Industrial Aviation Management : A Primer in European Design, Production and Maintenance Organisations

This book outlines the structure and activities of companies in the European aviation industry. The focus is on the design, production and maintenance of the components, assemblies, engines and the aircraft itself. In contrast to other industries, the technical aviation industry is subject to many specifics, since its activities are highly regulated by the European Aviation Safety Agency (EASA), the National Aviation Safety Authorities and by the aviation industry standard EN 9100. These regulations can influence the companies' organization, personnel qualification, quality management systems, as well as the provision of products and services. This book gives the reader a deeper, up-to-date insight into today's quality and safety requirements for the modern aviation industry. Aviation-specific interfaces and procedures are looked at from both the aviation legislation standpoint as well as from a practical operational perspective. Dr. Martin Hinsch has over 15 years of aviation industry experience. He worked for Lufthansa Technik in Germany, Switzerland and the Middle East, focusing on Process & Quality Management. He holds a Professorship in Aviation Management, is a certified aerospace auditor according to EN 9100, and he is also the CEO of AeroImpulse - Aerospace Consulting. Dr. Hinsch has authored several books on aviation management to critical acclaim Preface 5 Contents 6 Table of Figures 11 Table of Tables 14 Table of Abbreviations 15 1 Introduction 18 2 Authorities and Official Organisations 21 2.1 European Aviation Safety Agency (EASA) 21 2.2 National Aviation Safety Authorities in the EASA Area 24 2.3 International Civil Aviation Organization (ICAO) 25 2.4 Federal Aviation Administration (FAA) 26 3 Regulations and Approvals 27 3.1 EASA Regulations 27 3.1.1 EASA Regulatory Structure 27 3.1.2 EASA Part 21J – Design 32 3.1.3 Part 21G – Production 39 3.1.4 Part 145 – Maintenance 44 3.1.5 Part M – Continuing Airworthiness 49 3.2 European Aviation Standards of the EN 9100 Series 52 3.3 Introduction to the FAA Legislation 57 3.3.1 FAA Regulations 57 3.3.2 FAA Approvals 58 References 61 4 Design 63 4.1 Basic Design Organisation Requirements 63 4.2 Essential Design Organisational Structures 65 4.2.1 Design Assurance System 65 4.2.2 Type-Certification 67 4.2.3 Office of Airworthiness 69 4.3 Specification of Design Projects 71 4.3.1 Definition and Tasks 71 4.3.2 Formal Design Specification Requirements 72 4.3.3 Content and Structure of Design Specifications 73 4.4 Production, Maintenance & Operating Documents 78 4.4.1 Production Documents (Approved Design Data) 78 4.4.2 Operating and Maintenance Documentation 80 4.4.3 Verification and Release 80 4.5 Design Classification 81 4.6 Design Certification Process (Major) 84 4.6.1 Certification Programme 84 4.6.2 Safety Assessment 87 4.6.3 Showing of Compliance 92 4.6.4 Type Investigation 97 4.6.5 Type-Certification 98 4.7 Management Basics of Major Design Projects 101 4.7.1 Tasks and Characteristics of Design Management 101 4.7.2 Project Preparation 104 4.7.3 Project Flow 105 4.7.4 Project Structures 108 4.8 Minor Design Changes 111 4.9 Repairs 112 4.10 Component Development 115 4.10.1 Specification of Parts 116 4.10.2 Construction of Components 118 4.10.3 Qualification and Approval of Parts 120 4.11 ETSO Parts 122 4.12 PMA Parts 123 References 124 5 Maintenance Management 126 5.1 Tasks and Objectives of Maintenance Management 126 5.2 Maintenance Programmes 128 5.2.1 Necessity of Maintenance Programmes 128 5.2.2 From MRB Report to Maintenance Programme 129 5.2.3 Structure and Contents of Maintenance Programmes 134 5.2.4 Life Cycle Monitoring and Status Reporting 138 5.3 Reliability Management 139 5.3.1 Purpose and Objectives of Reliability Management 139 5.3.2 Components of a Reliability Programme 141 5.4 Notifications by Authorities and Manufacturers 145 5.4.1 Airworthiness Directives (ADs) 145 5.4.2 Manufacturer Notifications 149 References 150 6 Aviation Production Management 151 6.1 Production and Maintenance Planning 151 6.2 Job Cards 152 6.3 Technical Document Management 156 6.4 TOP Requirements 160 6.4.1 Technical Requirements 161 6.4.2 Organisational Requirements 162 6.4.3 Personnel Requirements 163 6.5 Infrastructure, Work Environment and Equipment 163 6.5.1 Infrastructure and Work Environment 163 6.5.2 Equipment 164 6.6 Release Certificates and Conformity Statements 165 6.6.1 Purpose and Procedure of Release and Conformity Certificates 165 6.6.2 Types of Release Certificates 167 References 171 7 Production 172 7.1 Fundamentals of Production of Aviation Products, Parts and Appliances 172 7.2 Quality Management Systems in Production 175 7.2.1 Fundamental Quality Requirements and Approval Requirements 175 7.2.2 Independent Control and Quality Assurance System 177 7.2.3 Function of Independent Quality Assurance 179 7.2.4 Quality Systems of Suppliers Without Part 21G Approval 179 7.3 Part and Component Production as Well as System Integration 180 7.3.1 Production Planning and Control 181 7.3.2 Product Quality Assurance and Acceptance 185 7.4 Aircraft Production 187 7.4.1 Assembly of Shells and Fuselage Segments 187 7.4.2 Assembly of Wings and Tail Units 191 7.4.3 Final Assembly Line (FAL) 191 7.4.4 Ground and Flight Testing 193 7.4.5 Aircraft Handover 194 7.5 VIP Aircraft Completion 194 7.5.1 Market Structure 194 7.5.2 Design, Manufacturing and Installation of a VIP Cabin 197 7.6 Archiving Production Records 200 References 201 8 Maintenance 202 8.1 Aircraft Maintenance Basics 202 8.1.1 Definitions for Maintenance 202 8.1.2 Characteristics of Aircraft Maintenance 203 8.1.3 Quality Requirements and Approval Requirements 204 8.2 Line Maintenance Versus Base Maintenance 206 8.3 Scheduled Versus Unscheduled Maintenance 207 8.3.1 Scheduled Maintenance 207 8.3.2 Unscheduled Maintenance 208 8.4 Setup of a Maintenance Organisation 209 8.5 Production Planning in Maintenance 211 8.6 Production Controlling in Maintenance 212 8.7 Line Maintenance 214 8.7.1 Line Maintenance Setup 214 8.7.2 Line Maintenance Procedures – Terminal 216 8.7.3 Line Maintenance Procedures – Ramp and Hangar 218 8.8 Base Maintenance 221 8.8.1 Base Maintenance Characteristics 221 8.8.2 Base Maintenance Layovers 222 8.9 Component Maintenance 226 8.9.1 Typical Maintenance Workshop Structure 226 8.9.2 Component Maintenance Procedures 227 8.10 Engine and Propeller Maintenance 230 8.11 Archiving Maintenance Records 232 References 233 9 Material and Service Supply 234 9.1 Selection and Monitoring of Suppliers 235 9.1.1 Selection of Suppliers 235 9.1.2 Supplier Evaluation and Release 236 9.1.3 Supplier Monitoring 238 9.2 Material Control and Handling 239 9.2.1 Material Tracking (Traceability) 239 9.2.2 Acceptance of Goods 242 9.2.3 Stock Keeping 247 9.2.4 Material Handling 249 9.2.5 Nonconforming Products 252 9.2.6 Suspected Unapproved Parts and Counterfeit Parts 253 9.3 Subcontracting 256 9.3.1 Preparation and Monitoring of Subcontracting 256 9.3.2 Subcontracting in the Context of the Extended Work Bench 260 9.3.3 Subcontracting to Approved Aeronautical Organisations (Part 21G/Part 145) 263 9.3.4 Specifics of Subcontracting Design Services 264 9.3.5 Specifics for Procuring External Staff 265 References 267 10 Personnel 269 10.1 General Staff Qualification Requirements 269 10.2 Qualification of Production Staff 272 10.2.1 Production and Maintenance Staff Without Release Authorisation 272 10.2.2 Certifying Production Staff as per Part 21G 273 10.2.3 Certifying Maintenance Staff in Production According to Part 145 276 10.3 Qualification of Administrative Staff 278 10.3.1 Qualification Requirements for Executive Staff 278 10.3.2 Qualification Requirements of Operational Administrative Staff in Production and Maintenance 279 10.4 Specific Characteristics of Design Staff Qualification According to Part 21J 280 10.5 Special Staff Qualifications and Authorisations 281 10.6 Human Factors 282 10.7 Continuation Training 284 References 285 11 Quality and Safety Management 286 11.1 Quality Management Systems 287 11.1.1 Quality Management Basics 287 11.1.2 Purpose and Objectives of Quality Management Systems 288 11.1.3 Documentation of a Quality Management System 291 11.2 Safety/Risk Management Systems 298 11.2.1 Safety and Risk Management Basics 298 11.2.2 Organisational Framework 299 11.2.3 Risk Management 301 11.2.4 Safety and Risk Monitoring 306 11.2.5 Promoting Safety Expertise and Culture 307 11.3 Auditing 308 11.3.1 Auditing Types 309 11.3.2 Internal Auditing 310 11.3.3 External Auditing 314 11.4 Occurrence Reporting Systems 316 11.5 Authority Liaison 320 References 321 Annex 322 Index 352 "This book outlines the structure and activities of companies in the European aviation industry. The focus is on the design, production and maintenance of components, assemblies, engines and the aircraft itself. In contrast to other industries, the technical aviation industry is subject to many specifics, since its activities are highly regulated by the European Aviation Safety Agency (EASA), the National Aviation Authorities and by the aviation industry standard EN 9100. These regulations can influence the companies' organization, personnel qualification, quality management systems, as well as the provision of products and services. This book gives the reader a deeper, up-to-date insight into today's quality and safety requirements for the modern aviation industry. Aviation-specific interfaces and procedures are looked at from both the aviation legislation standpoint as well as from a practical operational perspective."-- Provided by publisher Front Matter ....Pages i-xxi Introduction (Martin Hinsch)....Pages 1-3 Authorities and Official Organisations (Martin Hinsch)....Pages 5-10 Regulations and Approvals (Martin Hinsch)....Pages 11-46 Design (Martin Hinsch)....Pages 47-109 Maintenance Management (Martin Hinsch)....Pages 111-135 Aviation Production Management (Martin Hinsch)....Pages 137-157 Production (Martin Hinsch)....Pages 159-188 Maintenance (Martin Hinsch)....Pages 189-220 Material and Service Supply (Martin Hinsch)....Pages 221-255 Personnel (Martin Hinsch)....Pages 257-273 Quality and Safety Management (Martin Hinsch)....Pages 275-310 Back Matter ....Pages 311-345