14 0 701 KB
AIRCRAFT MAINTENANCE ORGANIZATION MANUAL ( A M O M )
REVISION NUMBER : 16 DATED : MARCH 15, 2010
PT. REKATAMA PUTRA GEGANA DGCA AMO 145/14700 www.rpgrekatama.co.id
GENERAL
RECORD OF REVISIONS
AMO MANUAL
APPROVAL Prepared by:
Approved by:
March 15, 2010 Indra Setiawan
March 15, 2010 Suyoso RECORD OF REVISION
Revision Number
Revision Date
Page(s) Affected
Insertion Date
Original 01 02
May 10, 05 Apr 15, 06 Dec 21, 06
May 10, 05 Apr 15, 06 Dec 21, 06
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03
Jan 29, 07
Jan 29, 07
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05 06 07
Mar 27, 07 May 18, 07 July 13, 07
Mar 27, 07 May 18, 07 Jul 13, 07
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All All General (vi), Section 0 (1), Section 1 (3,4,6,10), Section 2 (1,2), Section 3 (1,2,4,6,7,8,9,10,12,13,14,15) General (i,ii,iii,iv), Section 1 (2,11,12), Appendix 2 (1) General (i,iii,v), Appendix 1 (1,2,3,4,5,6, 7,8,9) General (i,iii,v), Appendix 1 (1,2) General (i,ii), Appendix 1 (1) General (i,iii,v), Section 1 (2), Appendix 1 (1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, 16,17), Appendix 2 (1) General (i,iii,v), Appendix 1 (1,2,3,4,5,6, 7,8,9,10,11,12,13,14,15,16,17,18,19,20) General (i,iii,v), Appendix 1 (1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16, 17,18,19, 20,21,22) General (i,iii,v), Appendix 1 (1) General (i,iii), Section 2 (2) Appendix 2 (1) General (i,iii), Section 1 (2), Section 2(2), Appendix 2 (1) General (i,iii), Section 1 (2), Appendix 2 (1) General (i,iii), Section 0 (1), Section 1(2), Section 2 (1,2), Section 3 (13), Appendix 2 (1) General (i,iii), Appendix 2 (1) General (i,iii,iv,v), Section 1 (2,12,13), Section 2 (2), Appendix 2 (1,2)
May 22, 09 Mar 15,10
Fudin Fudin
Revision Number : 16
Date : March 15, 2010
Initials
Page : i
GENERAL
MANUAL DISTRIBUTION LIST
AMO MANUAL
" " Assigned to
Master Manual
Indra Setiawan
Quality Control
PT. RPG
RPG-01
DGCA
Subdit Standardisasi Kelaikan Udara
DSKU Jakarta
RPG-02
Suyoso
President Director
PT. RPG
RPG-03
Doddy Priabudi
Business and Operational Mgr
PT. RPG
RPG-04
Arya Dian D.
Maintenance Mgr
PT. RPG
RPG-05
Masta
General Affair Mgr
PT. RPG
Revision Number : 03
Title or Organization
Contact Information
Manual Code
Date : January 29, 2007
Page : ii
GENERAL
SECTION GENERAL
SECTION 0 SECTION 1
SECTION 2 SECTION 3
LIST OF EFFECTIVE PAGES
PAGES i ii iii iv v vi 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
REVISION DATE Mar 15, 10 Jan 29, 07 Mar 15, 10 Mar 15, 10 Mar 15, 10 Dec 21, 06 Feb 27, 09 Apr 15, 06 Mar 15, 10 Dec 21, 06 Dec 21, 06 Apr 15, 06 Dec 21, 06 Apr 15, 06 Apr 15, 06 Apr 15, 06 Dec 21, 06 Jan 29, 07 Mar 15, 10 Mar 15, 10 Feb 27, 09 Mar 15, 10 Dec 21, 06 Apr 15, 06 Apr 15, 06 Dec 21, 06 Apr 15, 06 Dec 21, 06 Dec 21, 06 Dec 21, 06 Dec 21, 06 Dec 21, 06 Apr 15, 06 Dec 21, 06 Feb 27, 09 Dec 21, 06 Dec 21, 06
SECTION APPENDIX 1 APPENDIX 2
AMO MANUAL
PAGES 1 1 2
REVISION DATE Dec 12, 07 Mar 15, 10 Mar 15, 10
Quality Control Manager
DGCA Inspector
Name : Indra Setiawan Date : March 15, 2010
Name : Herry A. Arief, ST, MMTr Date : 29-03-2010
Revision Number : 16
Date : March 15, 2010
Page : iii
GENERAL
TABLE OF CONTENT
AMO MANUAL
" GENERAL
RECORD OF REVISION......................................................i MANUAL DISTRIBUTION LIST ...........................................ii LIST OF EFFECTIVE PAGES ...............................................iii TABLE OF CONTENT.........................................................iv CHIEF EXECUTIVE STATEMENT.........................................vi
SECTION 0
INTRODUCTION............................................................ 1
SECTION 1
COMPANY ORGANIZATION ............................................ 1 1.1
General ................................................................ 1
1.2
Organizational Structure......................................... 2
1.3
Key Personnel Duties and Responsibilities................ 3 1.3.1 President Director........................................ 3 1.3.2 Manager of Quality Control ......................... 4 1.3.3 Inspector.................................................... 6 1.3.4 Maintenance Manager.................................. 7 1.3.5 Chief Workshops ........................................ 8 1.3.6 Mechanic .................................................... 9 1.3.7 Chief Material.............................................. 10 1.3.8 Business and Operational Manager ............... 11 1.3.9 General Affair Manager ................................ 12 1.3.10 Technical Publication ................................... 12
SECTION 2
HOUSING & FACILITY.................................................... 1 2.1 Maintenance Facility .............................................. 1 2.2 Facility Floor Plan .................................................. 2
SECTION 3
POLICY AND PROCEDURES ............................................ 1 3.1 General ................................................................ 1 3.2 Manual Revision and Control ................................. 2
Revision Number : 16
Date : March 15, 2010
Page : iv
GENERAL
TABLE OF CONTENT
AMO MANUAL
" 3.3 Personnel.............................................................. 3 3.3.1 Employee Certificates .................................. 3 3.3.2 Employee Qualifications ............................... 4 3.3.3 Mechanic ................................................... 4 3.3.4 Rosters and Roster Record ........................... 5 3.3.5 Training Program ........................................ 6 3.3.6 Inspection Personnel ................................... 8 3.4 Certificate Limitations and Privileges ...................... 9 3.5 Performance of Work at a Location Other Than The Approved Maintenance Organization ................. 10 3.6 Inspection by The DGCA ........................................ 12 3.7 Maintenance of Personnel, Housing, Facilities, Equipment, Materials and Technical Data ................ 12 3.8 Availability of Certificate......................................... 13 3.9 Record of Work ..................................................... 13 3.10 Reports of Serious Failures Malfunctions or Defects............................................................. 14 3.11 Establishment and Revision of Capability ................. 15 APPENDIX 1 CAPABILITY LIST........................................................... 1 APPENDIX 2 ROSTER OF AUTHORIZED PERSONNEL ........................... 1 ROSTER OF PERSONNEL ............................................... 2
Revision Number : 16
Date : March 15, 2010
Page : v
GENERAL
CHIEF EXECUTIVE STATEMENT
AMO MANUAL
This Approved Maintenance Organization Manual (AMO Manual) defines the organization and procedures which is referred to Civil Aviation Safety Regulations (CASR) Part 145 and the policies of the PT. Rekatama Putra Gegana. It is accepted that the procedures of the organization do not override the necessity for compliance with the Civil Aviation Safety Regulations, Airworthiness Directive or other requirements published by the DGCA from time to time. I commit myself to respect the AMO Manual requirements and to allocated all the resources needed. I request to all managers and staff manager to thoroughly and seriously contribute to their implementation and to propagate them in order to obtain the commitment of all. All personnel should be complied with these procedures during accomplishing the job. I am sure that this AMO Manual will be great valuable optimation to high quality and airworthiness requirements.
PT. REKATAMA PUTRA GEGANA
SUYOSO PRESIDENT DIRECTOR
Revision Number : 02
Date : December 21, 2006
Page : vi
SECTION 0
INTRODUCTION
AMO MANUAL
This manual describes the housing, facilities, equipment, personnel, and general operating rules pertinent to the operation of PT. Rekatama Putra Gegana, certificated by the Directorate General of Civil Aviation (DGCA) under CASR Part 145. All rating issued to PT. Rekatama Putra Gegana by the DGCA under CASR Part 145 are described in its Operations Specification. This manual includes a description of the policies and procedures that will be used by PT. Rekatama Putra Gegana to meet all requirements of CASR Part 145 that pertain to : 1. Aircraft Maintenance Organization (AMO) Manual. 2. Quality Control Manual. The information contained in this manual explains the systems used by PT. Rekatama Putra Gegana when performing maintenance, preventive maintenance or alteration on civil aviation articles. When more detail is required to accomplish or record a particular operation, those details are contained in the applicable manufacturer instructions for continued airworthiness e.g., maintenance, overhaul, and repair manuals, service bulletins, service information letters, standard practice manual, Airworthiness Directives, and/or other applicable data acceptable to or approved by The DGCA. The maintenance, preventive maintenance, or alteration of civil aviation articles will be performed in accordance with The Applicable Civil Aviation Safety Regulations (CASR). PT. Rekatama Putra Gegana will not maintain or alter any article for which it is rated of the appropriate housing, facilities, equipment, personnel, or technical data are not available.
Revision Number : 14
Date : February 27, 2009
Page : 1
SECTION 1
COMPANY ORGANIZATION
AMO MANUAL
" Reference : CASR Part 145, Section 145.51(a)(4) and Section 145.209(a). 1.1 General Employees are hired to perform work on civil aviation articles based on their knowledge and experience. An employee’s initial qualifications are determined
by
employment
history,
training,
certification,
knowledge,
experience, and practical tests. Job assignments, including the performance of maintenance, inspection, or supervision, are based on the employee’s qualifications.
Revision Number : 01 "
Date : April 15, 2006
Page : 1
SECTION 1
COMPANY ORGANIZATION
AMO MANUAL
1.2 Organizational Structure PT. Rekatama Putra Gegana’s organization is as shown in the following chart. The chart includes each management position with authority to act on behalf of the AMO.
President Director
Manager of Quality Control
Maintenance Manager
Business and Operational Manager
Propeller Inspection
Propeller Shop
Radio, Instrument and Accessories Inspection
Radio Instrument and Acessories Shop
Purchasing
Emergency Equipment Inspection
Emergency Equipment Shop
Finance
NDT Inspection
NDT Shop
Personel
Specialized Services Inspection
Specialized Services Shop
Receiving Inspection
Technical Publication
Revision Number : 16
Date : March 15, 2010
Marketing Staff
General Affair Manager
IT and Administration
Page : 2
SECTION 1
1.3
COMPANY ORGANIZATION
AMO MANUAL
Key Personnel, Duties and Responsibilities This duties and responsibilities of the individuals that fulfill managerial, supervisory, inspection and maintenance positions in PT. Rekatama Putra Gegana are set forth in this section of the manual. These person will be listed on PT. Rekatama Putra Gegana rooster as set forth in this manual. Additionally, the qualifications for each position are set forth in this manual. The training requirements for each position responsible for performing maintenance, preventive maintenance or alterations will be set forth in a separate section/manual that is specifically approved by the DGCA. One person may fill more than one position. 1.3.1 President Director The President Director is directly in charge as Accountable Manager of the PT. Rekatama Putra Gegana. In addition to the complete administration of PT. Rekatama Putra Gegana, this position will ensure that the PT. Rekatama Putra Gegana continues to comply with applicable government requirements. With respect to the CASRs, the Accountable Manager shall ensure the PT. Rekatama Putra Gegana continues to meet the requirements for providing adequate housing, facilities, equipment, and personnel appropriate to the ratings of the PT. Rekatama Putra Gegana. In addition, the Accountable Manager shall ensure the financial resources are available to adjust to any changes in workload or to adjust the workload to the resources available. In addition to the overall duties and responsibilities listed above, the Accountable Manager has the following specific responsibilities : •
Ensure that all revisions to this manual are coordinated with DGCA.
•
Ensure
adequate
fire-fighting
equipment
is
available
at
PT. Rekatama Putra Gegana. •
Ensure adequate safety precautions are observed by PT. Rekatama Putra Gegana personnel.
Revision Number : 02
Date : December 21, 2006
Page : 3
SECTION 1
•
COMPANY ORGANIZATION
AMO MANUAL
Establish the criteria for hiring personnel for positions responsible for
maintaining,
supervising,
or
inspecting
maintenance
or
alterations of civil aviation articles. •
Establish the requirements for initial and recurrent training for all personnel involved in the maintenance, preventive maintenance, and/or alteration of civil aviation articles.
•
Is incharge of the Corrective Action Program and determines the approriate actions to be taken when deficiencies are discovered or reported.
•
Initiate work outside the AMO’s fixed location as delineated in this manual.
•
Act as the liaison with all customers.
•
Act as the liaison with all Government officials. The
Accountable
Manager
may
delegate
any
duties
and
responsibilities of any personnel of PT. Rekatama Putra Gegana to qualified persons. However delegation of duties does not relieve the specified position of their responsibilities under this manual or CASRs. 1.3.2 Manager of Quality Control The Manager of Quality Control reports to the Accountable Manager and is responsible for the operations of the Quality Control Department. It will be the Manager of Quality Control’s responsibility to: •
Coordinate and distribute revisions to this manual. (Ensure that the manual is kept current and accurate.)
•
Sign the revised list of effective pages of this manual.
•
Coordinate DGCA inspections as delineated in this manual.
•
Respond to any request for inspection of PT. Rekatama Putra Gegana’s certificate.
•
Ensure that the work accomplished outside the AMO’s fixed location is performed in accordance with this manual.
Revision Number : 02
Date : December 21, 2006
Page : 4
SECTION 1 "
•
COMPANY ORGANIZATION
AMO MANUAL
Determine the final disposition of articles failing to meet the incoming inspection review.
•
Determine
equivalency
of
tools
and
equipment
used
by
PT. Rekatama Putra Gegana’s (other than that reccomended by manufacturers) and document that determination. •
Ensure appropriate calibrations and checks are made on the tools and equipment used by PT. Rekatama Putra Gegana (including technician’s personal tools).
•
Ensure records of all calibrations and checks are kept current, and the calibrations are performed in accordance with the standards and procedures described in this manual.
•
Audit all maintenance function contractors before use and maintain the results of those audits.
•
Establish and maintain the AMO employment and training records.
•
Continuously review the PT. Rekatama Putra Gegana’s training program to ensure all PT. Rekatama Putra Gegana’s training needs are met. (If applicable).
•
Perform
PT.
Rekatama
Putra
Gegana’s
“self-evaluation”
to
determine whether it has the housing, facilities, equipment, material, data, and trained personnel to add an article to its Capability List. •
Maintain the AMO roster for the AMO by ensuring that changes in personnel or job duties are reflected on the roster within five (5) business day as required by this AMO manual.
•
Train, direct, supervise and assist all personnel performing work under the AMO certificate as directed by the Accountable Manager.
•
Determine that, if the customer’s work scope is limited in nature, the requested maintenance, preventive maintenance or alteration can be accomplished within the applicable data despite any other damage or discrepancies noted.
Revision Number : 01 "
Date : April 15, 2006
Page : 5
SECTION 1
•
COMPANY ORGANIZATION
AMO MANUAL
Ensure that determinations concerning major alterations/repairs are accomplished as delineated in this AMO manual.
•
Ensure all incoming, hidden damage, preliminary, in-process, and final inspections are performed in accordance with the procedures set forth in this AMO manual.
•
Initiated work outside the AMO’s fixed location as delineated in this AMO manual.
•
Submit reports of serious failures, malfunctions or defects in accordance with the procedures described in this AMO manual. The Manager of Quality Control may delegate duties and
responsibilities to any qualified personnel. Delegation of duties does not relieve the Manager of Quality Control of his overall responsibility under this manual or the CASRs. 1.3.3 Inspectors Personnel performing inspection functions report to the Quality Control Manager and are responsible for performing duties as directed and assigned. Inspector(s) are responsible for performing preliminary, hidden damage, in-process and final inspections on civil aviation articles in accordance
with
manufacturer’s
the
current
instructions
for
technical continued
data
provided
airworthiness,
in
the
service
bulletins, service letters, airworthiness directives, government and industry standard practices, and other data acceptable to or approved by the DGCA. Inspector(s) are specifically responsible for : •
Ensuring that they are thoroughly familiar with the inspection methods, techniques, aids, tools and equipment used within their assigned area of responsibility.
•
Maintaining proficiency in using the inspection aids in their assigned area of responsibility.
Revision Number : 02
Date : December 21, 2006
Page : 6
SECTION 1 "
•
COMPANY ORGANIZATION
AMO MANUAL
Ensuring that the inspection tools and equipment, including inspection aids, used to perform inspections are in proper working order and proper calibration information is affixed.
•
Understanding tolerances,
the
current
limitations,
and
specifications
involving
procedures
established
inspection by
the
manufacturer of the article(s) being inspected. •
Ensure all inspections are properly performed and recorded, and all records are properly executed before final approval for return to service of articles maintained or altered by PT. Rekatama Putra Gegana.
1.3.4 Maintenance Manager The Maintenance Manager reports to the Accountable Manager and is responsible for the operations of the Maintenance Department. It will be the Maintenance Manager’s responsibility to : •
Ensure all personnel are trained in the approriate safety practices and procedures, including proper use and location of fire fighting equipment.
•
Periodically check the fire and safety equipment to ensure serviceability and adequacy.
•
Ensure that the mechanics have the approriate technical data available during the performance of maintenance, preventive maintenance, and alterations activities.
•
Ensure that CASR Part 121, 125, 129 and 135 customer requirements are obtained, made available and followed by inspection personnel.
•
Ascertain qualifications of all technical employees prior to work assignment through tests and evaluation of their previous experience.
•
Train, assist and supervise mechanics in proper work procedures and practices.
Revision Number : 01 "
Date : April 15, 2006
Page : 7
SECTION 1 "
•
COMPANY ORGANIZATION
AMO MANUAL
Ensure the shop equipment and tools are maintained in good working order.
•
Ensure the shop premises are maintained in a clesn and orderly manner.
•
Ensure
that
all
maintenance
or
alteration
processes
are
appropriately completed and documented on the maintenance forms as set forth in this manual. •
Determine whether a hidden damage inspection should be performed,
what
should
be
done
and
properly
perform
maintenance. •
Initiate requisitions for stock as required for the work being performed. The
Maintenance
Manager
may
delegate
duties
and
responsibilities to any qualified personnel. However, delegation of duties does not relieve the Maintenance Manager of his responsibilities under this manual or the CASRs. 1.3.5 Chief Workshops The Chief Workshop is responsible to the Maintenance Manager for the overall operation of the workshop section. In addition the Chief Workshop is responsible for : •
The planning, direction and coordination of activities within the section, and the planning of its activities in conjunction with other sections or department, as required.
•
Assuring that the repair and overhaul of all articles and components within the Chief Workshop jurisdiction is accomplished within the authority of the PT. Rekatama Putra Gegana and that the work is inspected by Quality Control.
•
Training and assisting subordinates in the proper work procedures and practices to be followed.
Revision Number : 01 "
Date : April 15, 2006
Page : 8
SECTION 1 "
•
COMPANY ORGANIZATION
AMO MANUAL
Maintaining all workshop equipment and tools in a serviceable working condition, assuring that periodic checks and calibrations are made on special tools and test equipment and that current records are maintained of those tests and calibrations.
•
Ascertaining that all necessary maintenance entries on maintenance forms and work orders used by PT. Rekatama Putra Gegana are properly executed by the responsibility mechanics.
•
To insure that the workshop section premises are kept in a clean and orderly manner.
•
Initiating purchase requisitions for stock as required.
•
The quality of work performed by the personnel in the workshop section.
•
Making available to the workshop section the required technical data on all articles overhauled or repaired by the workshop section and ensuring that only current data is used. The data will include manufacturer’s
maintenance
and
overhaul
manuals,
service
bulletins, parts specifications, related Directorate General of Civil Aviation approved data and any other technical data used by the PT. Rekatama Putra Gegana. •
The proper handling of all part while in repair process trough the workshop and when work is completed.
•
The maintain of all workshop section records. The Chief Workshops may delegate all duties to any qualified
assistant as necessary, however, such delegation does not relieve the chief workshop of the overall. 1.3.6 Mechanic Personnel assigned maintenance functions duties shall report to the maintenance manager and specifically responsible for : •
Properly executing the duties assigned.
Revision Number : 01 "
Date : April 15, 2006
Page : 9
SECTION 1
•
COMPANY ORGANIZATION
AMO MANUAL
Performing maintenance and alteration tasks on civil aviation articles in accordance with the current technical data provided in the manufacturer’s instructions for continued airworthiness, services bulletins, service letters, airworthiness directives, government and industry standard practices, and other data acceptable to or approved by the DGCA.
•
Ensuring that they are thoroughly familiar with all tools and equipment, including inspection aids, used within their assigned area of responsibility.
•
Properly
record
the
work
performed
on
the
appropriate
maintenance record. 1.3.7 Chief Material The Chief Material reports to the Maintenance Manager and is responsible for the operations of the stockroom. Specifically, it is the Chief Material’s responsibility to : •
Perform the incoming review to identify, control, segregate, and maintain all materials (including raw materials and parts) according to the manufacturer requirements or standard industry practices.
•
Ensure work performed by outside sources and incorporated in articles undergoing maintenance, preventive maintenance, or alteration in PT. Rekatama Putra Gegana was properly performed and documented.
•
Ensure the preservation of all articles or parts, while carried in inventory, including parts that are subject to the deterioration and self-life specification.
•
Execute specified self-life requirements.
•
Ensure the preservation and storage of all materials, parts, and supplies in a condition enabling them to be installed or used on civil aviation articles.
•
Control and distribute the inventory.
Revision Number : 02
Date : December 21, 2006
Page : 10
SECTION 1
•
COMPANY ORGANIZATION
AMO MANUAL
Distribute any technical information, documents or data received through the stock room.
•
Ensure that parts that have been designated as scrap are approriately dispositioned. The Chief Material may delegate duties and responsibilities to any
qualified personnel. However, delegation of duties does not relieve the Chief Material of his overall responsibilities under this manual and the CASRs. 1.3.8 Business and Operational Manager The Business and Operational Manager is responsible to the Accountable Manager for the Business and Operational Department. In addition the Business and Operational Manager is responsible for : •
Develop a business research and business plan for domestic and overseas business/international market.
•
Establish draft maintenance contract and/or agreement dealing with customer under coordination with Quality Control Manager to ensure that contract and/or agreement dealing do not over ride the quality requirements.
•
Check legality of contracts, general terms of agreement and make legal comments/general conditions, terms and their correctness before submitting them for signing off.
•
Keep contracts, general term of agreements and all related documents to be up.
•
Perform business research for the development of potential domestic market and international market.
•
Establish technical handling service agreement with customer.
•
Develop business plan for each customer periodically. The Business and Operational Manager may delegate all duties to
any qualified assistant as necessary, however, such delegation does not
Revision Number : 03
Date : January 29, 2007
Page : 11
SECTION 1 "
COMPANY ORGANIZATION
AMO MANUAL
relieve the Business and Operational Manager of the averall responsibility. 1.3.9 General Affair Manager The General Affair Manager is responsible to the Accountable Manager for the general affair department. In addition the General Affair Manager is responsible for : •
Planning and controlling budgeting of the company, preparing financial report, invoicing policy, debt payment and calculates cost of each department.
•
Planning, coordinating, performing and evaluating human resources management activity covering planning and development of employee and other work relation management in accordance with company policy.
•
Keeping & coordinating facilitate training perform by PT. Rekatama Putra Gegana.
•
To provide adequate housing and facilities including continued maintenance there of. The General Affair Manager may delegate all duties to any
qualified assistant as necessary, however, such delegation does not relieve the General Affair Manager of the overall responsibility. 1.3.10 Technical Publication The person named or an individual delegated that responsibility will : •
Making
available
the
required
manufacturer’s
maintenance
manual, overhaul manual, service bulletin, specification and other technical data. •
Ensuring be maintained current at all times that technical data’s will.
•
Revise the technical data or manuals.
•
Making list current technical data and controlling the updating.
Revision Number : 16 "
Date : March 15, 2010
Page : 12
SECTION 1 "
•
COMPANY ORGANIZATION
AMO MANUAL
Making copies the current technical data and distributed with clearly identifying them it’s controlled copies.
•
Making communications with sources of technical data or manuals if necessary.
If the manual or technical data has been completely revised, old technical data’s shall be destroyed or clearly marked “FOR REFERENCE ONLY”. To prevent access to information that is not maintained current no employee may make a copy of the manuals or pages.
Revision Number : 16 "
Date : March 15, 2010
Page : 13
SECTION 2
HOUSING & FACILITY
AMO MANUAL
Reference : CASR Part 145, Section 145.37 (a) through (f) and Section 145.103 (a)(1)(2). 2.1 Maintenance Facility The PT. Rekatama Putra Gegana Maintenance Facility, DGCA Certificate Approved Maintenance Organization No. 145/14700 is completely housed in an concrete and brick housing with include offices, locate in Jl. Bima No. 90 Bandung. It has total area 788 square meters, consist of : 1. Total Area 788 square maters, alocated for : -
Building area
433 m2
-
Workshop
260 m2
-
Stores
9 m2
-
Office
150 m2
-
Toilet
8 m2
2. Parking area and car port 355 m2 3. Electrical power, water and air pressure -
Electrical power
220 Volt, 380 Volt, 3 Phase 11 KVA
-
Water
Weel with electrical pump, tank capacity 800 ltr
-
Compressed air
Electric compressor 4 PK, 485 lt/min
-
Tank capacity
200 ltr pressure 200 PS
Note : Any changes to the location or in its housing and facility must be approved by the DGCA (Reference : CASR Part 145.105).
Revision Number : 14
Date : February 27, 2009
Page : 1
SECTION 2 " 2.2
HOUSING & FACILITY
AMO MANUAL
Facility Floor Plan
"
Revision Number : 16 "
Date : March 15, 2010
Page : 2
SECTION 3
POLICY AND PROCEDURES
AMO MANUAL
3.1 General This manual describes the housing, facilities, equipment, personnel, and general operating rules pertinent to the operation of PT. Rekatama Putra Gegana, certificated by the Directorate General of Civil Aviation (DGCA) under CASR Part 145. All rating issued to PT. Rekatama Putra Gegana by the DGCA under CASR Part 145 are described in its Operations Specification. This manual includes a description of the policies and procedures that will be used by PT. Rekatama Putra Gegana to meet all requirements of CASR Part 145. The information contained in this manual explains the systems used by PT. Rekatama Putra Gegana when performing maintenance, preventive maintenance or alteration on civil aviation articles. When more detail is required to accomplish or record a particular operation, those details are contained in the applicable
manufacturer
maintenance,
overhaul,
instructions and
repair
for
continued
manuals,
airworthiness
service
bulletins,
e.g.
service
information letters, standard practice manual, Airworthiness Directives, and/or other applicable data acceptable to or approved by the DGCA. The Maintenance, preventive maintenance, or alteration of civil aviation articles will be performed in accordance with the applicable Civil Aviation Safety Regulations (CASRs). PT. Rekatama Putra Gegana will not maintain or alter any article for which it is rated if the appropriate housing, facilities, equipment, personnel, or technical data are not available. The Quality Control Manager is responsible for full compliance with all procedures outlined in this system as appropriate to any item being inspected, repaired, overhauled or altered by PT. Rekatama Putra Gegana. The airworthiness of those items and compliance with their requirements depends upon the compliance activities to the procedures of this system.
Revision Number : 02
Date : December 21, 2006
Page : 1
SECTION 3
POLICY AND PROCEDURES
AMO MANUAL
Reference : CASR Part 145, Section 145.163 (a)(b)(c), Section 145.209 (c) and Section 145.7 (a)(7) 3.2 Manual Revision and Control This Manual will be maintained current at all times. PT. Rekatama Putra Gegana shall assign copies of its manual as required to ensure that all personnel have easy and ready access to it. The Directorate General of Civil Aviation shall be assigned a copy of this manual. A complete list of the assigned copies of the manual can be found in this manual. To prevent access to information that is not maintained current, no employee may make a copy of the manual or pages from the manual, without clearly identifying them as uncontrolled copies. The Accountable Manager is responsible for coordinating all revisions to this manual with the Directorate General of Civil Aviation by forwarding a copy of the contemplated changes thirty (30) days prior to the issuance date for comment. If comments are received, they will be dispositioned in accordance with the Civil Aviation Safety Regulations (CASRs). If no comments are received, the manual revisions will be distributed within fifteen (15) days of final issuance. Distribution to the DGCA will be by first class mail, return receipt requested or electronic mail unless otherwise directed in writing by the Directorate General of Civil Aviation. Upon review by the DGCA or after the thirty (30) days period, whichever is shorter, the Manager of Quality Control shall sign the revised List of Effective Pages to indicate approval before copying, distribution and insertion. The Master Manual shall contain the original documents signed by the Manager of Quality Control. If at any time the DGCA finds any portion of this manual unacceptable due to non-compliance with an enumerated CASRs, PT. Rekatama Putra Gegana shall initiate expedited manual change procedures. The DGCA initiated change shall be accomplished within 15 days of written notification of the noncompliance in accordance with the procedures in this manual. Revision Number : 01
Date : April 15, 2006
Page : 2
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The Manager of Quality Control is responsible for coordinating and distributing revisions to this manual. Revisions will be distributed to all those assigned a controlled copy of the manual, along with an acknowledgement sheet. The person named on the cover of the manual copy, or an individual delegated that responsibility will : a. Revise the manual. b. Make the appropriate entry in the Record of Revisions c. Insert the updated List of Effective Pages d. Sign and return the revision acknowledgement form to the Manager of Quality Control. The individual to whom the manual copy is assigned is responsible for updating this manual, even if the task is delegated. If the Manager of Quality Control does not receive the acknowledgement form within 2 weeks of the revision distribution, he will contact the individual responsible for the manual. If the manual has been completely revised, old manuals shall be destroyed or clearly marked “FOR REFERENCE ONLY.” Reference : CASR Part 145, Section 145.161 through 145.163 3.3 Personnel 3.3.1 Employee Certificates Whenever PT. Rekatama Putra Gegana determines that an individual certificate is required for the performance of duties, it may initiate the application for that employee to become a mechanic certificated under Part 65 of the CASRs. Moreover, PT. Rekatama Putra Gegana will attempt to collect the certificate of any mechanic when they are no longer employed by the company. However, it should be noted that a mechanic certificate is only Revision Number : 01
Date : April 15, 2006
Page : 3
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valid for the work performed within the scope of assigned duties at PT. Rekatama Putra Gegana. 3.3.2 Employee Qualifications Employee are hired to perform maintenance on civil aviation articles based upon their knowledge and experience. The employee’s initial qualifications
are
determined
by
employment
history,
training,
certification, knowledge, experience, and practical tests. Job assignments, including the performance of maintenance, inspection or supervision, are based upon the employee’s initial qualifications. Additionally, the employee qualifications listed in this manual will be the basis for determining the initial and recurrent training requirements. 3.3.3 Mechanic Prior to being authorized to perform supervised maintenance, preventive maintenance, or alterations duties, PT. Rekatama Putra Gegana shall determine that the individual : a. Has experience, through training, knowledge, employment history or practical tests necessary to perform the scope of work assigned. b. Is proficient in using the tools, equipment, and inspection aids applicable to the scope of work assigned. c. Understands the methods, techniques, and practices outlined in the manufacturer’s maintenance documents, and other data acceptable to or approved by the DGCA. d. Understands the procedures set forth in this manual for documenting the work performed.
Revision Number : 02
Date : December 21, 2006
Page : 4
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POLICY AND PROCEDURES
AMO MANUAL
3.3.4 Rosters and Roster Records a. Roster Records PT. Rekatama Putra Gegana maintains a roster of all managerial,
supervisory
and
inspection
personnel
that
have
responsibility for compliance with the CASRs. For each person on the roster, PT. Rekatama Putra Gegana maintains current the following information : •
Present title and scope of employment.
•
Total years of experience in the type of work assigned by reference to the date the experience started.
•
Employment history, including name of previous employer and length of employment by month and year.
•
Type and number of any certificate held along with any ratings or limitations. PT. Rekatama Putra Gegana, through the Quality Control
Manager, will revise the roster within 5 business days in the following situations: •
Termination of employment.
•
Assignment of a new person to the inspection team.
•
Changes in current title or scope of employment.
•
Personnel additions.
The Quality Control Manager will maintain the roster and make it available for review by all employees. b. PT. Rekatama Putra Gegana Roster PT. Rekatama Putra Gegana shall keep a roster for managerial, supervisory, and inspection personnel that will include the name of individual, the individual’s title, the person’s inspection authority (preliminary, in-process, final and approval for return to service) and/ or responsibility (management or technical supervision) and a sample of the person’s stamp, initial or signature. Revision Number : 01
Date : April 15, 2006
Page : 5
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The Quality Control Manager is responsible for ensuring the roster is kept current. Each supervisor and manager who becomes aware of a change in personnel, termination or change in assignment that would affect the roster must notify the Quality Control Manager by e-mail, telephone or in-person. The Quality Control Manager will obtain the required information necessary to update the roster within five (5) business days of any change. 3.3.5 Training Program The Quality Control Manager is responsible for managing the training program and will be responsible for ensuring that revisions are submitted to DGCA for review and approval. All training program in PT. Rekatama Putra Gegana will be accomplished by resources management or manufacturer field service representative under coordination with PT. Rekatama Putra Gegana management or other qualified training center, except for the inspection personnel training program is established by chief inspector of PT. Rekatama Putra Gegana to improve the specialized skills for supporting function of the maintenance workshops. To achieve the quality standard, it is needed to create a development program plan of training method, establish a guideline for the qualification and certification personnel, which is expected to give an optimal achievement of the results. PT. Rekatama Putra Gegana’s Accountable Manager is responsible for ensuring that adequate numbers of personnel are available to accomplish the types of work authorized under the AMO certificate. These personnel must have detailed knowledge of the particular maintenance function or technique they are involved in, based on formal training or extensive experience. All employees, including inspection personnel, shall receive training as determined necessary for the qualifications and performance of their Revision Number : 02
Date : December 21, 2006
Page : 6
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AMO MANUAL
work assignment. Initial and/or recurrent training may be required as determined by the nature of the work, the qualifications necessary for the position, experience, knowledge, certification, and previous training of the individual. Training may be on the job or by classroom instruction. All employees shall receive continual on the job training on parts handling, cleaning, and identication; the requirements of this manual and standard practice manuals relating to their job assignment; the general policies and procedures of this AMO and the applicability of the CASRs to the work performed by PT. Rekatama Putra Gegana. To support this process, PT. Rekatama Putra Gegana maintains in its personnel records the basic qualifications, training, and experience of its maintenance technicians, supervisors, and managers. The records shall indicate the type of training method, duration of each session, date each segment or session was completed, the location of each session, any certificates received, completion or passage or any testing of any required, the name of the trainer or instructor and his qualifications if pertinent. Most training will be recorded on the appropriate AMO, however, any documentation establishing the information listed above may be used to the determine an employee’s qualifications for any job assignment. Training records will be maintained as long as the individual accomplishes work for PT. Rekatama Putra Gegana and for at least 2 years thereafter. When PT. Rekatama Putra Gegana’s maintenance Training Program becomes an DGCA-approved program, all revisions must also be approved by the DGCA before implementation. The Manager of Quality Control is responsible for continuously evaluating the training program to ensure it meets all of PT. Rekatama Putra Gegana’s needs and the applicable CASRs. If a change is required or desirable, the Manager of Quality Control will develop a proposed
Revision Number : 02
Date : December 21, 2006
Page : 7
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revision to the training program and transmit it to the Accountable Manager for approval. Once approved by the Accountable Manager, a copy of the draft revision will be sent to the DGCA Office with oversight responsibility for PT. Rekatama Putra Gegana for approval. After receiving DGCA approval, the Manager of Quality Control will create a final manual revision, taking into account any DGCA recommendations or requirements. The revision will then be distributed in a manner similar to the distribution of this manual. 3.3.6 Inspection Personnel Inspection personnel are required to be adequately trained and qualified to support the various maintenance activities. Such training shall be in accordance with the policies and procedures as laid down in par 3.3.5 Training Program. Apart from above training, inspection personnel are required to be thoroughly familiar with all inspection methods, techniques and equipment used in their area of responsibility to determine the quality of airworthiness of an article undergoing maintenance, repair or alterations. All personnel must also maintain proficiency in the use of the various types of inspection aids to be used for inspection of the particular items undergoing inspection. Available data for all inspection personnel are current specifications involving inspection tolerances, limits, and procedures as set forth by manufacturer of the product undergoing inspection and other forms of inspection information such as DGCA airworthiness directives, manufacturer’s service letters etc. Files of maintenance manuals, engineering letters, service letters, etc. are maintained in the applicable work areas and the master copies are held in Quality Control Manager office. All inspection personnel of PT. Rekatama Putra Gegana are required to be thoroughly familiar with the requirements of this manual, DGCA Revision Number : 02
Date : December 21, 2006
Page : 8
SECTION 3
POLICY AND PROCEDURES
regulations,
airworthiness
directives
AMO MANUAL
and
advisory
circulars,
manufacturer’s service letters and bulletins and engineering orders. The basic inspection system requires workshop mechanic to sign their last name for work performed by them prior to submitting the item to inspectors for final acceptance. Inspectors will indicate their acceptance of work performed by using the inspector’s acceptance stamp next to the item on the work forms. Reference : CASR Part 145, Section 145.209(d) and 145.215 3.4 Certificate Limitations and Privileges PT. Rekatama Putra Gegana may maintain and alter any of the articles covered by its ratings and approve for return to service those articles. If there are any special technical data, equipment, personnel or facilities required, PT. Rekatama Putra Gegana must also have those available. For work that PT. Rekatama Putra Gegana accomplishes at a location other than its fixed location, it must follow the procedures described in this manual. All major repairs and major alterations must be accomplished with data approved by the DGCA. PT. Rekatama Putra Gegana AMO with limited rating will perform maintenance, preventive maintenance, or alteration if it is listed on a current capability list acceptable to the DGCA or on the AMO’s Operation Specifications (Appendix 1 Capability List). The Quality Manager will be conducting self-evaluation for each revision on capability list (use form capability evaluation), to determine that PT. Rekatama Putra Gegana has all of the housing, facilities, equipment, materials, technical data, process, and trained personnel in place to perform the work on the article as required by CASR Part 145.
Revision Number : 02
Date : December 21, 2006
Page : 9
SECTION 3
POLICY AND PROCEDURES
AMO MANUAL
Upon listing an additional article on its capability list, the Quality Manager will be notifying DGCA and provide the copy of the revised list for DGCA acceptance. Reference : CASR Part 145, Section 145.203 3.5 Performance of Work at a Location Other Than the Approved Maintenance Organization Generally, PT. Rekatama Putra Gegana does not perform maintenance, preventive maintenance, or alteration at a location other than its fixed location. If a customer requests such a work, PT. Rekatama Putra Gegana will notify the DGCA in writing, explaining the circumstances triggering the need to work at a location other than the AMO fixed location. The request and approval documents shall then be filed in the articles work order package. The Manager of Quality Control is responsible for ensuring that the above steps are followed. PT. Rekatama Putra Gegana will perform work away from its fixed location on a recurring basis. This work will be performed under the procedures set forth in this manual. Only the Accountable Manager or Quality Control Manager may initiate the forms associated with performing work at a location other than the AMO. It should be noted, however, that the work order package may be initiated and completed after the maintenance has been accomplished and will include only those forms applicable to the job work scope. The work scope shall be limited to those maintenance or inspection actions that can be accomplished with personnel, equipment, material, tooling, and technical data that can be transported to or are available where the maintenance will be performed. Therefore, upon initiation of a request for offlocation work, the Accountable Manager or Quality Control Manager shall request that the customer provide as detailed a description as possible of the Revision Number : 02
Date : December 21, 2006
Page : 10
SECTION 3
POLICY AND PROCEDURES
AMO MANUAL
discrepancy(ies), as well as the location of the article. This information shall be recorded along with a list of the required personnel, equipment, tooling, and data needed to accomplish the anticipated work scope. Only mechanic specifically familiar with and capable of performing the work scope anticipated shall be assigned to perform the maintenance requested. The Accountable Manager or Quality Control Manager will assign the technicians. The Accountable Manager or Quality Control Manager shall ensure that the personnel, equipment, tooling, and data necessary to accomplish the requested work scope (including the pertinent sections of this manual) are made available to the mechanic. The Accountable Manager or Quality Control Manager shall ensure that there is adequate and continual communication between the mechanic in the field and the AMO. Upon arrival, the mechanic shall determine that the location where the work is to be performed is safe and protected from the elements as required by the applicable maintenance data. The exact location of where the work is actually performed shall be documented. If any equipment is used during maintenance other than that originally listed by the Accountable Manager or Quality Control Manager, the technicians will record the use of that equipment by listing that by nomenclature, type, manufacturer, and date of last calibration, as applicable. Documentation of the work performed may be recorded in the aircraft and/ or propeller log in accordance with CASRs. However, a record of the work performed shall also be entered for inclusion into the Work Order Package which will be generated, to the extent necessary, in accordance with the procedures outlined in this manual. Normally, a Form RPG 06 Work Order will not be generated for work performed at a location other than the AMO. However, if a Form RPG 06 Work Order is generated, it will be completed as outlined in this manual. Any article or part thereof removed from the outside location and transported to the AMO for a more complete work scope, shall be routed
Revision Number : 01
Date : April 15, 2006
Page : 11
SECTION 3
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through the repair station in accordance with the procedures set forth in this AMO manual. Reference : CASR Part 145, Section 145.223 3.6 Inspection by The DGCA PT. Rekatama Putra Gegana will allow the DGCA to inspect the inspection system, records, and procedures to determine compliance with CASRs at any reasonable time. PT. Rekatama Putra Gegana will ensure, through the wording in its contract/purchase orders with any individual or organization to whom it contracts maintenance functions which does not hold an DGCA certificate, that the DGCA is permitted to inspect that contractor while work is being performed on the AMO’s behalf. Any required coordination during DGCA inspections will be responsibility of the Manager of Quality Control. This function may be delegated as approriate. Reference : CASR Part 145, Section 145.103 through 145.109 3.7 Maintenance of Personnel, Housing, Facilities, Equipment, Materials, and Technical Data PT. Rekatama Putra Gegana shall maintain personnel, housing, facilities, equipment, materials, and technical data at least equal in terms of quality and quantity as when they were found by the DGCA to meet applicable requirements for the issuance of the certificate and ratings. Additional and more detailed information concerning personnel, housing, facilities, equipment, materials, and technical data can be found in this manual.
Revision Number : 02
Date : December 21, 2006
Page : 12
SECTION 3
POLICY AND PROCEDURES
AMO MANUAL
Reference : CASR Part 145, Section 145.5 3.8 Availability of Certificate PT. Rekatama Putra Gegana certificate shall be made available to the public and the DGCA for inspection. The Manager of Quality Control is responsible for responding to such DGCA requests. Reference : CASR Part 43, Section 43.9 CASR Part 145, Section 145.209(i) and 145.219 3.9 Record of Work A detailed record of all work performed by PT. Rekatama Putra Gegana shall be maintained for each article undergoing maintenance or alteration. The description of the work performed shall be set forth in the work order package documents (use Form RPG 08 Shop Activity Report). All steps in each work order package document shall be completed or determined to be inapplicable to the scope of work requested by the customer. If any steps that are on standard forms are found to be inapplicable, they will be crossed out and initialed by the individual making that determination. Also, a brief explanation of why the step is inapplicable will be noted. Documents will be completed by the persons performing each work step described. Completion of work step will be indicated by the person performing the step initialing, signing or stamping the appropriate place on the document. Inspectors shall indicate the acceptance of the work or inspection performed by affixing their initials, signature or stamp next to the technicians on the work order package document. All records of work performed, including records of work performed by outside sources, shall be retained in the work order package file for not less than two years from the date the article was approved for return to service.
Revision Number : 14
Date : February 27, 2009
Page : 13
SECTION 3
POLICY AND PROCEDURES
AMO MANUAL
Reference : CASR Part 145, Section 145.221 3.10 Reports of Serious Failures Malfunctions or Defects 3.10.1 Definition A serious failure, malfunction or defect is one that is not covered or contemplated by a manufacturer’s instructions for continued Airworthiness (e.g., repair, maintenance or overhaul manuals), Service Bulletins, service letters, Airworthiness Directive, and/ or other data acceptable to or approved by the DGCA. 3.10.2 Responsibility The Quality Control Manager is responsible for the proper and timely filing of reports on serious failures, malfunctions or defects. These reports will be made within ninety-six (96) hours after discovery on a form and in a manner acceptable to the DGCA and describe the condition completely, without with holding any pertinent information. 3.10.3 Special Circumstances If the report may prejudice PT. Rekatama Putra Gegana, the Quality Control Manager will notify the responsible DGCA office and develop with them and appropriate disposition consistent with the CASRs. If the condition could result in an imminent safety hazard to flight, the DGCA office will be provided a preliminary report via telephone or electronic means.
Revision Number : 02
Date : December 21, 2006
Page : 14
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AMO MANUAL
Reference : CASR Part 145, Section 145.215(c) 3.11 Establishment and Revision of Capability The Quality Control Manager is responsible for insuring that the AMO Certificated Capability List is consistent with the AMO ratings. Before placing an article on the capability list, the Quality Control Manager will : 1. Determine that the article is within the scope of the AMO ratings. 2. Perform self evaluation to determine that this AMO has the appropriate housing, facilities, equipment, material, technical data, processes and trained personnel to perform the work on that article as required by CASR Part 145. 3. Document the results of the self evaluation. 4. Keep a copy of the self evaluation assesment on file. 5. Coordination with DGCA. The Quality Control Manager will review and approve the evaluation before establishing or revising the Capability List. The Capability List is a controlled document, and once and initial list or revision has been approved by Quality Control Manager it will forwarded to the DGCA within seven days of creation or revision.
Revision Number : 02
Date : December 21, 2006
Page : 15
APPENDIX 1
CAPABILITY LIST
AMO MANUAL
See related document of PT. Rekatama Putra Gegana’s Appendix 1 List of Current Capability in accordance with Shop Capability Self Evaluation which has been approved by DGCA.
Revision Number : 10
Date : December 12, 2007
Page : 1
ROSTER OF AUTHORIZED PERSONNEL
APPENDIX 2
AMO MANUAL
Reference : CASR Part 145, Section 145.161 NO
NAME
POSITION
DGCA LICENCY A1, A4
AREA OF RESPONSIBILITY Return to Service and All Inspector
1
Indra Setiawan
Manager of Quality Control
2
Kaidjo
Propeller Inspector
A1, A3, A4, C2
Propeller Shop
3
Agus Rachman
Radio, Instrument and Accessories Inspector
C4
Radio, Instrument and Accessories Shop
4
Rudi Tarudi
Emergency Equipment Inspector
A1, A4
Emergency Equipment Shop
5
Dadang Hermawan
NDT Inspector
All area (Intern and Extern Shop)
6
Djoko Sumbarto
NDT Inspector
7
Ojon Darjana
Specialized Service Inspector
NDT Level II for U, E, P, M Methode NDT Level II for U, P, M, X, E Methode -
8
Rudi Tarudi
Chief Material
A1, A4
SIGN
STAMP
All Area (Intern and Extern Shop) Specialized Service Shop Receiving and Storage
Note : AUTHORIZE PERSONNEL STAMP Has two (2) type of stamp used in PT RPG issued to authorize personnel or inspectors with red ink. Type 1 : The Stamp circle from 10 (ten) mm diameter with RPG Word and numbering 3 (three) digits started from No. 001 locate inside of circle. This stamp is used both release work accomplishment and/or release certificate. e.g :
RPG 001
10mm
Type 2 : The stamps pentagon form with RPG Word and numbering 3 (three) digits, located inside of pentagon. This stamp is used to release work accomplishment. e.g : RPG 003
10mm
Revision Number : 16
Date : March 15, 2010
Page : 1
APPENDIX 2
ROSTER OF PERSONNEL
1
Suyoso
President Director
-
AREA OF RESPONSIBILITY All
2
Doddy Priabudi
A1, A4, C1
Bussiness
3
Indra Setiawan
Bussiness and Operational Manager Maintenance Manager
-
All Maintenance Shop
4
Indra Setiawan
Chief of Propeller
-
Propeller Shop
5
Gunadi
-
Radio, Instrument and Accessories Shop
6
Tarwo
-
Emergency Equipment Shop
7
Djoko Sumbarto
Chief of Radio, Instrument & Accessories Chief of Emergency Equipment Shop Chief of NDT Shop
NDT Shop
8
Handi Hardian
Chief of Specialized Service Shop
NDT Level II for U, P, M, X, E Methode -
9
Fudin
Technical Publication
NO
NAME
DGCA LICENCY
POSITION
Revision Number : 16
-
AMO MANUAL
SIGN
Chief of Specialized Service Shop
Technical Publication
Date : March 15, 2010
Page : 2
© PT. Rekatama Putra Gegana