one calendar month.

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

SUSPECTED UNAPPROVED PARTS

A suspected unapproved part (SUP) is any part, component, or material that is suspected of not
meeting the requirements of an “approved part”. A part that, for any reason, a person believes in not
approved. Reasons may include findings such as a different finish, size, color, improper (or lack of)
identification, incomplete or altered paperwork, or any other questionable indication. Reference FAA
Advisory Circular 21-29 (as revised).

An unapproved part is any part that does not meet the requirements of an “approved part” as defined
in FAA Advisory Circular 21-29 (as revised). This term also includes parts that have been improperly
returned to service (contrary to 14 CFR Parts 43 or 145).

When a suspected unapproved part is discovered, this repair station will immediately notify the FAA by
calling the FAA Aviation Hotline at 1-800-255-1111 or 1-866-835-5322 by email to 9-AWA-ASY-
[email protected] or to the physical address shown below. All suspected unapproved
parts reported will be identified and quarantined in the repair station pending further investigation by
FAA Personnel. The complete electronic copy of FAA Form 8120-11 may be sent electronically via
internet site.

Physical Mailing Address for SUP notification:

Federal Aviation Administration

Office of Audit and Evaluation, Aviation Safety Hotline, Rm 911
800 Independence Avenue, SW, Washington, DC 20591
ATTN: AAE-300

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

HOUSING AND FACILITIES

The FAA Certified Repair Station No. FJ3D503L shares facilities with Leach International, which is
completely housed in a two bay concrete tip-up building of approximately 100,000 square feet. The area
is divided as follows:

45,000 square feet of Electronics manufacturing, including fabrication, assembly and test.
Products manufactured include relays, printed circuit board assemblies, hybrid microcircuits and
mechanical assemblies. Approximately 20,000 square feet of this is shared with the repair station.
The shared areas (see figure on next page) are the MSC area (1) , the Subminiature group A
screening and electrical test areas (2) , the entire Power & Control manufacturing and test areas
(3) , the entire Equipment area (4) , the Hybrid electro-mechanical assembly and electrical test
areas (5) Environment and Burn-in test area (6) .

8,000 square feet of material handling area including receiving inspection and calibration (7),
stores (8), receiving and shipping (9) and maintenance (10). These areas (less shipping and
receiving) provide indirect support to the repair facility. PDA (Power Distribution Area)/ LIE
(Leach International Europe) Product Repair Area and LIE (Leach International Europe)
Consignment Stock (11).

10,400 square feet of laboratories including R & D and qualification testing.

34,000 square feet of offices, including administration, accounting, engineering and sales, and
cafeteria.

The building is heated by natural gas and air conditioned by approximately 400 tons of air conditioning
package units. Lighting in the assembly areas is maintained at 100 monitored foot-candles at the bench
level. The building is fully sprinkler equipped and remotely monitored. Security guards provide 100%
coverage. Facility power is supplemented by 934 KVA of 400 Hz generators and 4000 amps of 28vdc
power for testing and evaluation. Additional services routed throughout the manufacturing area include
Nitrogen, CO2, compressed air and chilled water.

A class 100,000 Clean Room supports Hybrid manufacturing and a class 100 Clean Room supports relay
Millipore Inspection. Numerous Laminar flow benches are utilized for relay adjustment prior to sealing.

Hazardous materials are identified as required by regulation and flammable substances are retained in
fire safe cabinets until required. Painting is performed in an isolated room (see Facility Floor Plan).

Repair station work orders are identifiable (segregated) by the utilization of a unique light green paper.
Airworthy components are identified (segregated) by the attached 8130-3 tag. Non-repairable parts
remain on the receiving shelf in MSC until return to the customer or until they are identified as scrap
and rendered inoperable.

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

CHANGE OF LOCATION, HOUSING, OR FACILITIES

The repair station shall not change location of its housing without written approval from the FAA.

The repair station shall not make any changes to its housing or facilities required by 14 CFR Part 145.103
that could have a significant effect on its ability to perform maintenance, preventive maintenance,
overhaul, or alterations under its repair station certificate and operations specifications without written
approval from the FAA.

If the repair station does change its location, housing, or facilities, it will adhere to any FAA prescribed
conditions, including any limitations, under which a certified repair station must operate during the
change.

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS

FACILITY FLOOR PLAN

*Areas are shared by

Repair Station and
Manufacturing

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Title: SECTION III - OPERATIONS – HOUSING, FACILITIES, EQUIPMENT, DATA AND
MATERIALS
DESCRIPTION OF OPERATIONS
Parts for repair are delivered to the MSC Material Service Center by shipping/receiving department.
MSC verifies the paperwork is appropriate. The parts are inspected for identification and any obvious
damage. Then MSC personnel select the appropriate traveler. Parts are then delivered to the appropriate
Repair Station areas for testing and repair (if required) Test is performed per applicable Acceptance Test
Procedure, determine the necessary repair if the parts fail. After the repair, final Inspection is performed
according to the specifications. FAA 8130-3 tag is issued by the 14 CFR Part 65 certificated repairman.
MSC receives the complete job order and parts and send it to shipping to ship back to the customer.

EQUIPMENT AND MATERIALS/EQUIVALENT TOOLS AND EQUIPMENT

DESCRIPTION OF EQUIPMENT
The equipment utilized by the repair station encompasses a wide variety ranging from standard hand
tools (screwdrivers, wrenches, calipers, etc.) to custom designed welding fixtures. Examples of tooling
include modified hand tools used for adjusting relays, vacuum and standard ovens, environmental
chambers (hot/cold), custom assembly tooling, custom holding fixtures for assembly and destructive
testing, aqueous and solvent cleaning systems, laser sealing systems, scales, power supplies, volt and
current meters oscilloscopes, custom electronic test equipment, microscopes, soldering equipment,
automated wire cutting devices, paint guns and compressors, labeling machines, plating tanks and racks,
etc.

EQUIPMENT LISTINGS
Equipment required to support the ratings held are listed in the various process specifications utilized to
perform the repair functions. A list of calibrated equipment is available at the Calibration department. It
is maintained as an electronic recall system and can be printed if required. Operators are required to
verify the currency of all calibration labels prior to using any calibrated equipment.

LEASED EQUIPMENT
At this time there is no intent to rent or lease any equipment necessary for the repair of product.

EQUIVALENT TOOLS AND EQUIPMENT

All equipment utilized is the same equipment used by Leach International for the original production of
like products.

PREVENTIVE MAINTENANCE
Equipment requiring preventive maintenance is listed on the Facilities computerized preventive
maintenance system. Similar to the automated calibration recall system, this system generates reports of
equipment coming due for preventive maintenance. New equipment requiring preventive maintenance
is entered into the system and obsolete equipment is deleted as necessary. A list of equipment requiring
preventive maintenance is available from the Facilities department computerized preventive
maintenance system as described in FAC 000, Preventive Maintenance.

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SECTION IV

CAPABILITY LIST

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Title: SECTION IV - CAPABILITY LIST

CAPABILITY LIST
The capability list includes all products currently repaired and overhauled by Leach International North
America known to be used on type certificated (TC) vehicles. This list is maintained by Quality
Assurance. The list includes both Parts Manufacturer Approval (PMA) parts and non-PMA parts with
identified TC use. The list is formulated from information provided by the Sales department and review
of the MSC repair station database. It is posted to the intranet and at the company web site
(www.esterline.com) as a PDF file and is under revision control. The list shall be revised as new TC
usage product is identified. Upon revision, a new revision is posted in both the company intranet and the
company web site under Product Support. The FAA Flight Standards District Office (FSDO) is notified
of revisions to the capabilities list by e-mail (cover letter) that lists the revisions and the new revision is
available to the FSDO through the company web site. If the website copy is unattainable, please email
[email protected] to obtain a copy by email.

CAPABILITY LIST SELF-EVALUATION

Self-evaluation shall be performed whenever it is required to revise the capability list. The need to revise
the capability list can be driven by: 1) the identification of a TC application of a product not on the
current capability list by Sales, 2) the issuance of a new PMA approval, and 3) a repair request for a part
not listed on the current capability list. Once the need to revise the capability list is identified, Manager
MSC/ Supervisor, Repair Station or designee shall perform self-evaluation utilizing the Capability List
self-evaluation checklist form, MSC-035 (see Forms Manual).

Record the name of the person performing the self-evaluation, the product model number, and the source
of the request on the checklist. Verify the repair station is rated to perform maintenance on the product.
If the model number is a current production product, then the repair station has adequate housing and
facilities, necessary the special tools and test equipment recommended by the manufacturer, and the
equipment, materials, and qualified personnel necessary to perform maintenance on the product. Verify
that approved repair data either exists for the product family or has been submitted for approval.

Once the self-evaluation checklist is completed and indicates that the repair station has the capability
and resources necessary to perform the repair, the Manager, MSC/Supervisor, Repair Station, or her/his
designee forwards the self-evaluation form to the Manager, Quality Systems by either hard copy or e-
mail. The self-evaluation checklist is reviewed and approved by Manager, Quality Systems. If the self-
evaluation is found to be unacceptable, the item under consideration will not be added to the capability
list and the customer will be notified.

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SECTION V

APPROVED TRAINING PROGRAM REVISIONS

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Title: SECTION V – APPROVED TRAINING PROGRAM REVISIONS
TRAINING
Repair Station personnel shall be trained and qualified per the requirements of 512-0006-003-000 FAA
Approved Repair Station Training Program Manual, latest revision. Any subsequent revisions will be
submitted to the FSDO for approval prior to release. Any changes to 512-0006-003-000 FAA Approved
Repair Station Training Manual will go through Quality Management systems process and the final draft
will be sent to FSDO by Manager, Quality Systems for FSDO review. After FSDO’s review and
approval, the final draft process shall be formally released. The FSDO will be notified by email that the
revision has been released and a hardcopy for review will be provided via U.S. Mail within 5 business
days. Upon receiving the Approval letter from FAA, it will be placed in front of final released document
and the Manager, Quality Systems shall remove the obsolete version from the Intranet and company web
site and post the new revision.
Repair Station personnel shall be thoroughly familiar with all inspection methods, techniques, and
equipment used to determine the quality or airworthiness of the product. Repair station personnel
maintain proficiency in using various inspection aids by daily application, classroom training, factory
training or On the Job (OJT) as necessary.
Training will be scheduled as necessary for personnel to become familiar with new products and
product/process improvements. The supervisory and lead personnel in each work area shall conduct
training and will be responsible for the coordination of retraining. An annual assessment of the repair
station training will be conducted and documented on the RS Annual Training Program review log QAF-
287 (See Forms Manual) by Manager MSC/Supervisor, RS. As an alternative, or as necessary,
management personnel, if qualified, can also perform training. Training will be recorded via Training
Attendance Roster - FAA Approved Repair Station FJ3D503L (See Forms Manual) QAF-224-RS.
Training records will be maintained for each employee. Records will indicate the type of training,
method, duration, date of completion, Percentage Grade (if applicable), and include the name of the
instructor that conducted the training. Copies of special skills certification issued will be kept in the
employee’s files. Training records are used to support employee qualifications, proficiency and
knowledge of applicable specifications, regulations and tasks. Qualification may also be supported by
educational history and job experience. Records of training subject areas, qualified trainers, and a list of
those employees, job classifications or departments that require training are maintained. Records are
maintained of the types of training each employee has received and when. Copies are retained of
completed training materials such as attendance sheets, tests, etc. Hard copies of training records are
delivered to Human Resources for retention.
The Manager, Quality Systems or his delegates will be responsible for identifying those processes
requiring training, for assuring that personnel selection and job assignment are based on education,
training and/or experience, for identifying employees/job classifications that need training, and for
determining who is qualified to instruct employees and in which subjects. There will be a periodic
assessment of employee competence via daily monitoring of performance (including quality of output)
to determine if new training is required or if retraining is necessary outside the retraining cycle of one
year. Training modules and materials are developed to meet specific reoccurring or OJT training
requirements. This RSM, current specifications involving tolerances, limitations and procedures of the
products inspected and other information such as the Code of Federal Regulation (CFR) or Airworthiness
Directives are available for use. Manager, MSC/Supervisor, Repair Station is responsible for assuring
that the training schedule is reviewed and that training is conducted when required. Designated
instructors will deliver all completed test material to Manager, MSC/Supervisor, Repair Station and the
completed Leach International Training Records for retention in the employee files, to Human
Resources.
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SECTION VI

WORK AT OTHER LOCATIONS

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Title: SECTION VI - WORK AT OTHER LOCATIONS

POLICY AND PROCEDURE

All work associated with the repair, alteration, and overhaul of products by this repair station is
performed at Leach International North America in Buena Park. Should the need arise to perform the
repair, alteration, and overhaul of products at other locations, Leach International North America shall
make the appropriate Operations Specification change request to the FAA-FSDO and will revise this
manual to meet the requirements of FAR 145.203 prior to performing any such activity.

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SECTION VII

MAINTENANCE OF 14 CFR PART 121, 125, AND 135 AIRCRAFT AND FOREIGN
CARRIERS OR PERSONS UNDER 14 CFR PART 129

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Title: Section VII - MAINTENANCE OF 14 CFR PART 121, 125, AND 135 AIRCRAFT
AND FOREIGN CARRIERS OR PERSONS UNDER 14 CFR PART 129

POLICY AND PROCEDURE

This repair station will perform this work in accordance per the operator’s purchase/repair order and in
compliance with each air carrier or operator’s continuous airworthiness maintenance program and
applicable sections of maintenance manuals, where existing. The repair station shall also follow the
operator’s FAA approved inspection program, when specified. If the operator’s purchase/repair order
reference specifications, orders, manuals are other than Leach specifications; the Repair Station will
contact the operator prior to any work. Correspondences with each operator will be maintained in the
Repair Station when specific manuals or other instructions are not available/applicable. This repair
station will maintain a current copy of the applicable section of each operator’s manual, when required
by the operator’s purchase/repair order that contracts with this repair station for the performance of that
operator’s maintenance. The Manager, MSC/Supervisor, Repair Station will be responsible for keeping
current repair documents and/or manuals as required by the operator’s purchase/repair order available in
the Repair Station. In the absence of specific instruction, the repair station will not perform maintenance
until such instruction is provided. MSC and Overhaul routers will be issued upon compliance with
operator’s requirements.

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SECTION VIII

CONTRACT MAINTENANCE

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Title: SECTION VIII - CONTRACT MAINTENANCE

POLICY AND PROCEDURE

All work associated with the repair and alteration of products by this repair station is performed at Leach
International North America in Buena Park. This section is not applicable for the repair station as no
work is contracted out. At this time there is no intent to contract out repair station work. Should the need
arise for contracted maintenance functions, Leach International North America will revise this manual
to document the procedures for controlling contracted maintenance and shall submit a list of contractors
per the requirements of 14 CFR Part 145.217. The contract maintenance functions must be approved by
the FAA prior to their use.

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SECTION IX

RECORDS

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Title: SECTION IX - RECORDS

RETENTION AND RETREIVAL

All documentation generated during product repair is maintained in hard copy format and filed by RMA
number. This data is maintained in the MSC files for at least two years. After two years the data can be
transferred off site to a contracted data storage facility for retention and retrieval per QAP 2.3, Data
Retention/Data Control. The minimum retention period for all data is ten years from return to service.

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Quality Control Manual

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SECTION I

INSPECTIONS

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 Title: SECTION I - INSPECTIONS

GENERAL
This section documents the procedure for establishing and maintaining the inspection of raw materials
to ensure acceptable quality, performing preliminary inspection of all product that are maintained or
modified, the inspection of all products involved in an accident for hidden damage, and performance of
the final inspection and approval for return to service for maintained product.

PARTS RECEIVING POLICY

Raw materials, piece parts, and subassemblies from external approved resources used in the repair and/or
alteration of products in the repair station shall be inspected by Receiving Inspection. The Manager,
Quality Systems is responsible to ensure that all incoming materials, AN or MS and other hardware,
parts, component, equipment and other products procured for use by the repair station are subject to
receiving inspection per QAP5.7, Receiving Inspection Procedure, to assure conformance to part
number, purchase order and/or other applicable specifications. QAP 5.7 Receiving Inspection Procedure
covers, but is not limited to, the detailed instructions for performing incoming inspections of raw material
and standard parts and checks for proper documentation, identification, and traceability of parts,
conformity to a specification and acceptable quality, shelf life, contamination, shipping damage and state
of preservation. The records of such inspection shall be maintained and the trace numbers are
electronically issued and printed. Products with shelf life limitations are processed and inspected in
accordance with QAI 303, Control of Age Sensitive Material. Any products that fail to meet applicable
specifications are processed per QAP 6.1, Control and Review of Nonconforming Material. These are
placed in the secure Material Review Board cage until dispositioned for repair, return to vendor, scrap,
etc. Products found to conform to requirements are transferred to the stockroom per OPR 012,
Stockroom Material Handling Procedure.

ACCEPTANCE PIECE PARTS/SUBASSEMBLIES UTILIZED IN REPAIRS

Piece parts and subassemblies used in the repair and/or alteration of products in the repair station are
requisitioned from Leach stockroom. These piece parts and subassemblies shall be inspected by Repair
Station Inspector; as instructed in QAP 5.7 Leach Receiving Inspection Procedure on QAF-234-RS
form. The records of the inspection shall be maintained according to QAP 2.3, Data Retention/Data
Control.

GENERAL TEST REQUIREMENTS

All functional checks, repair/alteration work, and final inspections will be performed at the department
responsible for the initial fabrication of the subject product and by authorized repair station personnel.
The processing and testing shall be performed in accordance with the latest revision of the article
approved data/documentation requirements, and in the sequence planned on the specific repair station
Router. Compliance to Air-Carrier Continuous Airworthiness Maintenance Program (CAMP)
requirements of FAA Part 121/135 operators, and subsequent instructions flowed to Leach International
by the air-carrier shall take precedence for repair station compliance over articles maintained and
returned to service and in accordance with FAA Part 145.205(a). Manager, MSC/Supervisor, RS must
verify the current revision of any maintenance manual or service bulletin if applicable and record on
QAF-272 on a monthly basis.

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Title: SECTION I – INSPECTIONS

PRELIMINARY INSPECTION
Products received in the MSC for repair will be given an identification and damage check to determine
proper identification, physical condition, and warranty status by MSC personnel. Perform visual
inspection of the container and contents for shipping damage, packing, and proper paperwork.
Compliance with Service Bulletins and Airworthiness Directives is determined. (At this time only
applicable to the 9207-10296 (PCD) Product Control Drawing on our Capability List.) The results of the
identification and damage will be recorded on the MSC Analysis form. Report damaged product to the
Manager, MSC/Supervisor, Repair Station. Parts are issued to Inspection for preliminary visual
inspection and to the electrical test personnel for functional test. The parts are then passed on to the repair
station personnel for analysis, and determination of reparability.
HANDLING OF PARTS/PRODUCTS
Handling of parts and products shall be as described in section III of the RSM.
TAGGING AND IDENTIFICATION OF PRODUCTS
Initial Tagging and Identification of products shall be performed by the Repair Station in accordance
with section III of the RSM. In addition, nonconforming material shall be processed as documented in
QAP 6.1, Control and Review of Nonconforming Material. Nonconforming material shall be recorded
according to QAP 6.1 Control and Review of Nonconforming Material.
INSPECTION FOR HIDDEN DAMAGE
The preliminary inspection performed by the repair station personnel will not be limited to the failure
identified by the customer, but includes a thorough and searching inspection for hidden damage in all
visible areas of the subject product. Other inspections performed by other repair station operators,
occurring during the teardown and analysis of the product shall also include examination for any
secondary evidence that could result from an accident such as heat or fire. All areas adjacent to such
damage shall be inspected for damage. The results of all inspections shall be recorded on the router,
including all evidence of any such damage. All hidden damage appearing to be the result of an accident
(excessive heat, fire, excessive shock, mishandling, etc.) shall be reported to the customer.
IN-PROCESS INSPECTION AND FINAL PRODUCT VERFICIATION
Products will be functionally tested in accordance with a MSC Router or Overhaul Router prepared by
the MSC Coordinator to verify the reason for return. Troubleshooting will be performed as necessary to
confirm cause and corrective action. Troubleshooting will always be recorded on the Returned Goods
Analysis Sheet, MSC-002. (See Forms Manual). The MSC Router or Overhaul Router will be cross-
referenced to the MSC Analysis Form to assure continuity of documentation, part numbers, and date
code/serialization. A copy of the Returned Goods Analysis Sheet will accompany the MSC Router or
Overhaul Router in process. Qualified Repair Station inspection personnel listed on the repair station
roster shall approve all Inspection callouts on the router using a Repair Station Inspection stamp.

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Title: SECTION I - INSPECTIONS

IN-PROCESS INSPECTION AND FINAL PRODUCT VERFICIATION (Continued)

In process inspections, function test(s), and or calibration(s) will be accomplished in accordance with
applicable drawings and specifications identified on the current technical data. The individual
performing the task will record each inspection and test at the appropriate sequence and block on the
MSC Router. Operator is responsible for completion status of each prior operation; if a discrepancy is
identified the operator shall notify the area leader. In the event there is work turned over from one shift
to another the area leader is responsible to communicate and assign the specific job. The leader or
Supervisor will take appropriate action per OPR 017 (Production Handling for work-in process).

Product non-conforming conditions will be documented on the MSC Router or Overhaul Router per
QAP 6.1, Control and Review of Nonconforming Material, and either re-worked to applicable drawings
and specifications or will be withheld from further processing pending MSC, and/or customer
disposition.

CONTINUITY OF INSPECTION RESPONSIBILITY

See section II of this QCM.

FINAL INSPECTION AND RELEASE TO SERVICE

Repairmen included on the Repair Station Roster shall perform the Final Inspection. Final inspection for
all repaired products will be in accordance with the applicable approved technical data. Final Inspection
shall include a review of all documents used during maintenance (routers, etc.) as well as inspection of
the product. The Final Inspection must be signed-off on the Final Inspection block of the MSC Router
or Overhaul router by a repairman certificated under 14 CFR Part 65.

The MSC Analysis Form MSC-010 will be completed by Repair Station personnel as listed on Repair
Station roster and reviewed by Certified Repairman. The product shipping documentation, identified as
repaired and serviceable, will be processed and forwarded together with the MSC Router or Overhaul
Router, a completed 8130-3 tag (See Forms Manual) signed by an FAA Certified Repairman for each
item and a copy of the MSC Analysis form to Shipping Inspection for acceptance and delivery.

The MSC Router or Overhaul Router, together with the MSC Analysis Form, Shipping, and Customer
documentation, will be maintained on file in this Repair Station for a period of not less than two (2)
years.

DUTY TIME LIMITATIONS

Each certificate holder (or person performing maintenance or preventive maintenance functions for it)
shall relieve each person performing maintenance or preventive maintenance from duty for a period of
at least 24 consecutive hours during any seven consecutive days, or the equivalent thereof within any
one calendar month.

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SECTION II

CONTINUITY OF MAINTENANCE AND INSPECTION RESPONSIBILITIES

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Title: SECTION II - CONTINUITY OF MAINTENANCE AND INSPECTION
RESPONSIBILITIES

CONTINUITY OF INSPECTION RESPONSIBILITY

Continuity of inspection shall be assured through the use of a MSC Router or Overhaul Router (See
Forms Manual, for typical generic MSC Router and Overhaul Router). The MSC Router or Overhaul
Router shall delineate each step of the repair/alteration sequence. The steps shall be performed in
sequence and no step shall be stamped until the operation is complete. Steps that are not applicable to a
specific product shall be marked as not applicable (“N/A”). Note: Only, designated personnel, have the
authorization to (N/A) tasks/step. The designation letter will be initiated by the Manager, Quality
Systems and kept on file.

At Final Inspection, the Repair Station Inspection personnel shall assure that the MSC Router or
Overhaul Router is complete and correct as the first step of Final Inspection. The Repairman shall review
all paperwork for completeness and correctness prior to preparation of release to service documentation.
In this manner, for each repair/alteration performed, it shall be assured that all necessary operations are
performed and that a record of those responsible is maintained.

STAMPS
Acceptance of work performed by the repair station shall be signified by stamping the appropriate box
on the MSC Router or inspection form along with the date the work is accepted. The Manager, Quality
Systems or his delegates are responsible for assuring that this procedure is adhered to and that Repair
Station stamps for different functions shall be clearly distinct from one another and shall not resemble
the stamps of customers or regulatory agencies. Manager,, Quality Engineering/Designee is responsible
for controlling, bonding, issuing, and maintaining logs on the test and inspection stamps as described in
QAP 1.8, Stamp Control. The Supervisor, Repair Station is responsible for controlling, bonding, issuing,
and maintaining logs on the Operations stamps. Stamp Issue Logs will be maintained to ascertain the
status of any inspection and test stamp in existence at Leach International. Revisions of the Stamp Issue
Logs shall be dated and archival copies maintained for a period of ten years. The Stamp Issue Logs shall
contain the following information as a minimum: date of revision, stamp number issued, the status of
stamp issued, name of stamp holder, department number of stamp holder, stamp issued date, bond date,
comments (condition of bonded stamps, reason for return). Stamps shall be bonded for a minimum of
six (6) months prior to re-issue. Lost stamps are to be reported immediately to the responsible
Department designee. Stamps shall be bonded for a minimum of two (2) years prior to re-issue where
the stamp has been reported as misplaced. Relocated stamps may be removed from two (2) year bond.

AUDITS
Leach Repair Station (FJ3D503L) maintains the audit system that is independent of the components
maintenance repair process and their release to service inspections. The Annual Repair Station Audit is
performed as described in the Quality Assurance System section of the EASA Supplement.

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SECTION III

REPAIR STATION INSPECTION PERSONNEL

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Title: SECTION III - REPAIR STATION INSPECTION PERSONNEL

GENERAL
This section documents the procedure for establishing and maintaining proficiency of Repair Station
inspection personnel to assure that they are thoroughly familiar with the applicable regulations and the
inspection methods, techniques, practices, aids, equipment and tools used to determine the airworthiness
of a product.
REQUIREMENTS OF REPAIR STATION INSPECTION PERSONNEL
Inspectors must demonstrate proficiency in using the various types of inspection equipment and visual
aids required prior to performing repair station work. They must pass a written (English) general
examination and must understand, read, and write English. Classroom training examination in English
is considered equivalent to written English examination. The course examination pass/fail criteria shall
follow the requirements listed in 512-0006-003-000 FAA Approved Repair Station Training Program
Manual. The Supervisor Repair Station and or qualified delegate is responsible for assessing the
capability of the inspectors and assuring that only capable persons are issued inspection stamps.
Repair Station inspection personnel require access to and proper knowledge of current technical data to
perform their tasks. They need to be familiar with the RSM and QCM for the repair station, as well as
the applicable federal aviation requirements. The Manager, MSC/Supervisor, Repair Station or designee,
is responsible for assuring that repair station inspection personnel have received training to become
familiar with these documents and assuring that training records are maintained as described in 512-
0006-003-000 Repair Station Training Program Manual.
The Document Control group of the Engineering Services department at Leach controls technical data
utilized for Leach OEM repairs listed on Leach capability list. Current technical data is maintained in
Adept (Engineering Document Control) as described in QAP 2.1, Documentation Control. Manager,
MSC/Supervisor, Repair station is responsible for reviewing Air Carrier Websites as described in MSC
(Material Service Center) procedure 512-0024-000-000 and internal documentation changes,
determining if they significantly affect operations in their area, and performing training if determined to
be of significant effect.
LIE, as OEM, controls technical data utilized for LIE OEM repairs listed on Leach capability list
through LIE controlled Portal(See detailed Instructions in section IV of Quality Control Manual)
The Final Inspection must be conducted by an authorized repairman certificated under 14 CFR Part 65,
and listed on the Repair Station Roster as having such authority. Only certified repairmen may approve
articles for return to service.
Manager, MSC/Supervisor, Repair Station is responsible for monitoring the proficiency of Repair
Station inspection personnel working in their areas and assuring that proficiency is maintained.
Proficiency shall be monitored through observation of work quality and during yearly training. Loss of
proficiency observed as increased repair and rejections shall require immediate retraining.
Repair station management is responsible for assuring that all repair station Inspection Personnel have
employment summary documented as required in the RSM section II.

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SECTION IV

TECHNICAL DATA

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Title: SECTION IV – TECHNICAL DATA

GENERAL
This section documents the procedure for ensuring that current technical data is available for the scope
of work the repair station is performing. Approval for return to service requires approved technical data
that is acceptable to the FAA. The Manager, Quality Engineering is responsible for Technical Data and
the Manager, MSC/Supervisor, Repair Station is back-up for this function.

ACCEPTABLE TECHNICAL DATA

In the absence of Manufacturer’s technical data (such as maintenance manuals or Service Bulletins),
Engineering data (DER approved data or data developed by the repair station and approved by the FAA)
is required for repair station work.

CURRENCY OF DATA
Current technical data shall be available to all Repair Station personnel. For performing maintenance,
preventive maintenance, or alterations for an air carrier that has continuous airworthiness maintenance
program under part 121 or part 135, Leach International Repair Station follows the air carrier's
instructions. The latest instructions will be obtained according to process defined in 512-0024-000-000
(Material Service Center Procedure) prior to repair. This is accomplished thru the generation and
maintenance of repair routers. These repair/overhaul routers shall be available for each product family
identified on the capabilities list. These repair/overhaul routers are generated and maintained per OPR
015, Router and Operation Maintenance and bill of materials are maintained per QAP 7.5.1.004.
Examples of repair and overhaul routers are available in section VII of this QCM. The remaining
technical data shall consist of the current revisions of the referenced product control specifications,
manufacturing specifications, and process specifications as specified in the Repair Procedure, 512-0006-
002-000.
For Leach OEM (Original Equipment Manufacturer) product repair at Leach repair station;
1. QAP 2.1, Document Control, controls the currency and availability of this technical data.
2. ENG 003, Document and Data Control, is used to control revisions of this technical data.
For LIE (Leach International Europe) OEM product Repair at Leach Repair Station;
1. LIE is responsible for translating the latest technical data into English and uploading to the LIE
Portal. LIE is responsible to ensure translation is accurate, current and complete. Leach Repair
Engineer is responsible to contact LIE for any discrepancy in translation identified during the
repair process.
2. Leach Repair Station Management/Designee is responsible to ensure all Repair Station
personnel on having access the technical data for repair.
3. LIE is responsible for revision control of Technical Data and notifies Leach Repair Station
management for any technical data revision changes.
4. Leach Information Technology Department is responsible to maintain portal security and issue
the repair station personnel access to the LIE Portal.
5. Leach Repair Station Management is responsible to instruct and ensure the Repair Station
personnel to use the latest revision of technical data.

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CONTROL OF COMPUTER TEST SOFTWARE
For Leach OEM product repair at Leach repair station;
Computer software utilized for the acceptance of product testing is controlled by 552-0245-000-000,
Procedure for Documentation and Control of Test Equipment/Acquisition Software. Information on the
responsibility for software maintenance, revision, and distribution of this software is included in this
procedure.
For LIE (Leach International Europe) OEM product Repair at Leach Repair Station;
Computer software utilized for acceptance of product testing is controlled by LIE (Leach International
Europe). LIE (Leach International Europe) is responsible for software maintenance, control, revision,
verification and distribution and etc.

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SECTION V

TOOLS/EQUIPMENT CALIBRATION

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Title: SECTION V – TOOLS/EQUIPMENT CALIBRATION

CONTROL OF PRECISION TOOLS AND TEST EQUIPMENT

The Manager, Quality Systems is responsible for Calibration. Measurement (precision tools, gauges,
scales, and meters) and test equipment (M&TE) used in repair station operations are subject to periodic
checks and calibration in accordance with the QAP 4.1, Equipment Control and Calibration. Leach
contracts outside calibration sources to perform the calibrations. The outside sources are responsible for
the specific calibration procedures. Both Leach and its contracted calibration service maintain
computerized calibration tracking systems, which include all equipment requiring calibration. The
systems generate both recall lists noting equipment shortly coming due for calibration and calibration
overdue lists. The calibration coming due lists assist in acquisition of equipment for calibration prior to
the calibration becoming delinquent and are issued monthly to those departments with equipment coming
due for calibration. The past due list is used to assist in the location of equipment which has not been
returned for recalibration in a timely manner.
All the equipment and tools used to maintain articles are recommended by the article’s manufacturer. If
there is equivalency recommended by article’s manufacturer and applied at Leach repair process, the
basis of equivalency is defined as the article meet the original manufacturer’s standards and
specifications in all respects regarding tolerances, repeatability, and accuracy. The equivalency shall be
demonstrated, documented and approved by Manager, Quality Systems, or designee. The records shall
be maintained according to QAP 2.3 Data Retention/Data Control.
At no time will any person be permitted to perform work on product using measurement or test
equipment that is out of calibration. Area supervisors will randomly check calibration labels, QAT-010
(See Forms Manual), and QA audit to assure that M&TE used is in calibration. If at any time a piece of
M&TE inadvertently exceeds its calibration due date, it will immediately be removed from service
(physically or Do not Use Tagged), QAT-006 (See Forms Manual), until a calibration check has been
performed.

All repair station personnel, before using M&TE, are responsible to check that the equipment has a
current calibration label attached. Any piece of M&TE found in the repair station without a current
calibration label attached shall be reported to Calibration and red tagged to prevent use.

Notification of out of tolerance conditions shall be provided by the calibration source. The “Out of
Tolerance Notification Form”, QAF-036 (See Forms Manual) shall be filled out by Leach’s Calibration
Coordinator. Equipment that was identified as out of tolerance shall be immediately brought to the
Manager, Quality Systems’ attention via an “Out of Tolerance Notification Form” for evaluation. The
evaluation shall determine if the out of tolerance condition had any possible detrimental effect on
accepted products and if the equipment requires an interval adjustment. The “Out of Tolerance
Notification Form” shall state the current calibration status, current as found condition including details
of the problem, prior as found condition, previous calibration date, current calibration date and identify
for interval review equipment found out of tolerance during the current and last calibration. All out of
tolerance evaluations shall be completed and returned within 30 days of finding unless required earlier
by Leach’s Calibration Coordinator and kept in each individual instrument’s history file in the calibration
laboratory. When the calibration source supplies its own “Out of Tolerance Notification Form” that form
may be used in lieu of Leach’s form, provided the requirements of QAF-036 are met. Note that Leach
International does not allow personal MT&E tools to be used.

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Title: SECTION V – TOOLS/EQUIPMENT CALIBRATION

CONTROL OF PRECISION TOOLS AND TEST EQUIPMENT (Continued)

An Out of Tolerance condition occurs when the instrument does not meet its current rated accuracy
between a working standard and the MT&E being tested. The Manager, Quality Systems or designee
shall make determination of significantly out of tolerance conditions. Work in process (WIP) and items
in Stores, affected by significantly out of tolerance conditions, and shall be purged. Problem Advisories
shall be issued for any shipped product associated with significantly out of tolerance conditions.

TEST EQUIPMENT CALIBRATION REQUIREMENTS

Calibration procedures and methods shall require standards traceable to the National Institute of
Standards and Technology. Test equipment shall be calibrated at periodic intervals established on the
basis of stability, purpose, and degree of usage. One year shall be the maximum established calibration
interval. Calibration sources shall ensure that measurements made are traceable to national, international,
or intrinsic standards of measurements where available. Where no national or international recognized
standard exists, the basis used for calibration shall be determined and documented. All Measurement and
Test Equipment (M&TE) must be labeled, marked or otherwise identified to indicate its calibration status
by using QAT-010 tag or a tag issued by the service provider. When it is impractical to apply a label
directly to an item, the label may be affixed to the instrument’s container or some other suitable means
may be used to reflect calibration status. As a minimum, every calibrated device must be labeled by
Leach, the calibration source or their approved sub-contractors with the date of calibration, any
limitations, the date of next calibration, and the identification or stamp of the individual or company
performing the calibration. Instruments limited for calibration must be tagged using a Limited Use label
QAT-011 (See Forms Manual or Calibration Source Labels) and provide a statement of any and all
functions being limited on Limited Use Label, QAT-008 (See Forms Manual or Calibration Source
Labels). Limitations at all times must be made available to the operator in written form. [Some examples
of limitations are the limitation of the use of a measurement device to one measurement range or to limit
the use of test equipment to a specific temperature range.] Calibration sources, utilized for calibration of
M&TE, must have the capabilities of performing the required services. Calibration sources should have
available all equipment needed for the calibrations they normally perform, whether owned, leased, rented
or borrowed. The calibration sources must assure that leased, rented or borrowed equipment meet the
same requirements as owned equipment. Calibration sources will be surveyed and evaluated yearly to
ensure that they are capable of performing the required services. The survey and evaluation shall be
documented per the requirements of QAP 4.1, “Equipment Control and Calibration”. Environmental
conditions should be appropriate for the type of work being performed. Only the environmental factors
that could affect the accuracy, stability, or performance of the calibration require control. Correction
factors may be applied by the calibration source to compensate for the accuracy of the equipment, thus
allowing calibration to continue. Leach shall retain calibration records for a minimum of seven years,
unless specified otherwise by contract. The calibration records shall be made available for customer
verification when contractually required.

The contracted calibration service certifies the use of standards, traceable to the National Institute of
Standards and Technology, for all calibrations performed.

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SECTION VI

DISCREPANCIES/CORRECTIVE ACTION

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Title: SECTION VI - DISCREPANCIES/CORRECTIVE ACTION

POLICY/PROCEDURE
Corrective action (C/A) performed to resolve deficiencies is applicable in as least four situations: C/A
as the result of deficiencies noted during the repair/release process, C/A as the result of the analysis of
returned product and C/A to resolve Internal and External audit findings.
Deficiencies noted during the repair/release process are recorded per QAP 6.1, Control and Review of
Nonconforming Processes. The scrap parts control for Repair station is processed according to QAP
6.1.3 Control of Scrap Material and Material Service Center Procedure 512-0024-000-000. Immediate
C/A is the simple repair of the product to a compliant condition for continued processing. Repetitive
noncompliance during the repair/release process indicated the need for review of housing, facilities,
equipment, personnel qualifications, and procedures to ensure that the noncompliance is not a systematic
problem. QAP 6.1, Control and Review of Nonconforming Processes, requires C/A for repetitive
occurrences of any noncompliant condition. QAP 6.3, Corrective/Preventive Action, documents the
formal C/A process on QAF-024 Corrective/Preventive Action Request form.
Repetitive deficiencies, attributed to poor design, poor processing, or inadequate workmanship
conditions, noted during troubleshooting of returned product, require corrective action to preclude the
release of other product with similar deficiencies. QAP 6.3, Corrective and Preventive Action,
documents the C/A process for external returns. In the event that Failure Analysis identifies any evidence
of potential violations of the regulations, the repair station should avail itself of the self-disclosure
program addressed by AC-00-58. Any Failure Analysis identifying manufactured defects that may affect
other released product requires the notification of customers of the possible deficiencies.
See QAP 6.3, Corrective and Preventive Action, for description of the Failure Analysis, C/A process.

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