Ed Harris Fiber Art 120 Commercial Place
Schertz, Texas 78154
October 17, 2000
Brad Buchanan - General Manager _______________________________
Bob Sawyer - CEO
Table of Revisions
Revision Number Revision Date Insertion Date Revised By Number of Pages Original October 17, 2000
List of Effective Pages
SECTION ADDED PAGE
DATE SECTION REM OVED PAGE
Introduction 1 10/17/00
1.0 General M anager 2 10/17/00
2.0 Chief Inspector 3 10/17/00
3.1.1 Performance of M aintenance 4 10/17/00
3.1.2 Certification 4 10/17/00
3.1.3 Change or revision of CCD 4 10/17/00
3.1.4 Duration of CCD 4 10/17/00
3.2.1 Limited Specialized Rating 5 10/17/00 3.2.2 Housing and Facilities 5 10/17/00 3.2.2 Housing and Facilities 6 10/17/00 3.2.3 Change in Facilities Location 6 10/17/00 3.2.4 Inspection of Facilities (FAA) 7 10/17/00 3.2.5 Personnel and Technicians 7 10/17/00 3.2.6 Records of Personnel 8 10/17/00
3.2.7 Inspection System 9 10/17/00
3.2.7 Inspection System 10 10/17/00
3.2.8 Inspection of W ork 10 10/17/00 3.2.9 Records and Reports 10 10/17/00 3.2.10 Reporting of Defects 10 10/17/00 3.2.11 CCD Documentation 11 10/17/00 3.2.12 Equipment & M aterials 11 10/17/00 3.3.1Privelages of Certificates 12 10/17/00
4.0 Appendix 13 10/17/00
4.1 Amendment Request 14 10/17/00
4.2 CCD - Bombardier CL601-3R 15 10/17/00
Table of Contents
Description Page Number
1.0 General Manager... 2
2.0 Chief Inspector... 3
3.0 Controlled Capabilities Document Procdures... 4
3.1.1 Performance of Maintenance... 4
3.1.2 Certification... 4
3.1.3 Change or Revision of CCD... 4
3.1.4 Duration of Controlled Capabilities Document... 4
3.2 Ratings, Housing, Equipment, Personnel, Inspection, Documentation... 5
3.2.1 Limited Specialized Rating... 5
3.2.2 Housing and Facilities... 5
3.2.3 Change in Facilities Location... 6
3.2.4 Inspection of Facilities (FAA)... 7
3.2.5 Personnel and Technicians... 7
3.2.6 Records of Personnel... 8
3.2.7 Inspection System... 9
3.2.8 Inspection of work ... 10
3.2.9 Records and Reports... 10
3.2.10 Reporting of Defects... 10
3.2.11 CCD Documentation... 11
3.2.12 Equipment and Materials... 11
3.3 Privileges of Certificates... 12
3.3.1 Privileges of certificates... 12
4.0 Appendix Forms/Approved Components... 13
4.1 Controlled Capabilities Document Amendment Request... 14
4.2 Controlled Capabilities Document - CL601-3R... 15
Fiber Art, was founded by Pat Pyka, Bob Sawyer and Ed Harris in April of 1996 as a composites manufacturing and engineering company. The company has become a supplier for the private aircraft industry. Expansion means diversification and Fiber Art, has evolved into many areas within the aircraft industry. Fiber Art fabricates parts per approved engineering or procedural documents supplied by their customers. Fiber Art offers to their customers the ability to repair the products which they have fabricated or like industry products. In order to control the product, part number, model of aircraft which the repair station is rated to perform work on Fiber Art is establishing a Controlled Capabilities Document (CCD).
The purpose of this CCD is to inform Fiber Art inspection and FAA personnel concerning which components the repair station is rated to perform work on. Fiber Art primary goal is to enhance its safety procedures in aircraft maintenance. Fiber Art realizes that procedure and polices must be dynamic and from time to time this manual shall be revised to reflect changes as required by the Federal Aviation Administration (FAA) and the industry.
The CCD contains company policies in regard to company repair station operations as applicable regulations under FAR’s 1, 21, 43, 65, 145, and FAA Order 8300.14 which are the FAA’s applicable rules and regulations under which Fiber Art operates.
It is mandatory that all company repairman have access to the CCD. Fiber Art personnel are require soon after date of hire to review the repair station manual and CCD to become familiar with the perspective locations of these in the company and the procedures and requirements outlined within them. Any statements or procedures which are not clear shall be clarified by the general manager.
Any maintenance or inspection procedures contrary to the repair station manual, CCD, or the FAR’s due to failure to read or correctly interpret their contents shall be grounds for punitive action or dismissal. A roster shall be kept of employees who have read or been issued this document. This roster shall be kept by the General Manager’s office.
The CCD shall be considered as separate document then the company repair station manual. When a request to revise or amend repair station rating occurs by the GM, the CCD shall be revised and submitted to the FSDO for approval within in five (5) days following revision request. Only those components/accessories listed in the CCD revision which the FAA Administrator has approved will be approved for return to service.
Page 2 General Manager
1.0 General Manager (GM)
The GM is responsible for the complete operation of the repair station. The GM shall provide adequate equipment, materials, storage, facilities (and maintenance) and competent personnel pertinent to the operation of the repair station.
The GM shall be responsible for the repair stations compliance with all applicable FAA regulations, manufacturer’s recommendations, and Repair Station Inspection Procedures Manual. Any changes of the repair station manual or CCD shall be forwarded to the FAA Flight Standards District Office in San Antonio, Texas. The Controlled Capabilities Document (CCD) shall be maintained by the GM. The GM will revise the CCD as necessary to include component parts which the repair station has the capability or repairing and placing back into service. The CCD shall be submitted for FAA approval at the time in which a revision to the repair station capabilities list is necessary. Only those components/accessories listed in the CCD revision which the FAA Administrator has approved will be approved for return to service.
The GM may delegated from time to time their duties as necessary. However, such delegation does not relieve the GM of their overall responsibilities. The delegation of duty by the GM shall be in writing and will name the person to whom delegated authority has been granted. The delegated person shall be made known to Fiber Art Repair Station personnel by a memo from personnel.
2.0 Chief Inspector (CI)
The CI is directly responsible to the General Manager for the overall operation of the inspection department. CI shall be responsible for directing, planning and laying out details of inspection standards, methods, and procedures used by the repair station in complying with all applicable FAA regulations and manufacturers recommendations.
CI shall assist, supervise, and direct all personnel assigned to the inspection department. CI shall ascertain that all inspections are properly performed on all completed work before it is release back to service. CI shall also make sure that the proper inspection records, reports, certifications of materials, and forms used by repair station are properly executed.
All repair orders and inspection forms pertaining to a repair shall be maintain in the CI files. The work order number shall be used to locate these files. Files shall be properly marked to allow location of them in a reasonable amount of time.
Current FAA specifications and airworthiness directives shall be maintained by the CI. A record system such as CD ROM or internet updates from the government shall be used to keep current with FAA regulations. CI shall secure and maintain technical data on all component parts or assembly’s overhauled or repaired by the repair station. This material will consist of manufacturer’s overhaul manuals, service bulletins, engineering repair orders, FAA manuals, etc... This data shall be kept on file for review by the FAA Administrator for a period of two (2) years after the repair is completed.
CI shall be responsible for making periodic checks of inspection tools. CI shall refer to Fiber Art’s approved Quality Control/Fabrication Manual Section 11 for calibration procedures.
CI shall be responsible for the proper execution of FAA Form 337 when required and the maintenance release pertinent to all items released to service by the repair station. An FAA Airworthiness Approval Tag (FAA Form 8130-3) may also be signed by the CI to return parts to service in accordance with FAR 43.9. Preliminary, hidden damage, and inspection system continuity shall be review by the CI. They shall make sure that proper tagging and identification of all incoming parts, material, and repairs is accomplished prior to release to production. CI shall review final acceptance of all materials, parts, supplies, and the airworthiness of components on which work has been performed.
CI shall make sure all rejected and unserviceable parts, after proper marking or tagging, are returned to the owner, or with his permission, destroyed and discarded.
The CI may delegate from time to time their duties as necessary. However, such delegation does not relieve the CI of their overall responsibilities. The delegation of duty by the CI shall be in writing and will name the person to whom delegated authority has been granted. The delegated person shall be made known to Fiber Art Repair Station personnel by a memo from personnel.
3.0 CONTROLLED CAPABILITIES DOCUMENT PROCEDURES 3.1.1 Performance of Maintenance
(a) Fiber Art shall perform all maintenance and repairs in conjunction with the following FAR’s 121 and 127, except regulations; 121.363, 121369, 121,373, 121.379, 127.131, 127.134, 127.136. 127.140. Furthermore applicable repairs in accordance with OEM repair manuals/instructions or other FAA approved data shall also be accomplished.
(b) Fiber Art shall perform all maintenance and repairs in accordance with the approved inspection program for the operator of a FAR Part 125 aircraft.
Fiber Art shall not repair any product it is not authorized to do so by the FAA Flight Standards District Office (From here on called “FAA Administrator”).
3.1.3 Change or Revision of CCD
(a) Fiber Art has shall apply for a change in repair station certificate in the prescribed manner (FAA Form 8310-3) of the FAA Administrator when necessary as follows:.
(1) When a change in location, housing, or facilities occurs.
(2) When a request to revise or amend rating occurs by the GM the CCD shall be revised and submitted to the FSDO for approval within in five (5) days following revision request. Only those components/accessories listed in the CCD revision which the FAA Administrator has approved will be approved for return to service.
(b) If Fiber Art sells or transfers its assets, the new owner must apply for an amended certificate in the manner prescribed in FAR 145.11.
3.1.4 Duration Controlled Capabilities Document
(a) Fiber Art shall do everything necessary to maintain its inspection and repair station certificate and CCD until revoked, surrendered, or suspended by the FAA.
(c) Fiber Art shall return its repair station certificate to the FAA Administrator when it expires or is revoked or suspended by the Flight Standards District Office of the FAA San Antonio, Texas.
3.2 RATINGS, HOUSING, EQUIPMENT, PERSONNEL, INSPECTION, DOCUMENTATION 3.2.1 Limited Specialized Rating
(a) Fiber Art’s repair station shall operate under a limited specialized rating for repair and maintenance of composite exterior and interior components for all fixed and rotorwing type aircraft.
(b) Limited ratings for airframe, engines, propellers, instruments, radio equipment, accessories, landing gear, floats, nondestructive inspection and testing, emergency equipment, rotor blades, aircraft fabric work shall not be applicable at this time.
(c) Fiber Art’s limited rating for specialized services involving composite exterior and interior component repair and maintenance requires the use of special materials and processes. Fiber Art has approved process specifications for the application of the materials used in repairs and maintenance. Fiber Art shall repair and maintain component parts and assembly’s per the OEM’s FAA approved specifications, engineering repair orders, structural repair manuals and any other FAA approved procedures.
3.2.2 Housing and Facilities
(a) Fiber Art shall maintain housing, space requirements, and facilities to adequately support the operation of the repair station. In addition to the procedures discussed in Fiber Art’s Quality Control Manual the following shall be practiced:
(1) All equipment and materials at Fiber Art’s facility shall be stored or maintained per manufactures instructions.
(2) Fiber Art shall maintain a safe and comfortable work space for its employees to accomplish the repair and maintenance work as require.
(3) All materials and parts shall be properly stored, protected, and segregated when necessary within Fiber Art’s facility.
(4) Parts and subassemblies requiring repair or maintenance shall be properly protected during disassembly, cleaning, inspection, repair, alteration, and reassembly. Protection shall include but is not limited to, weather elements, dust, and heat or cold. Workers shall be protected by issuing the proper equipment and safety devices while performing operations. All equipment shall be maintain per manufacturers instructions or written company policy.
(b) Adequate shop space for bench work and machine work shall be provided by Fiber Art for work to be performed. Machine work and bench work shall be properly segregated from each other.
(1.) Machine work shall be accomplished so no chips may inadvertently fall into a partially disassemble or assemble work piece.
(2) Parts cleaning operations shall be complete away from other areas of the shop.
(3) Fabrics synthetic and natural shall be cut, stored, and handle away from areas containing oils and grease. Frozen materials shall be kept in Fiber Art approved freezers.
(4) All painting and spraying shall be done within the spray booth. Booth fan shall be on at all times when spraying is being done. The spray booth shall be equipped with a filtering device and fire suppression.
(5) Precision testing and equipment shall be kept from areas where painting or spraying is being accomplished.
(c) Suitable assembly space shall be provided for repair and maintenance work. The space shall be adequate enough to handle the largest item being repaired or maintained.
(d) Storage facilities shall be provided and used exclusively for storing standard parts, spare parts, and raw materials. These storage areas shall be separated form the working area. Facilities shall be organized so only the parts and supplies which have been inspected shall be issued for any job. All parts and materials shall be protected using standard industry practices.
(e) Storage of parts awaiting assembly or disassembly shall provide protection against damage to them.
(f) Fiber Art personnel shall turn on ventilation fans as necessary to eliminate any fumes, heat, or dust from shop.
(g) Overhead shop lights shall be turned on at all times projects are in work.
(h) The temperature in the shop and work areas shall be adjusted to provide proper climate control to maintain airworthiness of the item being repaired or maintained.
Materials shall be store at temperatures per manufacturers instructions.
3.2.3 Change in Facilities Location
(a) Fiber Art shall not change its location, or change its housing and facilities required by 145.35 without written approval in advance from the FAA Administrator.
(b) Fiber Art understands the FAA Administrator may prescribe the conditions under which a repair station may operate if a change in housing, location, or facilities takes place.
3.2.4 Inspection of Facilities (FAA)
The FAA may inspect Fiber Art’s facility at anytime to review its inspection system, self auditing system, inspection records, and general ability to comply with FAR 145. Fiber Art requests that after such inspection any defects noted be sent in writing to the General Manager of Fiber Art.
3.2.5 Personnel and Technicians
(a) Fiber Art’s hiring policy allows for the screening of job applicants using a three step process as follows; advertisement listing qualifications required, application submittal, direct interview with GM. Only after this process is met is a candidate considered for employment. At the recommendation of the GM is a candidate hired. An employee must show the abilities and experience to accomplish and complete the work required at Fiber Art. Employees are evaluated on an throughout the year for team effort, appearance, safety, and work performance. Testing shall also be accomplished to develop and maintain skill levels.
(b) Fiber Art’s work load is dynamic in nature. Employees shall be hired as necessary to keep up with the volume of work load. Never will the number of employees fall below the necessary level to sacrifice safety or airworthiness of a repair or maintenance work order.
(c) Fiber Art shall provide adequate supervision of its employees. The ratio of supervisors to workers shall not drop below 1:10. Each work group shall be composed of experienced personnel and apprentices if necessary.
(d) Fiber Art shall maintain a repairman list within the facility of mechanics and repairman certified under FAR 65 Subpart’s D and E. The general manager shall be the person within Fiber Art who is directly responsible for the repair and maintenance functions of the repair station.
(e) Fiber Art shall hire as necessary employees, which have detailed knowledge of the maintenance and repair of composite interior components. Because of the limited access of San Antonio to this specialized training most of the personnel have received this training on the job at various employers. However Fiber Art has an active training program in place (Fiber Art 2000 Training Manual) for new hires with limited experience.
Page 8 3.2.6 Records of Personnel
(a) Fiber Art shall maintain on file at its facility for the FAA Administrator a supervisory and inspection personnel roster.
(1) Roster shall include the names, addresses, and phone numbers for all supervisory personnel including but not limited to management, foremen, technical supervisors, lay-up personnel, and crew chiefs.
(2) Roster shall include names, addresses, and phone numbers of all inspection personnel and chief inspector.
(b) Fiber Art shall maintain a summary of employment within its facility. This summary shall show compliance with all experience requirements necessary under FAR 145. The following information shall be included:
(1) Present title of employee (2) Total years experience (3) Past employment record (4) Scope of present employment (5) Any ratings employee holds
(c) Fiber Art shall change the roster as necessary to accommodate the following:
(1) Termination of employee
(2) Assignment of person to duties which require their name on roster (3) Any change of duties for personnel on roster
(d) Fiber Art shall not employ or contract with any person, unless it has current records on file for them.
3.2.7 Inspection System
(a) Fiber Arts approved (Quality Control/Fabrication Manual Volume I, Rev A 10/7/99) inspection system shall be employed at all phases of a repair or maintained article. This manual controls the inspection procedures for the following tasks:
Engineering Data/Document Control (Section 3) Purchasing (Section 4)
Receiving Inspection (Section 5) Production Inspection (Section 6) Rejected or Withheld Parts (Section 7) Shipping (Section 8)
Inspection Stamps (Section 9) Forms (Section 10)
Tool & Gage Control (Section 11) Material Review Board (Section 12) Reporting A Failure (Section 13) Sub-Contractor Control (Section 14)
(b) All Fiber Art inspection personnel shall have a copy of this manual and knowledge of the inspection criteria outline within the quality control inspection manual and Repair Station IPM.
(1) Inspection personnel must maintain proficiency with inspection aids provided by Fiber Art.
(2) Inspection personnel must understand and be made available current inspection procedures and specifications involving; tolerances, limitations, and manufacturers procedures on product being inspected. Other forms of information such as FAA airworthiness directives and bulletins also must be made available.
(3) In cases where special inspection devices are to be used, inspection personnel should be skilled in operating that equipment.
(c) All incoming materials shall be inspected per Fiber Arts approved Quality Control/Fabrication Manual Volume I Section 5.
(d) Inspection personnel shall maintain records for all repair components within Fiber Art’s facility recording any incoming defects. The inspection records which have accompanied the part to Fiber Art, shall be kept with the component until its release to service.
(e) Fiber Art shall inspected all incoming components for hidden damage. The result of this inspection shall be recorded on the appropriate company repair form.
(f) A copy of Fiber Art’s quality inspection self audit has been submitted with our Controlled Capabilities Document (CCD). Extra copies are available to the FAA Administrator for his review at Fiber Art’s facility. The Administrator shall be notified in writing of any future changes to the CCD.
(e) All Fiber Art employees are encourage to review the Quality Control/Fabrication manual as necessary to familiarize themselves with the criteria within it.
3.2.8 Inspection of Work
(a) Each article after servicing or maintenance shall be inspected by a qualified inspector. Fiber Art shall certify on the maintenance or alteration record accompanying the article, that it is airworthy with respect to the work performed.
(b) Fiber Art inspection personnel shall be proficient in using the various types of mechanical and visual inspection aids supplied by the company to perform inspections. Inspection personnel shall also show by experience they are qualified to understand the methods, techniques, and equipment used to determine the airworthiness of an article.
3.2.9 Records and Reports
Records shall be kept on all aircraft work performed at Fiber art. Mechanics and repairman shall sign all travelers after accomplishing a repair in the designate block.
Refer to the approved IPM or Quality Control/Fabrication Manual Volume I Appendix for copies of these forms. All inspections records shall be kept at Fiber Art’s facility for a minimum of two (2) years after work is completed.
3.2.10 Reporting of Defects
(a) The FAA shall be notified within 72 hours after Fiber Art discovers any serious defect or reoccurring unairworthy condition on any aircraft component. The report shall be file in the prescribed manner of the FAA Administrator.
(b) In event this that filing a report under paragraph (a) might prejudice the repair station the FAA Administrator shall be inform to determine if a report should be file.
(c) If the repair station is the holder of a Type Certificate, Supplemental Type Certificate (STC), or Parts Manufacturer Approval (PMA) or TSO authorization, they do not need to report a malfunction, defect, or failure under the provisions of FAR 145.63. However, the defect should and shall be reported under following FAR’s; 21.3, 37.17, 121.703,121.313,135.57.
3.2.11 CCD Documentation
(a) Fiber Art shall perform its maintenance and alteration duties in accordance with the standards under FAR 43. Copies of FAA approved OEM manufacturers service manuals, engineering repair orders, instructions, and service bulletins that relate to the components to be maintained shall be kept current.
(b) A Controlled Capability Document Amendment form shall be submitted to the GM by the CI at the time additional ratings are required by Fiber Art. A copy of this form can be found in Appendix 4.0. The GM shall incorporate the information collected on this form by revising the appropriate pages in the CCD. The revised CCD shall be submitted to the FAA Administrator. The FAA administrator must approved the new ratings request prior to release of component back to service.
3.2.12 Equipment & Materials
Fiber Art, Inc. Limited Rating applies to specialized processes and equipment require to manufacture composite components. Fiber Art maintains the following special equipment to process the composite materials:
Precision Quincy Oven P/N: EC-812-7 w/Honeywell Chart Recorder Dickson Humity Recorder P/N: THDx
Starret Granite Surface Plate P/N: 987535 Various Size Autoclaves (Pressure Pots)
Page 12 3.3 PRIVILEGES of CERTIFICATE
3.3.1 Privileges of Certificates
(a) Fiber Art shall use only certified repairmen to return to service any article which preventative maintenance has been performed on under FAR 145 Subpart D. Fiber Art’s commitment to a total quality management system for all parts leaving their facility shall insure proper maintenance has occur on all components.
(b) Fiber Art’s commitment to quality and safety and the privileges granted under a repair station shall apply to any location where Fiber Art personnel perform maintenance or repairs.
(c) Fiber Art shall only maintain or repair those products which it is rated to or has filed an application for an additional rating (FAA Form 8310-3) or has submitted a revised Controlled Capabilities Document to the FAA Administrator.
(d) All work completed under Fiber Art’s repair station certificate may not be return to service, unless it has been accomplished in accordance with technical data approved by the FAA Administrator.
(Appendix 4.1) Controlled Capabilities Document Amendment Request
Manufacturer OEM: ___________________________________________________________
Component Description: ___________________________________________________________
Part Number: ___________________________________________________________
Aircraft type/Model: ___________________________________________________________
Company Capability Level: (Check all that apply)
Overhaul ______ Repair ______ Calibration ______
Inspection _____ Testing _____
ATA Code: ___________________ FAA Rating: __________________________________________
List of Required Tools and Test Equipment: _______________________________________________
List of Approved technical Data: ________________________________________________________
List of Trained/Qualified Personnel: _____________________________________________________
Responsible Shop(s): _________________________________________________________________
General M anager: ___________________________________ Date:______________________
Chief Inspector: ___________________________________ Date:______________________
FAA FSDO: ___________________________________ Date: ______________________
Additional Information: __________________________________________________________________
Original Issue Date: ________________ Revision Date: __________________
Controlled Capabilities Document OEM Manufacturer: Bombardier Aerospace
Aircraft Type/Model: Challenger/CL601-3R
Component/Accessory Listing Limited Rating Specialized Services
Seq No. Part Number Part Name FAA Rating ATA Code* Approved Technical Data
1 600-31039-23 or -24 Wheel Bin Class II 52 OEM
2 600-31667-275 Fairing Assy (Main Landing Gear) Class II 52 OEM
* If Applicable
Original Issue Date: _______________________ Revision date:______________________