TRAINING PROGRAM MANUAL (TPM)

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TRAINING PROGRAM MANUAL (TPM)

REVISION NUMBER: 01

DATED: JULY 6, 2020

SMTA-13

MASTER MANUAL

PT. SIS MEL TRI AERO

NDT SPECIALIST | DGCA AMO 145D-1012

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CHAPTER 0 RECORD OF REVISIONS

TPM MANUAL

Revision 01 July 6, 2020 Page i

Revision Number Revision Date Page(s) Affected Insertion Date Initials 00 01 Mar 16, 20 Jul 6, 20

All Section and Pages All Section and Pages

Mar 16, 20 Jul 6, 20 Indra Indra Prepared by: Indra Setiawan Quality Control Manager

Approved by:

Nurhadi Wasisto Accountable Manager

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CHAPTER 0 MANUAL DISTRIBUTION LIST

AMO MANUAL

Revision 01 July 6, 2020 Page ii

MANUAL CODE ASSIGNED TO CONTACT INFORMATION

SMTA-13 (Master Manual) SMTA-14 (Controlled Copy) SMTA-15 (Controlled Copy)

Quality Control Manager Kasubdit Kelaikudaraan Accountable Manager

PT. Sis Meltri Aero DGCA Indonesia PT. Sis Meltri Aero

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CHAPTER 0 LIST OF EFFECTIVE PAGES

TPM MANUAL

Revision 01 July 6, 2020 Page iii

SECTION PAGES REVISION DATE

CHAPTER 0 i July 6, 2020 ii July 6, 2020 iii July 6, 2020 iv July 6, 2020 CHAPTER 1 1 July 6, 2020 2 July 6, 2020 3 July 6, 2020 CHAPTER 2 1 July 6, 2020 CHAPTER 3 1 July 6, 2020 2 July 6, 2020 CHAPTER 4 1 July 6, 2020 CHAPTER 5 1 July 6, 2020 2 July 6, 2020 CHAPTER 6 1 July 6, 2020 CHAPTER 7 1 July 6, 2020 CHAPTER 8 1 July 6, 2020 APPENDIX 1 1 July 6, 2020 2 July 6, 2020 3 July 6, 2020 APPENDIX 2 1 July 6, 2020 2 July 6, 2020 3 July 6, 2020 Quality Control Manager

Name : Indra Setiawan Date : July 6, 2020

DGCA Inspector

Name : ……….. Date : ………..

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GENERAL

TPM MANUAL

Revision 01 July 6, 2020 Page iv

CONTENTS PAGE

CHAPTER 0

RECORD OF REVISION ... i

MANUAL DISTRIBUTION LIST ... ii

LIST OF EFFECTIVE PAGES ... iii

TABLE OF CONTENTS ... iv

CHAPTER 1 GENERAL ... 1

1.1 Introduction to The Training Program ... 1

1.2 References ... 1 1.3 Purpose ... 2 1.4 General ... 2 1.5 Scope ... 2 1.6 Procedures ... 2 1.7 Responsibility ... 3 CHAPTER 2 BACKGROUND ... 1 CHAPTER 3 TRAINING NEEDS ASSESSMENT ... 1

3.1 Overal AMO Needs ... 1

3.2 Identification of Training ... 1

3.3 Change to AMO Work Scope ... 1

3.4 Annual Training Program Review ... 2

3.5 Individual Need Assessment ... 2

CHAPTER 4 COURSE DEFINITION ... 1

CHAPTER 5 SELECTION OF TRAINING METHODS AND SOURCE ... 1

5.1 Training Methods... 1 5.2 Training Sources ... 2 5.3 Training Instructors ... 2 CHAPTER 6 TRAINING DOCUMENTATION ... 1 CHAPTER 7 MEASUREMENT OF TRAINING EFFECTIVENESS ... 1

CHAPTER 8 WORK PERFORMED BY INTERIM MAINTENANCE EMPLOYEES ... 1

APPENDIX 1 TRAINING MATRIX 1. Personnel Training Requirement Matrix ... 1

2. Record Direct Maintenance Personnel Training ... 2

3. Training Program Schedule... 3

APPENDIX 2 TRAINING SYLLABUS 1. List of Abbreviation ... 1

2. Numbering Codes ... 2

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CHAPTER 1 GENERAL

TPM MANUAL

Revision 01 July 6, 2020 Page 1

1.1 INTRODUCTION TO THE TRAINING PROGRAM

This training program manual contains the policies and procedures PT. Sis Mel Tri Aero uses to determine its training requirements and to develop its training program.

The training program ensures each AMO employee has the knowledge and skills to capably perform assigned maintenance, preventive maintenance, and alteration tasks. The training program contents in this manual ensure PT. Sis Mel Tri Aero can respond to its employees’ changing training needs.

This manual sets forth the procedures for PT. Sis Mel Tri Aero to identify its training needs in a systematic manner, develop training and/or identify appropriate existing training, select the training methods, provide training, record training accomplishment, and measure the effectiveness of its training program.

PT. Sis Mel Tri Aero controls this document in accordance with the procedures for document control described in its Approved Maintenance Organization Manual (AMOM). A copy of this document and all revisions are provided to PT. Sis Mel Tri Aero’s.

The procedures for revising this document and submitting revisions to the DGCA for approval are described in this document, PT. Sis Mel Tri Aero uses a closed loop system to ensure that the training requirements for the company and employees are identified, PT. Sis Mel Tri Aero’s training standards are established, training is provided, and the training program is revised as necessary. Training program consists of the following basic components:

a. A training needs assessment to identify PT. Sis Mel Tri Aero’s overall training needs and individual employee training needs

b. The method for defining areas of study and/or courses/lessons made available to employees

c. The method for identifying training sources and methods available to employees for the areas of study, courses, and/or lessons

d. The method of documenting employee qualifications and training

e. The methods used to measure the effectiveness of the training program and to make changes as necessary. The Manager of Quality Control is responsible for ensuring PT. Sis Mel Tri Aero’s complies with all of the components of its training program.

The Accountable Manager has the overall authority for PT. Sis Mel Tri Aero’s training program. Any changes to the training program will be coordinated with the Accountable Manager.

1.2 REFERENCES:

a. CASR Part 145 Section 145.163. b. AC 145-10 AMO Training Program. c. AMO Manual.

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CHAPTER 1 GENERAL

TPM MANUAL

1.3 PURPOSE

AC 145-10 AMO Training Implemented in PT. Sis Mel Tri Aero, this document provides information on developing the AMO employee training program required.

1.4 GENERAL

The Employee Training Program Document contains the policies and procedures of PT. Sis Mel Tri Aero use to determine its training requirements.

1.5 SCOPE

This procedure applies to all training affects employees whose work is related to activities at PT. Sis Mel Tri Aero.

The categories of training consist of; 1. Indoctrination Training.

Indoctrination is initial training for new and existing employees covering the regulations, policies, and procedure.

2. Technical Training.

Technical Training is initial technical requirements for new and existing employees talking on new task to ensure appropriate technical skills training is provided.

3. Specialized Training.

Specialized training is specialized technical training or advanced training requirements for specific task or function to ensure all employees accomplishing maintenance remain capable of performing assigned task. 4. Recurrent Training.

Recurrent training is recurrent technical training for specific task of functions to ensure currency in existing or added capabilities.

5. Remedial Training.

Remedial training is remedial technical training requirements to correct demonstrated lack of skill or knowledge deficiencies.

1.6 PROCEDURES

PT. Sis Mel Tri Aero is responsible for ensuring is employee performing Maintenance, Preventive Maintenance and Alteration (including inspection) is capable of performing procedure PT. Sis Mel Tri Aero to identify appropriate existing training, select the training methods, provide training accomplished.

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CHAPTER 1 GENERAL

TPM MANUAL

1.7 RESPONSIBILITIES

The Quality Control Manager will:

1. Ensure the program are regularly reviewed to determine if any training deficiencies. 2. Decide on the appropriate training after consulting with all of the technical staff.

3. Ensure that the work performed by individual requiring additional training will not affect the Quality of work until the required training is successfully completed.

4. Outline training requirement on the result of training needs assessment.

5. Use training sources and method available to provide employee with the information necessary for them to perform assigned maintenance task correctly.

6. Create Personnel Training Requirement Matrix on SMTA Form TPM 01-03/20.

7. Create Record Direct Maintenance Personnel Training on SMTA Form TPM 02-03/20. 8. Create Training Program Schedule on SMTA Form TPM 03-03/20.

9. Determine where the individual will work to conduct the need assessment and ensure all individuals are provided training appropriate before they required beginning work.

10. Submit initial and/or revise of Document Training Program Manual PT. Sis Mel Tri Aero to DGCA for approval.

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CHAPTER 2 BACKGROUND

TPM MANUAL

Persons performing maintenance (including inspections), preventive maintenance, and alteration must be assessed and trained in accordance with the Directorate General Civil Aviation (DGCA)-approved procedures set forth in this manual. All other employees may be trained in accordance with the approved procedures of this manual at management discretion.

PT. Sis Mel Tri Aero’s has an established training program that includes Indoctrination (Initial, Recurrent), Specialized, and Remedial training areas of study for all of its employees. PT. Sis Mel Tri Aero’s has separate areas of study for the following staffing categories:

1. Technicians and other individuals performing maintenance, preventive maintenance, or alteration tasks such as: a. Inspectors

b. Supervisors c. Managers 2. Support staff

PT. Sis Mel Tri Aero’s has established minimum training standards for its job positions and methods to assess an individual’s skill level for each job function to determine training requirements.

The procedures in this manual enable PT. Sis Mel Tri Aero’s to revise its existing training program to ensure it continues to meet PT. Sis Mel Tri Aero’s needs and produce training consistent with all regulatory requirements.

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CHAPTER 3 TRAINING NEEDS ASSESSMENT

TPM MANUAL

PT. Sis Mel Tri Aero’s needs assessment is a two-part process that determines PT. Sis Mel Tri Aero’s overall training requirements, as well as individual employee training requirements.

3.1 Overall AMO Needs

To determine its overall training requirements, the Quality Control Manager must review PT. Sis Mel Tri Aero’s operations specifications (OpSpecs); capability list; job position duties and responsibilities listed in the AMO Manual; technical job functions and tasks; customer requirements; past, current, and expected scope of work; employment procedures for hiring; and current employee experience levels.

This needs-assessment will result in a description of the knowledge and skill standards for each defined job position or function.

Employees will then be assessed against the standard established for the position and tasks assigned. If it is determined that an employee does not possess the capability to perform a

Maintenance (including inspection), preventive maintenance, or alteration task, appropriate training will be administered.

PT. Sis Mel Tri Aero’s continuously evaluates its overall AMO training needs. However, PT. Sis Mel Tri Aero’s will specifically revise the training program when:

1. It identifies additional training needs.

2. Changes to its ratings, facilities, equipment, or work scope require additional training areas, classes, or lessons.

3.2 Identification of Training Needs

PT. Sis Mel Tri Aero may identify additional training needs through: 1. The needs assessment outlined in this manual.

2. DGCA or other external agency oversight findings. 3. Investigations that lead to voluntary disclosures. 4. Routine or special quality control audits.

5. Findings from the PT. Sis Mel Tri Aero Internal Evaluation Program. 6. Feedback from employees.

7. The results from audits related to maintenance human factors.

The Quality Control Manager regularly reviews the results and reports for additional training needs.

3.3 Changes to AMO Work Scope

Whenever PT. Sis Mel Tri Aero’s is planning to change its facilities, equipment, or scope of work as reflected in its OpSpecs or capability list, it will conduct a review of its current training program.

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CHAPTER 3 TRAINING NEEDS ASSESSMENT

TPM MANUAL

The need for additional training will be based on an analysis of the new work to be performed, the capability of employees, and the availability of in-house training.

Appropriate changes will be made to initial, recurrent, and specialized training areas of study, including existing courses or the addition of new courses, positions, and individuals requiring the training, and when the new training needs to be implemented and completed.

3.4 Annual Training Program Review

An annual review of the training program will verify if PT. Sis Mel Tri Aero has made any changes that might affect training and will analyze the measures of training effectiveness.

As a part of this annual review, PT. Sis Mel Tri Aero will analyze its job position duty and task assignments, its employee experience levels, and the method of delivery for various courses, new training techniques, or commercially available courses. It will make any changes that are required to ensure employees are capable of performing assigned tasks in accordance with the procedures set forth in their manual.

3.5 Individual Needs Assessment

PT. Sis Mel Tri Aero has established skill levels and qualifications for each job position based upon technical functions and tasks. In addition, PT. Sis Mel Tri Aero has developed methods to evaluate an individual to determine what knowledge, experience, or training establishes capability to properly perform the work.

Whenever PT. Sis Mel Tri Aero hires a new employee or transfers an employee to a new job position, the employee’s new supervisor will assess the individual’s skill level and qualifications against the requirements for the assigned functions or tasks.

The supervisor and the Quality Control Manager determine what training is necessary and ensure the individual’s training record is updated to reflect the assessment and training requirements. The supervisor will also work with the Training Department to ensure the individual receives the necessary training in the appropriate timeframe.

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CHAPTER 4 COURSE DEFINITION

TPM MANUAL

The Quality Control Manager will develop and revise areas of study, courses, and/or lessons based on the results of a training needs assessment:

1. An Area of Study will be developed to identify the entire scope of training available for a broad area of knowledge and skill requirements. It will include the appropriate number and level of courses or lessons to accomplish the defined objective. The areas of study will define the initial and recurrent requirements for the associated courses and lessons. Initial training will be provided to an employee for the first time.

2. Recurrent training will be information that supports, expands, or refreshes initial training areas of study, courses/lessons, or other requirements.

3. Remedial training will be assigned to ensure an employee who lacks demonstrated knowledge and has been provided the information necessary to accomplish assigned maintenance or alteration tasks properly.

a. Total required course of study hours or performance outcome. b. Staffing category.

c. Job function.

All Courses/Lessons shall be recorded by developing the following information as necessary to capture the required knowledge or skill:

1. Course/Lesson Title. 2. Objectives.

3. Prerequisites. 4. Course outline.

5. Required hours or performance outcome for each topic or lesson.

6. Training material including handouts, regulations, manuals, tools, or equipment used. 7. Training source(s).

8. Training method(s). 9. Instructor(s).

10. Instructor qualifications. 11. Method(s) of evaluation.

12. Other supporting information, as available such as instructor guides and courseware.

The information required by this Section shall be developed for all areas of study and/or courses/lessons made available to employees. This includes training provided by the on-the-job methodology.

The information on courses and lessons from outside sources will be evaluated to ensure the availability of enough information to determine its capability to impart the information required by PT. Sis Mel Tri’s needs assessment for the company or for the particular employee.

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CHAPTER 5 SELECTION OF TRAINING METHODS

AND SOURCES

TPM MANUAL

Using the information developed during the course definition phase, PT. Sis Mel Tri Aero will evaluate training method(s), source(s), and instructor(s) to determine whether the appropriate and necessary knowledge or skill will be transferred to employees.

5.1 Training Methods

The material to be presented, the level of personnel receiving the training, and alternatives available will be used to establish training methods for areas of study and/or courses/lessons. PT. Sis Mel Tri Aero uses various methods to train its employees including:

1. Formal classroom training. 2. On-the-job training (OJT). 3. Self-study.

4. Case study.

5. Computer-based training (CBT). 6. Distance learning.

7. Embedded training.

8. External classes and courses.

The company will use all available resources to provide the appropriate training. Many areas of study, courses, and lessons will be provided by more than one method. All methods will have a documented method of determining the amount of information that must be exchanged. Generally, this will be accomplished by completing the information required by Chapter 3 of this training manual. However, the validity of any particular method can be established by an evaluation of the employee’s capabilities.

5.2 Training Sources

Sources available for training will be continually monitored to ensure PT. Sis Mel Tri Aero aware of its alternatives. When a new or revised training need is identified, the available options will be reviewed. This process may include consultation with the DGCA other AMOs, manufacturers, and local colleges for available training.

If the training will be conducted by an outside vendor, an audit will be conducted to ensure it provides appropriate information. The audit may include an observation of training, a review of course outlines and materials, contact with previous training customers, and a review of instructor qualifications and experience. The extent of the audit will be based on an informal risk assessment related to the criticality of the training and the ability of PT. Sis Mel Tri Aero’s to assess the information imparted.

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CHAPTER 5 SELECTION OF TRAINING METHODS

AND SOURCES

TPM MANUAL

5.3 Training Instructors

Instructors shall be qualified based upon subject matter knowledge and teaching ability. Subject matter expertise may be established by experience, demonstrated knowledge, and/or certification. The ability to impart information can be determined by observation, demonstration, or experience. The evaluation of in-house instructors shall be documented in the course description.

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CHAPTER 6 TRAINING DOCUMENTATION

TPM MANUAL

The Quality Control Manager is responsible for establishing the standards for the creation and retention of training records for all PT. Sis Mel Tri Aero employees that perform maintenance (including inspection), preventive maintenance, and alteration tasks. The company maintains an electronic summary of all training provided. Each electronic report includes the employee’s name and job function, the needs assessment findings, a list of DGCA certifications, other applicable certifications and degrees, PT. Sis Mel Tri Aero qualifications and authorizations.

PT. Sis Mel Tri Aero will make the training records of employees performing maintenance (including inspection), preventive maintenance, and alteration tasks available to the DGCA or review upon request. The company maintains the individual training records for as long as an employee is employed at PT. Sis Mel Tri Aero and for two years thereafter.

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CHAPTER 7 MEASUREMENT OF TRAINING

EFFECTIVENESS

TPM MANUAL

The Quality Control Manager will regularly evaluate each course for its content, time, quality of the training materials (courseware), training facilities, and instructor. This is accomplished through observation, examination results, and feedback.

The Quality Control Manager to ensure PT. Sis Mel Tri Aero audits outside training vendors and in-house training courses is provided the results of these evaluations. The Manager of Quality Control resolves any discrepancies and will ensure the training program is reviewed on annual basis.

During the course design, PT. Sis Mel Tri Aero developed a method to evaluate each employee’s performance. This could include written or oral examinations or manipulative skill tests. The Quality Control Manager will analyze the results of all course examinations to determine if any changes are required to establish a basis for determining whether the course met its objectives and provided the information necessary to ensure the employee was capable of performing assigned tasks.

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CHAPTER 8 WORK PERFORMED BY INTERIM

MAINTENANCE EMPLOYEES

TPM MANUAL

During periods of heavy workload, PT. Sis Mel Tri Aero may supplement its workforce with interim maintenance employees. Before these individuals begin work for PT. Sis Mel Tri Aero they must undergo a needs assessment.

The Quality Control Manager must coordinate with the Inspector of the area where the individuals will work to conduct the needs assessment and ensure all individuals are provided training appropriate to the particular assignment before they are required to begin work.

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APPENDIX 1 TRAINING MATRIX

TPM MANUAL

1. Personnel Training Requirement Matrix

Plan of Training Program (Training Method and Source)

NO DESCRIPTION PARTICIPANT Manager and Supervisor Technician Inspection Personnel Other Training Method A AMO Workshop Training (Initial and Recurrent)

1 Review and Socialization CASR Part 145, 43, and 65     2 2 Company Manuals (AMO Manual and QC Manual)     2

3 Hazardous Material (Hazmat)    1

4 General Occupational Safety and Health Administration (OSHA)     1 5 Safety Management System (SMS)     1

6 Maintenance Human Factor     1

7 Inspector Airworthiness Course  1

8 Internal/External Audit Procedure  1

B Technician Workshop Training

1 Record and Record Keeping  2

D Specialized Training 2

1 Non Destructive Testing (NDT)   1,4

- Dye Penetrant (PT)   1,4

- Magnetic Particle (MT)   1,4

- Ultrasonic Inspection (UT)   1,4

- Eddy Current (ET)   1,4

- Radiography Inspection (RT)   1,4

- Boroscope Inspection (BT)   1,4

Note : Training Methods

1 Formal Class Room (External Training) Other: Management and Staff

2 Formal Class Room (Internal Training) 3 On The Job Training (OJT)

4 Self Study with guidance/Case Study/Seminar

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APPENDIX 1 TRAINING MATRIX

TPM MANUAL

2. Record Direct Maintenance Personnel Training

Training Need Assessment

Personnel Qualification Type of Training Direct Maintenance Personnel Indirect Maintenance Personnel I n te rv a l (y e a rs ) Me c h a n ic I n s p e c to r Man a g e r & S u p e rv is o r S to re man ( S h ipp ing & R e c e iv ing Tec h n ic a l P u b lic a tion A u d it o r S ta ff Man a g e r D ire c to r

A AMO Workshop Training (Initial and Recurrent)

1 Review and Socialization CASR Part 145, 43, and 65 3          2 Company Manuals (AMO Manual and QC Manual) 3          3 Hazardous Material (Hazmat) 3  

4 General Occupational Safety & Health Admin (OSHA) 3          5 Safety Management System (SMS) 3          6 Maintenance Human Factor 3          7 Inspector Airworthiness Course 3  

8 Internal/external Audit Procedure 3 

B Technician Workshop Training

1 Record and Record Keeping

D Specialized Training

1 Non Destructive Testing (NDT)

- Dye Penetrant (PT) 5  

- Magnetic Particle (MT) 5   - Ultrasonic Inspection (UT) 5  

- Eddy Current (ET) 5  

- Radiography Inspection (RT) 5   - Boroscope Inspection (BT) 5  

SMTA Form TPM 02-03/20

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APPENDIX 1 TRAINING MATRIX

TPM MANUAL

3. Training Program Schedule

Recurrent/Remedial Training Schedule

NO SUBJECT DURA TION MONTH ATT. ACC OMP. DAT E REM ARK S 1 2 3 4 5 6 7 8 9 10 11 12

A AMO Workshop Training (Initial and

Recurrent) 2 day

Prsn 1 Review and Socialization CASR Part 145,

43, 65 12 hrs

 Prsn

2 Company Manuals (AMO Manual and QC

Manual) 6 hrs

Prsn

3 DOT Hazardous Material (Hazmat) 2 day Prsn 4 General Occupational Safety and Health

Administration (OSHA) 6 hrs

Prsn

5 Safety Management System (SMS) 6 hrs Prsn

6 Maintenance Human Factor 6 hrs Prsn

7 Inspector Airworthiness Course 3 week Prsn 8 Internal/External Audit Procedure Prsn

B Technician Workshop Training Prsn

1 Record and Record Keeping 1 day Prsn

D Specialized Training Prsn

1 Non Destructive Testing (NDT) Prsn

- Dye Penetrant (PT) 1 day Prsn

- Magnetic Particle (MT) 1 day Prsn

- Ultrasonic Inspection (UT) 1 day Prsn

- Eddy Current (ET) 1 day Prsn

- Radiography Inspection (RT) 1 day Prsn - Boroscope Inspection (BT) 1 day Prsn

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APPENDIX 2 TRAINING SYLLABUS

TPM MANUAL

TRAINING SYLLABUS

NON DESTRUCTIVE TEST (NDT)

Entry Level Assistant Mechanic Mechanic Inspector Junior Senior Probation 3 Month Education: - High School. - Diploma 3 Aeronautic. - Experience > 3 month. BT Indoctrination: PT,MT,ET,UT,RT, Borescope - BT-01 - BT-02 - BT-05 > 24 months TT Level 1 PT,MT,ET, UT,RT - BT-03 - BT-04 - BT-06 > 24 months ATT Level 2 PT,MT,ET, UT,RT > 18 months CO MA  COMA  ST - Recertification: PT, MT, ET, UT, RT Level 2 - Basic Inspector  Recurrent : - BT 03 - BT 04 - BT 06 RO S T E R 1. LIST OF ABBREVIATIONS BT : Basic Training TT : Technical Training

ATT : Advance Technical Training ST : Specialized Training

PT : Fluorescent Penetrant Testing MT : Magnetic Particle Testing UT : Ultrasonic Testing ET : Eddy Current Testing RT : Radiography Testing

COMA : Certificate of Maintenance Approval NDT : Non Destructive Testing

HAZMAT : Hazardous Material

2. NUMBERING CODES

Code following type of training with letter alphabet and numeri 01,02, etc. (Sample TT-01 Technical Training Fluorescent Penetrant Testing)

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APPENDIX 2 TRAINING SYLLABUS

TPM MANUAL

3. TYPE OF TRAINING (INITIAL AND RECURRENT TRAINING) a. BASIC INDOCTRINATION TRAINING

BT-01 : Socialization CASR 43,65,145

BT-02 : Socialization Company Manuals (AMO and QC Manuals) BT-03 : Hazmat

BT-04 : Human Factor

BT-05 : Facility Security/Shop Safety BT-06 : SMS (Safety Management System)

b. TECHNICAL TRAINING

1) TT-01 FLUORESCENT PENETRANT TESTING (PT) a) Theory

b) Practical

2) TT-02 MAGNETIC PARTICLE TESTING (MT) a) Theory

b) Practical

3) TT-03 ULTRASONIC TESTING (UT) a) Theory

b) Practical

4) TT-04 EDDY CURRENT TESTING (ET) a) Theory

b) Practical

5) TT-05 RADIOGRAPHY TESTING (RT) a) Theory

b) Practical

c. ADVANCE TECHNICAL TRAINING (ATT)

1) ATT-01 FLUORESCENT PENETRANT TESTING (PT) a) Theory

b) Practical

2) ATT-02 MAGNETIC PARTICLE TESTING (MT) a) Theory

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APPENDIX 2 TRAINING SYLLABUS

TPM MANUAL

3) ATT-03 ULTRASONIC TESTING (UT) a) Theory

b) Practical

4) ATT-04 EDDY CURRENT TESTING (ET) a) Theory

b) Practical

5) ATT-05 RADIOGRAPHY TESTING (RT) a) Theory

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1

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

ADVANCE TECHNICAL TRAINING – NON DESTRUCTIVE TESTING ATT-01

1 Training Title ATT-01 Fluorescent Penetrant Testing (PT).

2 Objective Comprehend and able to Perform NDT Fluorescent Penetrant Testing (PT). 3 Prerequisites For Senior Mechanic

- More than 18 months as assistance mechanic and practical experience in procedures, practices, tools and equipment.

4 Instructor Qualification - Appropriate background for subject area ( such as formal training and/or experience.

- Teaching ability (the ability to impart information on the particular subject matter).

5 Technical Training: ATT-01 Fluorescent Penetrant Testing (PT)

ATT-01 Fluorescent Penetrant Testing (PT) 1. Introduction

Summary of NDT methods, history of liquid penetrant inspection, fundamental principles and applications.

2. Pre-cleaning

Reasons for pre-cleaning, methods of pre-cleaning, e.g. vapour degreasing, ultrasonic cleaning, applications and effectiveness of the pre-cleaning techniques, pre-cleaning methods and reasons why they shall or shall not be used.

3. Penetrant Techniques

Types of dyes, types of penetrant processes, categorization of penetrant application, comparison of techniques.

4. Penetrant Inspection Equipment

Stationary equipment, hand lines, automatic lines and

electrostatic, portable equipment, local application, selection of equipment.

5. Removal Techniques

Removers-solvent 7 hydrophilic, emulsifiers-lipophilic, how removers & emulsifiers work, application of removers & emulsifiers, selection of removal technique.

6. Component Drying

Reason for drying, method of drying, selection of drying, selection of drying techniques.

7. Development Techniques

Reason for development, types of developers, method of application, selection of developers, comparison of techniques.

Duration

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2 8. Inspection

Inspection area, white light, ultraviolet radiation and fluorescence, ambient light, cleanliness and component handling, true and false indications, types of discontinuities fixing and recording of

indications, report writing. 9. Post Cleaning

Reasons for post cleaning, methods of post cleaning, e.g. vapour degreasing, and ultrasonic cleaning, applications and

effectiveness of the post cleaning methods. 10. Quality Control Checks

Reasons for control checks, test pieces, blocks and panels, use of hand refractometer, line control checks in accordance with current specifications, penetrant, emulsifier, remover and developer checks in accordance with specifications. 11. Safety Precautions

Solvents and penetrants, ventilation, smoking, eating and drinking, clothing and footwear, eye protection, ultraviolet radiation, fire hazards.

12. Miscellaneous

Glossary of terms used in liquid penetrant inspection, instruction writing, procedures and specifications.

6 Training Duration - Theory held in classroom, duration: 16 hours - Practical 24 hours

Date: July 6, 2020 Bandung

Prepared by

Indra Setiawan

Quality Control Manager

Approved by

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3

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title ATT-02 Magnetic Particle Testing (MT).

2 Objective Comprehend and able to Perform NDT Magnetic Particle Testing (MT). 3 Prerequisites For Senior Mechanic

4 Instructor Qualification - Appropriate background for subject area (such as formal training and/or experience.

5 Technical Training: ATT-02 Magnetic Particle Testing (MT)

ATT-02 Magnetic Particle Testing (MT) 1. Introduction

Summary of NDT methods, History of Magnetic Particle Inspection.

2. Principles of Magnetism

Magnetic domains, nature of fields, magnets and their poles, lines of force, flux density and its units, field strength and its units, leakage fields, ferromagnetic materials, paramagnetic materials, diamagnetic materials.

3. Principles of Electromagnetism

Current flow, fields surrounding a conductor, right hand rule, coils/solenoids, right hand grip rule, magnetic properties of a material, hysteresis curves, field distribution inside and outside, magnetic and non-magnetic conductors.

4. Principles of Electricity

Currents, wave forms, single phase and three phase supplies, akin effects, measurement of current, sources of currents, choice of current waveform.

5. Methods of Magnetization

Current flow, threader bar, magnetic flux flow, coil, induction, permanent magnets, discontinuity direction with regard to the magnetic field, selection of magnetization technique, swinging (vector) field, sequential fields.

6. Magnetizing Equipment

Portable, mobile, bench type, yokes, permanent magnets, prods selection of equipment.

7. Preparation of Components

Reasons for pre-cleaning, pre cleaning methods, surface finish, background and contest sprays, post cleaning methods, corrosion protection.

Duration

(27)

4 8. Magnetic Inks

Oxides wet or dry, oxides fluorescent or colour contrast, carrier fluids, water conditioners, permeability, magnetic rubber, application of inks, selection of inks, mobility.

9. Inspection

Inspection area, white light, ambient light, ultraviolet radiation and fluorescence, cleanliness and component handling, types of discontinuities, true and false indications, fixing and recording of indications, report writing.

10. Demagnetization

Reasons for demagnetization, residual fields, coercive force, Curie point, principles of demagnetization, equipment required methods of checking for residual field strength.

11. Quality Control Check

Reasons fo control chekcs, test piece and components, line control checks in accordance with current specification. 12. Safety Precautions

Solvents and inks, ventilation, smoking, eating and drinking, clothing and footwear, eye protection, ultraviolet radiation, fire hazards, component arcing.

13. Miscellaneous

Glossary of terms used in magnetic particle inspection, instruction writing, procedures and specifications.

Prepared by

Indra Setiawan

Approved by

(28)

5

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title ATT-03 Ultrasonic Testing (UT).

2 Objective Comprehend and able to Perform NDT Ultrasonic Testing (UT). 3 Prerequisites For Senior Mechanic

4 Instructor Qualification - Appropriate background for subject area (such as formal training and/or experience).

5 Technical Training: ATT-03 Ultrasonic Testing (ET)

ATT-03 Ultrasonic Testing (ET). 1. Introduction

Summary of NDT methods, History of Ultrasonic Inspection. 2. Fundamental of ultrasonic

Ultrasonic waves, characteristic of wave propagation, type of ultrasonic waves, , transducer, characteristic ultrasonic beam, attenuation.

3. Characteristic of wave propagation

Frequency, wave length, velocity, ultrasonic wave, acoustic impedance.

4. Scan presentation

a-scan, b-scan, c-scan presentation, echo amplitude and its control.

5. Basic ultrasonic method

Throught transmition method, pulse echo method, resonance method, couplant.

6. Recording and evaluation method

Determination of the location, size and nature of defect, ultrasonic test report.

7. Calibration of test system

Calibration and reference test block, check equipment characteristic, method setting sensitivity, measurement of attenuation, determine of transfer loss for angle beam probe, couplant influence of test specimen on ultrasonic beam, selection ultrasonic probe.

Duration

(29)

6 8. Safety Precautions

Working environment, location of inspection, component under test.

Prepared by

Indra Setiawan

Approved by

(30)

7

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title ATT-04 Eddy Current Testing (UT).

2 Objective Comprehend and able to Perform NDT Eddy Current Testing (UT). 3 Prerequisites For Senior Mechanic

5 Technical Training: ATT-04 Eddy Current Testing (UT)

ATT-04 Eddy Current Testing (UT). 1. Introduction

Summary of NDT methods, History of Eddy Current Inspection. 2. Principles of Electromagnetism

Electromagnetic induction, Crack detection, Material thickness measurements, Coating thickness measurements, Conductivity measurements Material, quality and standardization.

Electricity, magnetism, magnetic field produce by a current, factor effecting eddy current.

4. Eddy current Equipment

Defect reaction according to position, impedance, influence of various parameter, typical material, auxiliary devices.

Reasons for cleaning, surface finish, surface roughness, grain, temperature, characteristic of probe, frequency and shape of probe.

6. Inspection

Surface testing, sub surface, tube testing, multi-frequency testing, geometry defect characteristic, case of point defect, case of large defect, case of multiple defect.

7. Quality Control Checks

Checks in accordance with current specifications, standard, code, inspection technic.

8. Safety Precautions

Working environment, location of inspection, component under test, personnel safety equipment.

Duration

(31)

8 9. Miscellaneous

Glossary of terms used in eddy current inspection, instruction writing, procedures and specifications.

Prepared by

Indra Setiawan

Approved by

(32)

9

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title ATT-05 Radiography Testing (RT).

2 Objective Comprehend and able to Perform NDT Radiography Testing (RT). 3 Prerequisites For Senior Mechanic

5 Technical Training: ATT-05 Radiography Testing (RT)

ATT-05 Radiography Testing (RT). 1. Introduction

Summary of NDT methods, History of Radiographic Inspection. 2. Principles of Electromagnetism

Electromagnetic induction, Crack detection, Material thickness measurements, quality and standardization.

Electricity, Bremsstrahlung field produce by a current, factor effecting radiation.

4. Radiographic Equipment and Film processing

Reasons surface roughness, grain, temperature, characteristic of Radiographic.

6. Inspection

7. Quality Control Facility Checks

Duration

(33)

10 9. Miscellaneous

Glossary of terms used in Radiographic inspection, instruction writing, procedures and specifications.

Prepared by

Indra Setiawan

Approved by

(34)

1

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

TECHNICAL TRAINING – NON DESTRUCTIVE TESTING TT-01

1 Training Title TT-01 Fluorescent Penetrant Testing (PT).

2 Objective Comprehend and able to Perform NDT Fluorescent Penetrant Testing (PT). 3 Prerequisites For Junior Mechanic

5 Technical Training: TT-01 Fluorescent Penetrant Testing (PT)

TT-01 Fluorescent Penetrant Testing (PT) 1. Introduction

Summary of NDT methods, history of liquid penetrant inspection, fundamental principles and applications.

2. Pre-cleaning

Reasons for pre-cleaning, methods of pre-cleaning, e.g. vapour degreasing, ultrasonic cleaning, applications and effectiveness of the pre-cleaning techniques, pre-cleaning methods and reasons why they shall or shall not be used.

3. Penetrant Techniques

Types of dyes, types of penetrant processes, categorization of penetrant application.

4. Penetrant Inspection Equipment

Stationary equipment, hand lines, automatic lines and electrostatic, portable equipment, local application. 5. Removal Techniques

Removers-solvent 7 hydrophilic, emulsifiers-lipophilic, how removers & emulsifiers work, application of removers & emulsifiers.

6. Component Drying

Reason for drying, method of drying, selection of drying. 7. Development Techniques

Reason for development, types of developers, method of application, selection of developers, comparison of techniques. 8. Inspection

Inspection area, white light, ultraviolet radiation and fluorescence, ambient light, cleanliness and component handling, true and false indications.

Duration

(35)

2 9. Post Cleaning

Reasons for post cleaning, methods of post cleaning, e.g. vapour degreasing, and ultrasonic cleaning, applications and

effectiveness of the post cleaning methods. 10. Quality Control Checks

Reasons for control checks, test pieces, blocks and panels, use of hand refractometer, line control checks in accordance with current specifications.

Solvents and penetrants, ventilation, smoking, eating and drinking, clothing and footwear, eye protection, ultraviolet radiation, fire hazards.

12. Miscellaneous

Glossary of terms used in liquid penetrant inspection, instruction writing, procedures and specifications.

Prepared by

Indra Setiawan

Approved by

(36)

3

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title TT-02 Magnetic Particle Testing (MT).

2 Objective Comprehend and able to Perform NDT Magnetic Particle Testing (MT). 3 Prerequisites For Junior Mechanic

5 Technical Training: TT-02 Magnetic Particle Testing (MT)

TT-02 Magnetic Particle Testing (MT) 1. Introduction

Summary of NDT methods, History of Magnetic Particle Inspection.

2. Principles of Magnetism

Magnetic domains, nature of fields, magnets and their poles, lines of force, flux density and its units, field strength and its units, leakage fields, ferromagnetic materials, paramagnetic materials, diamagnetic materials.

Current flow, fields surrounding a conductor, right hand rule, coils/solenoids, right hand grip rule, magnetic properties of a material.

4. Principles of Electricity

Currents, wave forms, single phase and three phase supplies, akin effects, measurement of current.

5. Methods of Magnetization

Current flow, threader bar, magnetic flux flow, coil, induction, permanent magnets, discontinuity direction with regard to the magnetic field.

6. Magnetizing Equipment

Portable, mobile, bench type, yokes, permanent magnets, prods selection of equipment.

Reasons for pre-cleaning, pre cleaning methods, surface finish, background and contest sprays, post cleaning methods, corrosion protection.

Duration

(37)

4 8. Magnetic Inks

Oxides wet or dry, oxides fluorescent or colour contrast, carrier fluids, water conditioners, permeability, magnetic rubber, application of inks.

9. Inspection

Inspection area, white light, ambient light, ultraviolet radiation and fluorescence, cleanliness and component handling.

10. Demagnetization

Reasons for demagnetization, residual fields, coercive force, Curie point, principles of demagnetization, equipment required methods of checking for residual field strength.

11. Quality Control Check

Reasons fo control chekcs, test piece and components, line control checks in accordance with current specification. 12. Safety Precautions

Solvents and inks, ventilation, smoking, eating and drinking, clothing and footwear, eye protection, ultraviolet radiation, fire hazards, component arcing.

13. Miscellaneous

Glossary of terms used in magnetic particle inspection. 6 Training Duration - Theory held in classroom, duration: 16 hours

- Practical 24 hours Date: July 6, 2020

Bandung Prepared by

Indra Setiawan

Approved by

(38)

5

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title TT-03 Ultrasonic Testing (UT).

2 Objective Comprehend and able to Perform NDT Ultrasonic Testing (UT). 3 Prerequisites For Junior Mechanic

5 Technical Training: TT-03 Ultrasonic Testing (ET)

TT-03 Ultrasonic Testing (ET). 1. Introduction

Summary of NDT methods, History of Ultrasonic Inspection. 2. Fundamental of ultrasonic

Ultrasonic waves, characteristic of wave propagation, type of ultrasonic waves, , transducer, characteristic ultrasonic beam, attenuation.

3. Characteristic of wave propagation

Frequency, wave length, velocity, ultrasonic wave, acoustic impedance.

4. Scan presentation

a-scan, b-scan, c-scan presentation, echo amplitude and its control.

5. Basic ultrasonic method

Throught transmition method, pulse echo method, resonance method, couplant.

6. Recording and evaluation method

Determination of the location, size and nature of defect, ultrasonic test report.

7. Calibration of test system

Calibration and reference test block, check equipment characteristic, method setting sensitivity, measurement of attenuation, determine of transfer loss for angle beam probe, couplant influence of test specimen on ultrasonic beam, selection ultrasonic probe.

Duration

(39)

6 8. Safety Precautions

Working environment, location of inspection, component under test.

Prepared by

Indra Setiawan

Approved by

(40)

7

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title TT-04 Eddy Current Testing (UT).

2 Objective Comprehend and able to Perform NDT Eddy Current Testing (UT). 3 Prerequisites For Senior Mechanic

5 Technical Training: TT-04 Eddy Current Testing (UT)

TT-04 Eddy Current Testing (UT). 1. Introduction

Summary of NDT methods, History of Eddy Current Inspection. 2. Principles of Electromagnetism

Electromagnetic induction, Crack detection, Material thickness measurements, Coating thickness measurements, Conductivity measurements Material, quality and standardization.

Electricity, magnetism, magnetic field produce by a current, factor effecting eddy current.

4. Eddy current Equipment

Reasons for cleaning, surface finish, surface roughness, grain, temperature, characteristic of probe, frequency and shape of probe.

6. Inspection

7. Quality Control Checks

Duration

(41)

8 9. Miscellaneous

Glossary of terms used in eddy current inspection. 6 Training Duration - Theory held in classroom, duration: 40 hours

Bandung Prepared by

Indra Setiawan

Approved by

(42)

9

LIMITED RATING NON DESTRUCTIVE TESTING

TRAINING PROGRAM

1 Training Title TT-05 Radiography Testing (RT).

2 Objective Comprehend and able to Perform NDT Radiography Testing (RT). 3 Prerequisites For Senior Mechanic

- Teaching ability (the ability to impart information on the particular subject matter). 5 Technical Training: TT-05 Radiography Testing (RT) TT-05 Radiography Testing (RT). 1. Introduction

Summary of NDT methods, History of Radiographic Inspection. 2. Principles of Electromagnetism

Electromagnetic induction, Crack detection, Material thickness measurements, quality and standardization.

Electricity, Bremsstrahlung field produce by a current, factor effecting radiation.

4. Radiographic Equipment and Film processing

Reasons surface roughness, grain, temperature, characteristic of Radiographic.

6. Inspection

7. Quality Control Facility Checks

Duration

(43)

10 9. Miscellaneous

Glossary of terms used in Radiographic inspection. 6 Training Duration - Theory held in classroom, duration: 40 hours

Bandung Prepared by

Indra Setiawan

Approved by

(44)