The new rule that controls what the repair station manual must contain is §145.209. We will go over it in detail, but while this is not a FAA requirement I recommend that before you jump into writing the sub-parts or chapters in your manual that you first provide the reader with an overview of what services the repair station provides, how it is organized, as well as company goals and objectives. Also include the name of the accountable manager, and department supervisors and their telephone and fax numbers. Why? Not only will the repair station manual be mandatory reading for all new and current employees, but it will be read by other organizations who may want to contract out your services. This is a good spot to fluff up your feathers and tell the world just who and what you are.
Sub-part A: General: ref: §145.209 (a)
1. Describe how each manual is revised, identified, distributed, controlled, who is responsible for these actions, and how each revision is controlled and recorded.
2. Make an FAA control page for each manual and list, so the FAA inspector can sign acceptance of the original manual(s) and revisions.
3. Describe procedures and feedback system to ensure that every manual has received and incorporated the latest revisions.
4. Give the number of manuals that will be used, how they are identified, and where they are physically located.
5. List the name of the individual(s) who are responsible to revise these manuals and lists (ref: §145.209(b)).
6. List the maximum amount of time allowed to revise all of the repair stations manuals (ref: §145.209(j)).
7. Describe procedures on how to revise the manual(s) and list(s) and how often the FAA will be notified of these revisions (ref: §145.209(k)).
8. Make a statement that the repair station will not operate or perform any maintenance unless properly certificated. Also point out where the repair station certificate and operation specifications are displayed (ref: §145. 5).
9. List the repair station's ratings (ref: §145.59 or 61 as applicable).
Sub-part B: Certification:
1. I would include a copy of the certification paperwork (ref: §145.51). This is not required, but might come in handy in the future.
2. Create an organizational chart that: (ref: §145.209(a))
a. Identifies each management position who can act for the repair station;
b. Includes area of responsibility assigned to each management position;
c. Describes duties and responsibilities of each position.
3. Can your brother-in-law understand the chart?
4. Are the titles in the organizational chart consistent with the titles and authority in the rest of the manuals?
5. Does the chart clearly show the separation of maintenance and inspection departments if applicable?
6. Describe how the repair station will address a change to its certificate, either an addition or removal of ratings, or transfer of assets (ref: §145.57).
7. A list, or reference to a list, that identifies by type, make, or model as appropriate of each article to be worked on (ref: §145.51(a)(3)).
8. Location of the quality control manual (§145.51(a)(3)).
9. Location of the training manual (§145.1).
10. Location of a list that identifies work that is contracted out to FAA repair stations or uncertificated persons.
11. A statement that says the repair station certificate must be returned to the FAA if the certificate is surrendered, suspended, or revoked (§145.55).
Sub-part C: Housing facilities, equipment, materials, and data: Ref: §145.101, 103, and 209 (c)
Describe, in paragraph form, an outline of the repair station facilities, its equipment, materials, and data used when the work is being done, and include the following:
1. A scaled drawing of the facilities, listing square footage for each work and segregated areas.
2. Identify all segregated work areas such as painting, battery charging stations, electronic work, parts room, welding, etc.
3. Identify areas where parts are in storage, awaiting maintenance, shipping, or in stock.
4. Identify the ventilation, lighting, temperature, and humidity controls including any special environmental conditions.
5. Identify the number of racks, hoists, trays, stands, benches, hydraulic mules, test equipment, etc.
6. Identify the kind and type of data available and if data is supplied by another party, how that is accomplished and kept current and who is responsible (§145.109(d)).
7. Identify how life-limited parts/stock items will be controlled and who is responsible.
8. Describe the stock/tool room operations, ordering of parts, the calibration of the special tools. How they are accomplished, tracked, and who is responsible (§145.109(b)).
9. If the repair station leases or rents equipment or tools, how is that handled, who is responsible, and how are items transferred.
10. If the repair station makes its own special tools, identify the procedures or data for determining that those tools are equal to the manufacturer's. Who makes that decision? (ref: §43.13 and §145.109(c)).
11. If the repair station has an airframe rating, it must make a statement that the facilities are big enough to fully enclose the largest make and model aircraft that is listed on its operating specifications (ref: §145.103(b)).
12. If work will be accomplished outside of its facilities, the repair station must list procedures, equipment, and facilities acceptable to the FAA (ref: §145.103(c)).
13. Describe how the repair station will operate if the repair station is changing its facilities, location, or housing (ref: §145.105).
Editor’s Note: In the February issue Bill O’Brien began a discussion on the new regulations for the Part 145 manual requirements.
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