Aircraft Maintenance Documentation
66 likes36,046 views
The document discusses aircraft maintenance documentation requirements according to the Federal Aviation Administration (FAA). Proper documentation is important for safety. Regulations require maintenance records to include a description of work done, completion date, and signature of the approving inspector. Common documentation errors that can lead to accidents include no records, inadequate work descriptions, and citing the wrong reference documents. Shift turnover between maintenance teams is also critical for safety and requires formal procedures.
Aircraft Maintenance Documentation
- 2. Federal Aviation Administration 2 Aircraft Maintenance Documentation Introduction This course provides a review of aircraft maintenance documentation requirements. It emphasizes the importance of proper documentation. It identifies common documentation problems that can lead to maintenance errors.
- 3. Federal Aviation Administration 3 Aircraft Maintenance Documentation Accident Data
- 4. Federal Aviation Administration 4 Aircraft Maintenance Documentation Regulation Cited
- 5. Federal Aviation Administration 5 Aircraft Maintenance Documentation Common Findings • No documentation. • Inadequate description of work performed. • Using the wrong reference.
- 6. Federal Aviation Administration 6 Aircraft Maintenance Documentation Maintenance Related Accident 3/24/2005 Prescott, AZ Robinson R22 The helicopter's main rotor drive belts broke on the base leg and the helicopter rolled over during the subsequent autorotation and landing. Upon exiting the helicopter, the instructor observed that the V-belts were shredded.
- 7. Federal Aviation Administration 7 Aircraft Maintenance Documentation Maintenance Related Accident A company mechanic had performed a 100-hour inspection about 4.3 hours prior to the accident flight. During the inspection, he had loosened the self locking nut and stop screw on the belt actuator housing assembly.
- 8. Federal Aviation Administration 8 Aircraft Maintenance Documentation Maintenance Related Accident The mechanic forgot to reposition the stop screw and tighten the nut. This action resulted in the main rotor drive V-belts becoming excessively loose. The belts exited their seated position on the lower pulley sheave and were severed.
- 9. Federal Aviation Administration 9 Aircraft Maintenance Documentation NTSB Finding Probable Cause The company mechanic's improper maintenance actions, which resulted in the total failure of the main rotor drive belt system
- 10. Federal Aviation Administration 10 Aircraft Maintenance Documentation Sept. 11, 1999 near Eagle Lake Texas. Continental Express Flight 2574 an EMB 120 In flight the left horizontal stabilizer leading edge bent down and then separated from the aircraft 14 passengers and crew killed near Eagle Lake Texas.
- 11. Federal Aviation Administration 11 Aircraft Maintenance Documentation
- 12. Federal Aviation Administration 12 Aircraft Maintenance Documentation NTSB Finding Departures from approved procedures included failures to solicit and give proper shift / turnover reports, failures to use maintenance work cards as approved, failures to complete required maintenance/inspection shift / turnover forms, and a breach in integrity of the quality control system.
- 13. Federal Aviation Administration 13 Aircraft Maintenance Documentation The Regulations (Title 14 CFR) • Part 43 MAINTENANCE, PREVENTIVE MAINTENANCE, REBUILDING, AND ALTERATION • Part 91 GENERAL OPERATING AND FLIGHT RULES Subpart E--Maintenance, Preventive Maintenance, and Alterations
- 14. Federal Aviation Administration 14 Aircraft Maintenance Documentation • Part 135 OPERATING REQUIREMENTS: COMMUTER AND ON-DEMAND OPERATIONS Subpart J--Maintenance, Preventive Maintenance, and Alterations • Part 121 OPERATING REQUIREMENTS: DOMESTIC, FLAG, AND SUPPLEMENTAL OPERATIONS Subpart L--Maintenance, Preventive Maintenance, and Alterations The Regulations
- 15. Federal Aviation Administration 15 Aircraft Maintenance Documentation • Part 145 Repair Stations The Regulations
- 16. Federal Aviation Administration 16 Aircraft Maintenance Documentation The Regulations Sec. 43.9 (a) Maintenance record entries. Except as provided in paragraphs (b) and (c) of this section, each person who maintains, performs preventive maintenance, rebuilds, or alters an aircraft, airframe, aircraft engine, propeller, appliance, or component part shall make an entry in the maintenance record of that equipment containing the following information: (1) A description (or reference to data acceptable to the Administrator) of the work performed. (2) The date of completion of the work performed. (3) The name of the person performing the work if other than the person specified in paragraph (a)(4) of this section. (4) If the work performed on the aircraft, airframe, aircraft engine, propeller, appliance, or component part has been performed satisfactorily, the signature, certificate number, and kind of certificate held by the person approving the work. The signature constitutes the approval for return to service only for the work performed.
- 17. Federal Aviation Administration 17 Aircraft Maintenance Documentation The Regulations Sec. 91.417 (a) (1) Maintenance Records The records must include-- (i) A description (or reference to data acceptable to the Administrator) of the work performed; and (ii) The date of completion of the work performed; and (iii) The signature, and certificate number of the person approving the aircraft for return to service.
- 18. Federal Aviation Administration 18 Aircraft Maintenance Documentation The Regulations Sec 91.417 (a) (2) Records containing the following information: (i) The total time in service of the airframe, each engine, each propeller, and each rotor. (ii) The current status of life-limited parts of each airframe, engine, propeller, rotor, and appliance. (iii) The time since last overhaul of all items installed on the aircraft which are required to be overhauled on a specified time basis.
- 19. Federal Aviation Administration 19 Aircraft Maintenance Documentation The Regulations (iv) The current inspection status of the aircraft, including the time since the last inspection required by the inspection program under which the aircraft and its appliances are maintained. (v) The current status of applicable airworthiness directives (AD) and safety directives including, the method of compliance, the AD or safety directive number and revision date. If the AD or safety directive involves recurring action, the time and date when the next action is required. vi) Copies of the forms prescribed by Sec. 43.9(a) for each major alteration to the airframe ,engines, rotors, propellers, and appliances.
- 20. Federal Aviation Administration 20 Aircraft Maintenance Documentation Record retention • The owner or operator shall retain the following records for the periods prescribed: • The records specified in paragraph (a)(1) of this section shall be retained until the work is repeated or superseded by other work or for 1 year after the work is performed. • The records specified in paragraph (a)(2) of this section shall be retained and transferred with the aircraft at the time the aircraft is sold.
- 21. Federal Aviation Administration 21 Aircraft Maintenance Documentation The Regulation • Sec. 135.427 Manual requirements • c) Each certificate holder shall put in its manual a suitable system (which may include a coded system) that provides for the retention of the following information--
- 22. Federal Aviation Administration 22 Aircraft Maintenance Documentation (1) A description (or reference to data acceptable to the Administrator) of the work performed; (2) The name of the person performing the work if the work is performed by a person outside the organization of the certificate holder; and (3) The name or other positive identification of the individual approving the work. •135.427 Manual requirements
- 23. Federal Aviation Administration 23 Aircraft Maintenance Documentation The Regulations Sec.145.219 Recordkeeping. (1) A description (or reference to data acceptable to the Administrator) of work performed. (2) The date of completion of the work performed. (3) The name of the person performing the work if other than the person specified in paragraph (a)(4) of this section. (4) If the work performed on the aircraft, airframe, aircraft engine, propeller, appliance, or component part has been performed satisfactorily, the signature, certificate number, and kind of certificate held by the person approving the work. The signature constitutes the approval for return to service only for the work performed.
- 24. Federal Aviation Administration 24 Aircraft Maintenance Documentation INCORPORATION BY REFERENCE • You don’t have to write a book. • The regulations permit reference to technical data in lieu of making a long step by step detailed entry • Common references include maintenance manuals, service letters, bulletins, work orders, advisory circulars (AC43.13-1B), and others • Major alterations may reference STC’s • Reference documents must be retained
- 25. Federal Aviation Administration 25 Aircraft Maintenance Documentation If the work performed on the aircraft, airframe, aircraft engine, propeller, appliance, or component part has been performed satisfactorily, the signature, certificate number, and kind of certificate held by the person approving the work. The signature constitutes the approval for return to service only for the work performed.
- 26. Federal Aviation Administration 26 Aircraft Maintenance Documentation Airworthiness Directive FAR Part 39
- 27. Federal Aviation Administration 27 Aircraft Maintenance Documentation AIRWORTHINESS DIRECTIVES An unsafe condition exist in a product. The condition is likely to exist or develop in other products of the same design.
- 28. Federal Aviation Administration 28 Aircraft Maintenance Documentation RESPONSIBILITY The Owner/Operator is primarily responsible for maintaining the aircraft in an airworthy condition, including compliance with ADs The Owner/Operator is responsible for ensuring that properly certificated persons perform the work.
- 29. Federal Aviation Administration 29 Aircraft Maintenance Documentation RESPONSIBILITY Maintenance personnel have the responsibility of compliance at the time they are performing inspections to determine all airworthiness requirements are met.
- 30. Federal Aviation Administration 30 Aircraft Maintenance Documentation RECORDS The owner must keep a record showing the current status of applicable ADs. This record must include the following: The current status of ADs applicable to the aircraft, including the AD number and revision date, the method of compliance, and the time in service, or the‑ ‑ cycles, and/or the date when the next action is required for a recurring AD.
- 31. Federal Aviation Administration 31 Aircraft Maintenance Documentation
- 32. Federal Aviation Administration 32 Aircraft Maintenance Documentation Sample Logbook Entry N12345 Tach/Hobbs: ____________ ACTT: ____________ Enter the type of inspection(s) performed: Enter accomplishment of all A.D.’s including the number, revision date, method of compliance, and if recurring, the next time/date it is due. Enter replacement or inspection of any component part with Airworthiness Limitations (include part, serial number, and total time in service for that component). Enter removal and installation of any serialized component replacement parts (include part, serial number, and total time in service for that component). Enter description of any other general maintenance performed. I certify that this aircraft was inspected in accordance with a (insert type) inspection and was determined to be in an airworthy condition. All work was accomplished in accordance with current Federal Aviation Regulations and manufacturer’s maintenance instructions. Details of work performed can be found on XYZ Company work order _______. ______________________ __________________________ ____________ Signature Certificate # Date
- 33. Federal Aviation Administration 33 Aircraft Maintenance Documentation DESCRIPTION OF WORK PERFORMED The description should be in sufficient detail to permit a person unfamiliar with the work, to understand what was done, and the methods and procedures used.
- 34. Federal Aviation Administration 34 Aircraft Maintenance Documentation Shift /Turnover The transfer of critical information between work groups or shifts It needs to be as detailed as necessary, depending on the tasks involved Sharing of information by the people doing the task
- 35. Federal Aviation Administration 35 Aircraft Maintenance Documentation Why is Shift/Task Turnover Important Data show that poor shift/task turnover is a common contributing factor to events. Challenges related to shift turnover include: 1. A high demand for teamwork and communication skills 2. Lack of structured and standardized policies and procedures 3. Using a location that is not conducive for discussion and planning
- 36. Federal Aviation Administration 36 Aircraft Maintenance Documentation Why is Shift/Task Turnover Important 4. Finishing workers are tired and want to depart facility. 5. Lack of adequate shift overlap to provide time to give one- on-one briefings between the teams 6. Absence of a process to ensure departing personnel have documented all tasks accomplished or started. 7. Minimal training on procedures for shift/task turnover High-quality shift/task turnover procedures enable improvement in practice and improve safety and accountability to all involved in the work.
- 37. Federal Aviation Administration 37 Aircraft Maintenance Documentation How do you implement a Shift/Task Turnover process? • Formalize policy and procedures that make the turnover as important as the work. • Communicate policy and procedures to all personnel. • Consider technology enhancements that improve the transfer of visual information (e.g., photos, graphics, movies).
- 38. Federal Aviation Administration 38 Aircraft Maintenance Documentation How do you implement the Shift/Task Turnover process? • Provide a time and place for formal shift/task turnover. • Ensure the quality of shift/task turnover Information. • Deliver initial and recurrent training on how to conduct a good shift/task turnover. • Define acceptable communication practices.
- 39. Federal Aviation Administration 39 Aircraft Maintenance Documentation Summary The basic requirements for aircraft maintenance documentations are the same. The method of meeting those requirements may be different depending on the type of operation.
- 40. Federal Aviation Administration 40 Aircraft Maintenance Documentation Summary It may be a simple airframe, engine, propeller log book, or an air carrier’s maintenance record system. A description of the work performed, date the work was performed and the signature with certificate number and type are always required.
- 41. Federal Aviation Administration 41 Aircraft Maintenance Documentation Common problems • No documentation. • Inadequate description of work performed. • Using the wrong reference. • Poor shift turnovers
- 42. Federal Aviation Administration 42 Aircraft Maintenance Documentation Easy solutions • Follow the regulations. • Follow company procedures (GMM). • Use the Maintenance Personal Minimums Checklist !
- 43. Federal Aviation Administration 43 Aircraft Maintenance Documentation BEFORE
- 44. Federal Aviation Administration 44 Aircraft Maintenance Documentation AFTER
- 45. Federal Aviation Administration 45 Aircraft Maintenance Documentation
- 46. Federal Aviation Administration 46 Aircraft Maintenance Documentation Thank you.
Editor's Notes
- #2: Title Slide
- #3: INTRODUCTION: This course provides a review of aircraft maintenance documentation requirements. It emphasizes the importunateness of proper documentation. It identifies common documentation problems that can lead to maintenance errors. Poor maintenance documentation can be a precursor to aircraft incidents or accidents. It can also lead to FAA enforcement actions.
- #4: Maintenance-related accidents and incidents are on a downward trend. However, maintenance-related accidents result in a higher likelihood of injury.
- #5: Mechanic violations fall into very consistent categories. Failure to perform maintenance and inspections in accordance with approved methods (43.13, 43.15) and failure to document such actions prior to return to service (43.5, 43.9) accounted for 90% of all maintenance violations
- #6: Common findings are improper documentation of maintenance. No documentation. It may be obvious that some maintenance action has been performed. You can not determine what action was done, or by whom, so the work has to be completed again. Inadequate description. You can not tell exactly what was done or if it was done correctly. Using the wrong reference. An example might be using the system description section of the M/M for a component replacement, or citing the wrong ATA chapter.
- #8: A company mechanic had performed a 100-hour inspection about 4.3 hours prior to the accident flight. During the inspection, he had loosened the self locking nut on the belt actuator housing assembly and had rotated the down-limit stop screw upward until the screw bottomed out in the actuator housing in the full up position. This maintenance action was not required as part of the 100 hour inspection.
- #9: Had this extra maintenance action be documented, it is reasonable to say this accident would have probably been prevented.
- #10: This statement was taken from the NTSB Factual Report.
- #11: This was a hard lesson in why proper maintenance documentation particularly shift turnover procedures are so important. On Sept. 11, 1999 On that day Continental Express Flight 2574 an EMB 120 aircraft, went down. In flight the left horizontal stabilizer leading edge bent down and then separated from the aircraft. The aircraft become uncontrollable. 14 passengers and the flight crew were killed near Eagle Lake Texas.
- #12: This is how the horizontal stabilizer was found. Notice anything missing? The entire leading edge is missing from the left side of the aircraft’s horizontal stabilizer.
- #13: This statement was taken from the NTSB Factual Report. “ Departures from approved procedures included failures to solicit and give proper shift / turnover reports, failures to use maintenance work cards as approved, failures to complete required maintenance/inspection shift / turnover forms, and a breach in integrity of the quality control system.” Poor shift turnover policies and procedures were a factor in this accident.
- #14: Let’s start by taking a look at some of the regulations. Title 14 of the Code of Federal Regulations to be exact, but let’s just call them by their common names Parts 43, 91 135, 121, 145. Part 43 is where you find the basic rules for Maintenance, Preventive Maintenance, and Alterations. Part 91 is where you find the basic operating rules for aircraft owners/ operators regarding Maintenance, Preventive Maintenance, and Alterations
- #15: Part 135 Subpart J. is where we find the rules for Maintenance, Preventive Maintenance, and Alterations that must be followed by 135 operators. Did you know that if an aircraft is listed on the Operations Specifications for a 135 air carrier, the 135 maintenance rules apply no matter who might be operating the aircraft. If the owner uses his turbo prop to take the family on vacation, he must follow the 135 operators maintenance procedures for maintenance documentation. That includes the Minimum Equipment List (MEL). Part 121 Subpart L is where we find the rules for Maintenance, Preventive Maintenance, and Alterations that must be followed by part 121 air carriers.
- #16: Part 145. is where we find the rules for Maintenance, Preventive Maintenance, and Alterations that must be followed by 145 repair stations.
- #17: Here is what is required by Part 43. Point out the requirements each paragraph of the slide. Description, Date, Signature & Certificate number and kind of certificate held i.e. A & or P IA or Pilot for items allowed under preventive maintenance. That’s in appendix A to Part 43 if you like to look it up.
- #18: Part 91 restates the same requirements we saw in Part 43. To put is in the simplest of term. Description, Date, Signature & Certificate information. This is not all that is required by Part 91.417 as far as aircraft records. Since Part 91 is an operating rule it applies to the Owner/Operator rather than maintenance personnel. With that being said all AMTs need to be aware of the requirements.
- #19: Sec 91.417 also has other requirements for aircraft records such as the total time in service, current status of life-limited parts and time since last overhaul of item required to be overhauled.
- #20: Sec 91.417 also includes t he requirement to document the inspection status of the aircraft, including the time since the last inspection. The current status of applicable airworthiness directives (AD) or service directive including, the method of compliance, the AD directive number and revision date. If the AD involves recurring action, the time and date when the next action is required. Safety Directives? What does that mean? This is new! As of April 2, 2010 Sec 91.417 was amended to include safety directives issued on Special Light Sport Aircraft by the manufactures of the aircraft. The aircraft record must also include copies of the form 337 Sec. 43.9(a) for each major alteration. If a fuel tank is installed within the passenger compartment or a baggage compartment, a copy of FAA Form 337 shall be kept on board the modified aircraft by the owner or operator.
- #21: The records specified in paragraph (a)(1) must be kept until the work is superseded or for one year. For section (a)(2) it’s for the life of the aircraft. The owner or operator shall make all maintenance records required to be kept by this section available for inspection by the Administrator or any authorized representative of the National Transportation Safety Board (NTSB).or any law enforcement officer.
- #22: Part 135 manuals must state the operator’s method to meet the requirements. They must explain in their manual just how maintenance actions are to be handled. What company form must be completed etc?
- #23: Part 135.427 states the same basic requirements. Description, Date, Signature & Certificate information.
- #24: Part 145.219 states the same basic requirements. Description, Date, Signature & Certificate information. The repair station’s manual will explain the specific requirements
- #25: Tell the story so that some one in the future reading your entry know what you did. Then read the slides bullets. A maintenance entry that describes what was done and gives a specific maintenance manual reference leaves little doubt as to what was done, and how it was done.
- #26: It is not necessary to add the phrase “and is approved for return to service” your signature says it for you.
- #27: Lets take a look at Ads. Each AD issued is an actual amendment to FAR Part 39.
- #28: An AD is issued when it is found that an unsafe condition exist in a product The condition is likely to exist or develop in other products of the same design
- #29: The Owner/Operator is primarily responsible for maintaining the aircraft in an airworthy condition, including compliance with ADs The Owner/Operator is responsible for ensuring that properly certificated person perform the work.
- #30: Maintenance personnel have the responsibility of compliance at the time they are performing inspections to determine all airworthiness requirements are met.
- #31: The owner must keep a record showing the current status of applicable ADs. This record must include the following: The current status of ADs applicable to the aircraft, including the AD number and revision date, The method of compliance, and The time‑in‑service, or the cycles, and/or the date when the next action is required for a recurring AD. An acceptable method of compliance should include a reference to either a specific portion of the AD or a manufacturer’s service bulletin, if the bulletin is referenced in the AD. The document that contains the current status of ADs/method of compliance may be the same as the record of AD accomplishment.
- #32: Here is a typical AD compliance record that could be used for a general aviation aircraft, or a large transport aircraft. The requirements are the same.
- #33: Note: Each line will come in one at time and fade. Talk about each line and type of entry as they appear.
- #34: The description should be in sufficient detail to permit a person unfamiliar with the work to understand what was done, and the methods and procedures used. When the aircraft leaves the hangar, your entry must speak for you. When the flight crew reviews the log book your entry is usually all they have to go by. Give them confidence that the maintenance task you performed was done correctly.
- #35: Another vital form of maintenance documentation is a shift/ turnover records. Shift turn of is the time to transfer of critical information between work groups or shifts. It needs to be as detailed as necessary, depending on the tasks involved. Sharing of information by the people doing the task. Do you think that aircraft maintenance documentation has never caused an accident?
- #36: Why is Shift/Task Turnover Important? Data show that poor shift/task turnover is a common contributing factor to events. Challenges related to shift turnover include: 1. Shift Turn over requires a high level of teamwork and good communication skills. 2. The lack of structured and standardized policies and procedures. 3. Using a location that is conducive for discussion and planning. Such as a high noise area
- #37: 4. Finishing workers are tired and want to depart facility. 5. Lack of adequate shift overlap to provide time to give one-on-one briefings between the team leaving and the team coming on. 6. Absence of a process to ensure departing personnel have documented all tasks accomplished or started. 7. Minimal training on procedures for shift/task turnover High-quality shift/task turnover procedures enable improvement in practice and improve safety and accountability to all involved in the work. CHECK wording in last paragraph
- #38: How do you implement a Shift/Turnover process? Formalize policy and procedures that make the turnover as important as the work. Communicate policy and procedures to all personnel. Consider technology enhancements that improve the transfer of visual information (e.g., photos, graphics, movies).
- #39: Provide a time and place for formal shift/task turnover. Dedicate a location for shift turnover meetings that is clean, comfortable, and relatively free of distractions. Access to computers and data sources should be provided, if appropriate. Include a dedicated time for a proper shift turnover within the regular work hours. Carry out the task turnover at the aircraft where the task is being accomplished. Ensure the quality of shift/task turnover Information. Standardize written communications. Ensure consistent level of detail in turnover documentation. Deliver initial and recurrent training on how to conduct a good shift/task turnover. Emphasize the criticality of shift/task turnover and impact on continuing safety. Emphasize use of checklists, shift status reports, and applicable shift/task turnover documents. Define acceptable communication practices. Describe how to conduct and participate in turnover meetings.
- #40: To summarize, the basic requirements for aircraft maintenance documentations are the same. Whether it is a Cessna 150 or a Airbus 380 The method of meeting those requirements may be different depending on the type of operation.
- #41: It may be a simple airframe, engine, propeller log book, or an air carrier’s maintenance record system. A description of the work performed, date the work was performed and the signature with certificate number and type are always required.
- #42: Let’s review. No documentation. The situation may be obvious that maintenance has been performed. You can not determine what maintenance action may have been done, or by whom, so the work has to be redone. Inadequate description. You can not tell what was done or if it was done correctly. Using the wrong reference. Such as using the system description section of the M/M for a component replacement or citing the wrong ATA chapter or maybe using an out of date manual. Shift turnovers should always be done by the people doing the work. Written description of what was accomplished, clear stop and starting points.
- #43: Follow the rules. Follow company procedures General Maintenance Manual (GMM). Use the Maintenance Personal Minimums Checklist !
- #44: Review the items on the Checklist. Before the Task KEEP THIS IN YOUR TOOLBOX!!
- #45: Review the items on the Checklist. After the Task
- #46: Contact your FAASTeam Program Manager or FAASTeam Representative for more information. Remember to Be Smart and Follow procedures.
- #47: Visit the FAASTeam Maintenance Hangar on our website FAASafety.gov ADD qms feed back link