Ano-002-Awrg-2.0 DT 4th April 2011

APPROVAL OF ORGANIZATION (MANUFACTURING)
AIR NAVIGATION ORDER
VERSION : DATE OF IMPLEMENTATION : OFFICE OF PRIME INTEREST : 04/04/2011
2.0 04-04-2011 AIRWORTHINESS DIRECTORATE ANO-002-AWRG-2.0
APPROVAL OF ORGANIZATIONS (MANUFACTURING)
04/04/2011
ANO-002-AWRG-2.0
A.
AUTHORITY:
A1. This Air Navigation Order is issued by Director General Civil Aviation Authority in pursuance of Rules 4, 5, 23, 25, 180, 334(7), 360 and all other enabling provisions of the Civil Aviation Rules, 1994 (CARs, 94).
B.
PURPOSE:
B1. The purpose of this ANO is to provide methods, acceptable to the Director General, for showing compliance with the manufacturing organization certificate required under Rule 23 of Civil Aviation Rules 1994.
C.
SCOPE:
C1. This ANO is applicable to all organization seeking having approval of PCAA for manufacturing of aircraft or its equipment.
D.
D1.
DESCRIPTION:
DEFINITIONS:
D1.1 The following terms when used in this ANO, have the meanings assigned to them respectively. Any term used in this ANO but not defined, shall have the same meaning as given in the Civil Aviation Ordinance, 1960, Pakistan Civil Aviation Authority Ordinance 1982, CARs, 1994 and relevant ICAO Annexes. D1.1.1 Amended Certificate of Type Approval: The holder of a Certificate of Type Approval (CTA) may apply for an amendment of the original Certificate of Type Approval (CTA) when the change to the type design is not so extensive as to require a new Certificate of Type Approval (CTA), and is classified as "major". Only a Certificate of Type Approval (CTA) holder may apply for a Certificate of Type Approval (CTA) amendment. D1.1.2 Appliances: Any instrument, mechanism, equipment, part, apparatus, appurtenance or accessory, including communication equipment, that is used or intended to be used in operating or controlling an aircraft in flight, as installed in or attached to the aircraft and is not a part of an airframe, engine or propeller. D1.1.3 Articles: A material, a component or an assembly used in a part as specified in the approved design data. D1.1.4 Certificate of Type Approval (CTA): A Certificate of Type Approval (CTA), as defined by CAR 94 rule 18A and 18B, includes the type design, the operating limitations, the Type Certificate Data Sheet (TCDS), the applicable regulations, and any other conditions or limitations prescribed by the Director General. D1.1.5 Manufacturer: The holder of a Certificate of an Organization Approval under CAR94 Rule 23(2) and of a Certificate of Type Approval (CTA), producing duplicate products in accordance with CAR94 Rule18A and 18B. D1.1.6 Major Modification: A major modification is a modification that is not listed in the aircraft, aircraft engine, or propeller specification: (1) that might appreciable affect weight, balance, structural strength, performance, powerplant operation, flight characteristics, or other qualities affecting airworthiness; or (2) that is not done according to acceptance practices or cannot be done by elementary operations. 04/04/2011 Page 1 of 33 ANO-002-AWRG-2.0
D1.1.7 Minor Modification: A minor modification is a modification that is other than a major modification. D1.1.8 Minimum Equipment List (MEL): is a list, contained in an aircraft Flight Manual or equivalent certification document, which specifies the minimum scale of equipment in an aircraft which must be serviceable for the aircraft to carry out specified operations. D1.1.9 MMEL: Master Minimum Equipment List
D1.1.10 Production Certificate: A Production Certificate is an authorization by the PCAA for a manufacturer to manufacture a product in compliance with the Civil Aviation Regulations. A PC may be versioned to either the holder of a CTA, a STC, or to a licensee of a CTA holder, who meets the requirements of rules 23 of CAR94. D1.1.11 Provisional Certificate of Type Approval (PCTA): A Provisional Certificate of Type Approval (CTA) may be versioned when all requirements for a Certificate of Type Approval (CTA) are not complete but the applicant can show compliance with CAR94. D1.1.12 Product: A product is an aircraft, an aircraft engine, or propeller. In regards to export airworthiness approvals, it includes components and parts of aircraft, of aircraft engines, and of propellers; also parts, materials, and appliances, approved under the Technical Standard Order (TSO) system. CTAs are only versioned for aircraft, aircraft engines and propellers. D1.1.13 Type Acceptance Certificate (TAC): Type Acceptance Certificate is versioned on the basis of accepting the Type Certificated versioned by another Contracting State. D1.1.14 Supplemental Type Certificate (STC): A STC is versioned for major design changes to a Certificate of Type Approval (CTA) when the change is not so extensive as to require a new Certificate of Type Approval (CTA). Minor changes do not require an STC. Any person may apply for a STC. D1.1.15 Supplier: Any person who furnishes articles or services related to the manufacturer of typecertificated products.
D2.
APPROVAL PROCEDURE:
D2.1 Application for approval shall be made in duplicate on PCAA form CAAF-101-AWXX available at PCAA web site www.caapakistan.com.pk. Copies of the form may be obtained from the local airworthiness field offices, which when completed, should be returned to the same address along with the following:D2.1.1 Company exposition manual (Refer Para D5 & D6 for details). D2.1.2 Capability list for which approval is required. D2.1.3 Fee as per latest version of Airworthiness Notice No AWNOT-003-AWXX.
Note:
In case the organization provides the technical literature in a form other than hard copies, then means of reading / printing the technical literature will also be provided by the organization.
D2.2 The certificate of approval shall be versioned on CAAF-001-AWXX along with the approval schedule CAAF-002-AWXX. The approval shall be valid for such period as specified therein, not exceeding one year. The organization shall be allocated a CAA organization approval number. This will be used for identification purpose in PCAA publications, letters and any other documents which are related to approval matters. The Certificate of Approval shall be DISPLAYED in a prominent location of
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the approved premises, whereas the approval schedule (CAAF-002-AWXX) shall be submitted to the airworthiness directorate at the time of renewal. D2.3 The airworthiness directorate shall have the right to witness tests or inspections in anyway associated with establishing the airworthiness of an aircraft, engine and equipment or any part thereof appropriate to the approval. D2.4 An approved manufacturing organization shall at all reasonable times permit all premises, product and records relevant to airworthiness to be inspected by PCAA authorized person(s), to determine whether the limitations, conditions and requirements relating to the grant or continuance of approval are being complied with. Detailed audit / inspection of the organization shall be carried out at least once a year by the Airworthiness field office of the area indicated in the checklist (Refer Para D15 Safety Audit and APPENDIX A). Non-conformance and observations pointed out during the audit / inspection are to be rectified with in the time specified. D2.5 The organization shall be maintained to the standard necessary to undertake the work for which it is approved, and the airworthiness directorate shall at all reasonable times, have access to the organization for the purpose of assessing the standard at any given time. D2.6 The airworthiness directorate shall be consulted where there is any difficulty about the interpretation of the requirements, the associated procedures, or on any airworthiness matter which in the opinion of the organization involves new procedures or techniques.
D3.
GRANT OF APPROVAL:
D3.1 In order to enable an assessment of the suitability of an organization for approval, the applicant shall comply with the requirements of this Air Navigation Order. The information provided by the organization, including the organization procedures, shall be evaluated against the company exposition manual, PCAA rules and relevant documents. When assessing an organization for approval, the airworthiness directorate will examine the systems used to control all manufacturing activities. This will include, where applicable:D3.1.1 D3.1.2 D3.1.3 D3.1.4 D3.1.5 D3.1.6 D3.1.7 D3.1.8 Organization structure. Manufacturing Process Sheet (MPS) of each part. Co-ordination within and between departments on airworthiness / manufacturing matters. Capability list with reference to their shops. Qualifications and experience of engineering management. Number and experience of engineering staff, both departmentally and in total. Working hours of the engineering staff with reference to their task. Procedures for the authorization of persons to carry out certifications, including training programs, required standards, examination procedures, records and the associated methods of control. The system by which the continuing validity of personal authorization certificates are assessed and subsequently revoked for any reason. Planning of manpower allocation and control. The implementation, review and amendment of the approved exposition manual. The procedures for the issuing service bulletins, modifications and manufacturer's technical information. The management and operation of reliability programs. System for implementation of the required action as a result of the reliability analysis. Page 3 of 33 ANO-002-AWRG-2.0
D3.1.9 D3.1.10 D3.1.11 D3.1.12 D3.1.13
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D3.1.14 D3.1.15 D3.1.16 D3.1.17 D3.1.18 D3.1.19 D3.1.20 D3.1.21 D3.1.22 D3.1.23 D3.1.24
Facilities and equipment. Component and material control. Technical records (Refer Para D 321. Technical publications and drawings. Concession assessment and implementation instructions. Feed back from operators, defect control and management system. Specialized support arrangements e.g. non-destructive testing. Storage facilities and procedures. Quality control and assurance. Details of weight and balance control system, if any Any additional information relevant to approval requested.
D4.
MANUFACTURING ORGANIZATION EXPOSITION MANUAL:
D4.1 An applicant applying for a manufacturing organization certificate is to develop an exposition manual. The purpose of an exposition manual is to show the details of the organization and means by which the organization will define its operation. Furthermore, it shows both its employees and the PCAA how it will conduct its day-to-day business in compliance with PCAA rule and regulations. D4.2 An exposition manual must assure the PCAA that the organization is in documentary compliance with the rules. Hence before the PCAA allows an organization to entry into the system, the exposition manual must be accepted by the Director General.
D5.
MAKING OF EXPOSITION MANUAL:
D5.1 An exposition manual may be produced as a single volume or any number of separate manuals depending on an organizations structure and size. Separate manuals should cover the following chapters:D5.1.1 Management and Policy. D5.1.2 Personnel. D5.1.3 Manufacturing Procedures. D5.1.4 Stores. D5.1.5 Document control. D5.1.6 Quality Assurance. D5.2 If the exposition manual comprises more than one volume, the make up of the exposition manual and the content of individual manuals must be described in the management part of the exposition manual. D5.3 Procedures should be established to ensure Managers hold copies of those parts of an exposition manual which affect their areas of responsibility and staffs are familiar with those parts of an exposition manual which affect their area of employment. D5.4 The applicant shall provide three copies of an exposition manual to PCAA which shall include information on the subjects detailed below (also refer APPENDIX B):
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D5.4.1 A statement signed by the Chief Executive confirming that the exposition manual defines the organizations procedures and associated personnel responsibilities, and will be complied with at all times. D5.4.2 A list of the persons nominated in accordance with this ANO. D5.4.3 The terms of reference of the persons nominated in accordance this ANO, as applicable to the activities covered by the approval. The specific subjects on which these persons are authorized to deal directly with the Airworthiness Directorate shall be defined within the terms of reference. D5.4.4 An organization chart showing the associated chains of responsibility of the persons nominated in accordance with this ANO. D5.4.5 Details of the facilities used for manufacturing the products together with information on the availability of equipment. D5.4.6 Quality control, directly affecting continuing airworthiness. D5.4.7 Details of training programs for personnel appropriate to the approval, together with details of the training facilities which will be used (Refer latest version of ANO -008-AWXX). D5.4.8 Any further matters which the Airworthiness Directorate prescribes as a result of initial assessment. D5.5 The exposition manual shall be reviewed periodically by the organization. Changes arising from the review and changes arising from supervisory visits by the Airworthiness Directorate shall be forwarded to the Airworthiness Directorate for approval. D5.6 The organization shall ensure that the exposition manual is amended as necessary to keep the information contained therein up-to-date and copies of all amendments shall be furnished promptly to all the organizations or persons to whom the manual has been versioned. D5.7 The organization shall provide to Airworthiness Directorate with a copy of organization exposition manual together with all amendments and / or revisions to it and shall incorporate in it such mandatory material as Airworthiness Directorate may require. D5.8 The version of manufacture organization approval by PCAA shall dependent upon the applicant demonstrating compliance with the requirements laid down by PCAA for such organization. Note: PCAA approved organizations when undertaking work outside their terms of Approval is deemed to be unapproved.
D6.
EXPOSITION MANUAL ACCEPTANCE:
D6.1 The acceptance of an organizations exposition manual by the Director General will be one step in the process of the approval. After the acceptance of the exposition manual, an audit will be conducted with reference to the exposition manual and other relevant rules. Only after the satisfactory report of the audit, the Manufacturing Organization Certificate can be versioned. Evidence of acceptance of the exposition is the version of a certificate; however the PCAA will normally stamp the pages of the exposition manual to signify that they have found the exposition acceptable at a particular status.
D7.
MULTIPLE CERTIFICATIONS:
D7.1 When an organization seeks certification under more than one Civil Aviation Rule Part each of which requires an exposition manual, it may be possible for some parts of the exposition manual to be common to each certificate. 04/04/2011 Page 5 of 33 ANO-002-AWRG-2.0
D7.2 For instance, if the same management set-up is used for each certificate, the management and policy part of the exposition manual could be common. Equally, all of the quality assurance procedures for one or more certificates could be placed in one manual. D7.3 Whatever format of exposition manual is chosen, it must be possible to clearly show how the requirements of each Part are satisfied. It is desirable that a compliance matrix is provided showing where compliance is shown in the exposition manual for each Part. This matrix should distinguish between those requirements which are common and those which are specific.
D8.
D8.1
PRIVILEGES OF THE APPROVAL:

The holder of a manufacturing certificate may:
D8.1.1 Manufacture those appliances and parts specified on the certificate and detailed in the holders exposition. D8.1.2 Version airworthiness release certificates for those appliances and parts stating that the product conforms to the Certificate of Type Design and is in a condition for safe operation.
D9.
SCOPE OF APPROVAL:
D9.1 Subject to compliance with the requirements of this ANO, an organization may engage in activities as stated in the Certificate of Approval.
D10.
RENEWAL OF APPROVAL:
D10.1 On every renewal, the Airworthiness Directorate may perform an audit of the organization as per scope of approval. This will also include the organizations base within the country and abroad. The expenditures on the outstation(s) audit abroad will be at no cost to PCAA. The organization will have to apply for renewal on form (CAAF-102-AWXX) in duplicate along with the following documents at least 03 months before the expiry date of the certificate: D10.2 Approval schedule (CAAF-002-AWXX). D10.3 Fee as per latest version of Airworthiness Notice No AWNOT-003-AWXX.
D11.
EXTENSION OF APPROVAL:
D11.1 An organization may apply for extension in the scope of approval on appropriate PCAA form in duplicate along with the following documents: D11.1.1 D11.1.2 required. D11.1.3 D11.1.4 Approval schedule (CAAF-002-AWXX). Three copies of the exposition manual amendments stating the details of the extension Capability list for which the extension is required. Fee as per latest version of Airworthiness Notice No AWNOT-003-AWXX.
D11.2 After receiving the above documents, fee, etc., an audit with reference to the capability list will be carried out.
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D12.
MANUFACTURING CERTIFICATE AMENDMENTS:
D12.1 An application to amend a manufacturing certificate is made in the same form and manner as the original version. Where the changes include changes to the manufacturing organizations exposition manual, only the changes need to be submitted. D12.2 Since a manufacturing certificate may be amended for several different purposes, the following paragraphs provides examples as to which method is applicable, in different circumstances: D12.2.1 The holder of a manufacturing certificate may make an application to add a supplemental type certificate or design approval to the manufacturing certificate. Upon evaluation and approval of the process control data and manufacturing facilities, as applicable, the PCAA will version a new certificate. The new certificate will automatically cancel the existing one. D12.2.2 When manufacture of completed products as well as spare parts has ceased, the holder of a manufacturing certificate should request deletion of the applicable supplemental type certificate or design approval from the manufacturing certificate. This can be accomplished by writing to the PCAA. A revised certificate will be issued and any superseded certificate would be revoked. D12.3 If the holder of a manufacturing certificate ceases to manufacture complete products, but continues to manufacture replacement parts, the certificate does not require an amendment.
D13.
ORGANIZATIONAL CHANGES:
D13.1 When the holder of a manufacturing certificate changes their organization in such a way as to necessitate a revision of their manuals or exposition manual, the PCAA is to be kept informed in writing. An acceptable means of compliance with the notification requirements is to notify the PCAA in writing of any changes. The PCAAs agreement to the change may be more readily obtained if the proposed wording of the change is fully defined and any supplementary information is provided to assist the PCAA in deciding whether the change is acceptable. D13.2 A change of supplier or in the delegation of quality functions to suppliers, which results in a change to the exposition manual of the holder of a manufacturing certificate should be considered as a change to the holders process control system.
D14.
SAFETY AUDIT AND INSPECTIONS:
D14.1 The PCAA operates a safety audit programme for all participants in the aviation system. The visits will be notified in advance. These arrangements will allow for forward planning by both the PCAA and the certificated organizations. D14.2 An organizations policy and procedures will be accepted by the PCAA during the entry process. These policies and procedures, documented in an organizations exposition manual, will form the agreed performance standard for an organizations safety audit programme. This safety audit programme will initially examine the certificate holders internal quality assurance system. Any deficiency found at this level will result in a broader and deeper investigation until the causal factors of the deficiency are identified. The on-going frequency and depth of audit will depend directly on the performance of the organization. D14.3 PCAAs level of confidence in an organization will be raised when it is found to comply with its documented procedures. PCAA may then consider reducing the frequency and depth of the audit programme. Conversely where the level of confidence is low, due to non-compliance, the level of auditing may be expected to increase. Whenever it is discovered, through an audit or other reporting method, that an organization is not conforming to its procedures, or complying with the PCAA rules, the Director General may suspend or revoke the certificate. 04/04/2011 Page 7 of 33 ANO-002-AWRG-2.0
D15.
ISSUANCE OF CERTIFICATES OF TYPE APPROVAL, SUPPLEMENTARY TYPE CERTIFICATE AND PRODUCTION CERTIFICATE:
D15.1 The certificate of type approval, supplementary type certificate and production certificate will be issued by PCAA in accordance with the procedures manual for certificate of type approval, supplementary type certificate and production certificate, for aircraft below 5700 kg, duly approved by the Director General. For further information regarding the issuance of a certificate of type approval, supplementary type certificate and production certificate the latest version of ANO related to type approval, supplementary type certificate and production certificate.
D16.
DESIGN APPROVAL:
D16.1 As per Annex 8, which states that when a Contracting State, other than the State of Design, versions a Type Certificate for an aircraft type, it shall do so on the basis of satisfactory evidence that the aircraft type is in compliance with the design aspects of the appropriate airworthiness requirements. In such cases, the organization will version a certificate of compliance stating that the aircraft manufactured is in compliance with the design standards of the state of design and with the airworthiness requirements (Refer Para D29 and Annex C and D for the Certificate of Compliance).
D17.
ISSUANCE OF PRODUCTION CERTIFICATE:
D17.1 A production certificate will be issued to the approved organization stating the type of product to be manufactured (Refer Para D16 above).
D18.
NOTIFICATION OF CEASING MANUFACTURING:
D18.1 If an organization decides to cease manufacturing activity, this rule requires the certificate holder to notify the PCAA. A letter should be sent to the Airworthiness Directorate PCAA, together with the certificate, within 30 days of ceasing activity.
D19.
LIAISON OFFICE:
D19.1 A liaison office headed by a qualified officer is to be established by the manufacturer for the purpose of coordination on all matters relating to airworthiness and also to act as a contact point with the Airworthiness Directorate, PCAA.
D20.
AUTHORIZATIONS FOR MANUFACTURING PERSONNEL:
D20.1 PERSONAL WORKING IN THE SHOP: D20.1.1 Authorizations to sign authorized released certificates (ARC) shall comply with the following:D20.1.1.1 Persons authorized to sign Authorized Released Certificates (ARC) are required to have personal shop approvals issued by the Airworthiness Directorate. Shop approval to personnel are NOT required if the organization has its own approval system duly approved and monitored by the Airworthiness Directorate. Incase the organization does NOT have its own approval system; the personal shop approvals will be issued by the Airworthiness Directorate (CAAF-004-AWXX). It shall only be used subject to their conditions of validity, and if the person holding the approval, is employed in the approved organization. The approval shall be valid for such period as specified therein, not exceeding a period of one year. Before forwarding the application form in duplicate (CAAF-105-AWXX) to the Airworthiness Directorate for grant of personal approval, candidate will have to appear in an oral examination at the field office level. The certificate of personal approval shall be initially issued by the Airworthiness Directorate and renewed by the Airworthiness field office responsible for the airworthiness control of the 04/04/2011 Page 8 of 33 ANO-002-AWRG-2.0
organization. The following documents for initial personal shop approval are to be attached with the application form (CAAF-105-AWXX): D20.1.1.2 Bio-data of the person applying for the personal shop approval (for initial version only). D20.1.1.3 Fee as per latest version of Airworthiness Notice No AWNOT-003-AWXX. D20.1.1.4 For renewal of the personal shop approval, the following documents are to be submitted: D20.1.1.5 Certificate of Personal Approval. D20.1.1.6 Fee as per latest version of Airworthiness Notice No AWNOT-003-AWXX. D20.1.1.7 Airworthiness Directorate will issue welder certificate to persons who are employees of an approved organization. The certificate will be issued as per requirements laid down in the latest version of Airworthiness Notice No.AWNOT-063-AWXX. Note: The personnel involved in shops where they are directly or indirectly exposed to any kind of radiation, fumes, arcing, etc are required to go through regular medical check-ups and are to maintain a medical fitness certificate issued by the companys approved doctor. The procedures for the medical check-ups are to be laid down in the companys exposition manual.
D20.2 DUPLICATE INSPECTION CERTIFICATION: D20.2.1 In this Para the following definitions shall apply:
D20.2.1.1 Control System - A system by which the flight path, attitude or propulsive force of an aircraft is changed. This includes the flight, engine and propeller controls, the related system controls and the associated operating mechanism. D20.2.1.2 Duplicate Inspection - An inspection first made and certified by one qualified person and subsequently made and certified by a second qualified person. D20.2.1.3 catastrophe. Vital Point - Any point on an aircraft at which single mal-assembly could lead to
D20.2.2 Before the release of an aircraft for it first production test flight, a duplicate inspection of all vital points and control system in an aircraft shall be carried out. D20.2.3 Vital points / controls systems subject to duplicate inspection must not be disturbed or readjusted after the first certified inspection and the second part of the duplicate inspection must, as nearly as possible, follow immediately after the first part. In some circumstances, due to peculiarities of assembly or accessibility, it may be necessary for both parts of the inspection to be made simultaneously. It is, therefore, desirable that the inspections of a control system are made as near as is practicable to the time of the intended flight and that the full extent of the disturbance is understood by both persons who carry out the duplicate inspections. D20.2.4 If a vital / control system is disturbed after completion of the duplicate inspection, that part, that has been disturbed, shall again be inspected in duplicate and a certificate of release to service issued before the aircraft flies. The duplicate inspection shall be the final operation to establish the integrity of the vital point / control system when all the work has been completed and shall take into account all the relevant instructions and information contained in the associated technical data. D20.2.5 follow:D20.2.5.1 D20.2.5.2 Persons qualified to make the first and / or second part of duplicate inspection are as
Aircraft maintenance engineer appropriately licensed in categories A, B, C, D & X or Persons duly approved by the Airworthiness Directorate or
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D20.2.5.3 Persons employed by approved Organizations, who are appropriately authorized to make such inspections and certify the task in accordance with company procedures. D20.2.6 Where appropriate to the type of component or unit forming part of control system, a schedule of inspections or functional tests shall be completed at time of manufacture, and duplicate inspection shall be certified on the section / parts of the component or unit which will be concealed during bench assembly and which cannot be proved during inspections and functional tests when installed on the aircraft control system. Duplicate inspection of the completed assembly of the component or unit, functioning and checking for correct relative movement shall be certified. D20.2.7 Organization exposition or procedure manual shall indicate the control systems and components / units of the control systems for the type of aircraft that will require duplicate inspection.
D21.
NOMINATED PERSONNEL:
D21.1 An applicant must identify their Chief Executive and other key personnel. The applicants nominated senior persons must be employed, contracted or otherwise engaged to work sufficient hours such that the individual can fulfill the management functions associated with the size and scope of the applicant's business. The Chief Executive and other critical members of an organization will exercise an appropriate level of control, direction, and responsibility, to ensure the continued effectiveness of the operation. Furthermore, the applicant must have in their exposition an organization chart showing the lines of responsibility extending from the Chief Executive through to each location where manufacturing staff are located. D21.2 The applicant shall nominate the following senior personnel for PCAA approval: D21.2.1 Head of manufacturing organization such as Chief Executive.
D21.2.2 Sectional head(s), as are appropriate to the class and level of work, for which approval is sought. Their functions will also include responsibility for the co-ordination with all appropriate departments so as to ensure compliance with the relevant airworthiness requirements, and who will be directly responsible to the Chief Executive / Airworthiness Directorate, PCAA for this purpose. D21.2.3 D21.2.4 Persons authorized to version Personal Authorization Certificates. Personnel working at the shop level.
D21.3 The applicant shall satisfy the Airworthiness Directorate that the senior persons nominated are capable and responsible persons and are conversant with the firms exposition manual, civil aviation rules and other regulations / requirements there under as relates to their responsibilities. Written evidence of their qualifications and experience are to be submitted. The applicant shall satisfy the Airworthiness Directorate that such persons are conversant with PCAA requirements and procedures. D21.4 It should be noted that where a change of the approved senior person is proposed, whether permanent or temporary (for a period of over 01 month), the organization is required to inform in writing and obtain approval from the Airworthiness Directorate prior to the notification of the change. The Airworthiness Directorate may require the organization to supply further information in order to satisfy itself as to the suitability of the personnel for the proposed position. D21.5 The organization is also to develop procedures that will deal with transfer of functions of the senior approved person to other suitable and qualified persons during periods of absence. The responsibilities and functions that are to be transferred to a person who is fit and proper, and meet the experience and qualifications set out in the exposition. If a senior approved person is on leave for a period of more then 01 month, then in such cases, the organization is to take temporary approval from the Airworthiness Directorate for the person who will be working in the place of the senior approved person. In accepting such contingency arrangements, the Airworthiness Directorate may impose limitations or conditions of a temporary nature for the period of the contingency. The conditions or limitations imposed by the Airworthiness Directorate in all cases will be clearly stated to the certificate 04/04/2011 Page 10 of 33 ANO-002-AWRG-2.0
holder in writing, and could be as simple as providing a time frame for events to take place or a total suspension of manufacturing activity.
D22.
SENIOR PERSONS RESPONSIBILITY:
D22.1 The intent of the rule regarding the responsibility and authority of the Chief Executive is to ensure that:D22.1.1 D22.1.2 D22.1.3 The manufacturing activities carried out by the organization can be financed. Those activities are carried out in accordance with current PCAA rules. The organization complies with the requirements of current PCAA rules.
D22.2 The Chief Executive must assure that manufacturing is conducted in compliance with the exposition and other relevant rule / instructions. Ensuring compliance with the exposition and other relevant rule / instructions is the responsibility of the senior approved persons and the assurance that the Chief Executive requires could be shown through the medium of the internal audit reports or inspections. D22.3 Under this rule, the organization must appoint senior approved persons responsible to the Chief Executive for:D22.3.1 D22.3.2 D22.3.3 D22.3.4 Note: Supply Production Inspection and test Internal quality assurance Additional areas may also be added.
D22.4 Titles may vary between organizations but the requirements are for management representatives for supply, production, inspection and testing, and internal quality assurance. D22.5 Functions are not to be combined, as they may conflict with responsibilities assigned to the intended positions, for example, the functions of Production Head and Quality Assurance. D22.6 The senior persons should be responsible for ensuring that:
D22.6.1
D22.6.1.1
SUPPLY:
Raw materials are inspected for compliance to the required specifications.
D22.6.1.2 Any assemblies sourced from external suppliers meet the requirements of the manufacturing Organization, particularly if the assemblies can not be completely checked on receipt. D22.6.1.3 Internal supply procedures include the acceptance, packaging, preservation, and delivery of products. D22.6.1.4 Liaison is maintained with all suppliers to ensure on time delivery of materials and parts necessary to support the manufacturing process. D22.6.1.5 requirements. The suppliers used are aware of the manufacturing organizations systems and
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D22.6.1.6 Any corrective action relating to supply and stores resulting from the internal quality assurance programme is quickly and effectively carried out.
D22.6.2
D22.6.2.1
PRODUCTION:
Appropriate materials are provided for the manufacturing process.
D22.6.2.2 Suitable arrangements for testing and inspection, including equipment and facilities, exist with providers of these services. D22.6.2.3 There are procedures for liaison with the appropriate design organization to allow for effective production and concessions and corrections to be made during the production process. D22.6.2.4 Staffs are appropriately authorized.
D22.6.2.5 Appropriate production process control exists including provisions for supply, processing, testing, storage of completed items, and version of those items for release. D22.6.2.6 Any corrective action relating to the manufacturing process resulting from the internal quality assurance programme is quickly and effectively carried out.
D22.6.3
D22.6.3.1
INSPECTION AND TESTING:

Any inspections and tests carried out are implemented and running effectively.
D22.6.3.2 Inspections and tests reflect the current state of the art of the aviation industry and provide the results necessary to show compliance with airworthiness requirements. D22.6.3.3 Suitable arrangements with providers of testing equipment and facilities are established and reflected in the exposition. D22.6.3.4 Support systems are effective in providing for the activities of the inspection personnel.
D22.6.3.5 Any corrective action relating to the inspection and testing resulting from the internal quality assurance programme is quickly and effectively carried out.
D22.6.4
INTERNAL QUALITY ASSURANCE:
D22.6.4.1 An applicant must establish an internal quality assurance system that meets the requirements of this rule. The requirements of this rule are common to all certificated organizations which require an internal quality assurance system. Detailed information on what is required for an internal quality assurance system is contained in the exposition manual. D22.6.4.2 The organization remains in compliance with the requirements of this ANO.
D22.6.4.3 The exposition and the associated procedures remain adequate for the scope of the organizations activities. D22.6.4.4 exposition. D22.6.4.5 organization. Personnel meet the initial and on-going training and qualification criteria defined in the Staffs are authorized appropriately for performing certifications on behalf of the
D22.6.4.6 Support systems are effective in providing for the activities of any internal quality assurance personnel.
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D22.6.4.7 Any corrective action relating to the exposition, procedures, qualifications, personnel, or support systems resulting from the internal quality assurance programme is quickly and effectively carried out.
D23.
IDENTIFICATION OF PRODUCTS:
D23.1 Each product is to be identified by a part number and serial number. Procedures are to be laid down in the company exposition manual.
D24.
PRODUCTION CONTROL PROCEDURES:
D24.1 This rule details the process control elements of a manufacturing organization. These elements ensure that conformity is assured at each step of manufacture. Process control includes provisions for:-
D24.1.1
SUPPLY:
D24.1.1.1 Supply is generally referred to in relation to those activities where items enter the organization. The holder of a manufacturing certificate is responsible for any parts, assemblies or services used in the manufacture of their product. The holders procedures should include methods to monitor and control all parts or services obtained from suppliers and all suppliers to whom the holder has delegated inspection duties for controlling conformity and quality. Note: The requirements for the Approval of Suppliers, Stockiest and Distributors have been laid down in the latest version of ANO-010-AWXX.
D24.1.2
PROCESS CONTROL:
D24.1.2.1 To provide control over the fabrication and assembly operations and to ensure that necessary inspections and tests are conducted in the proper sequence, production planning procedures should be utilized. The manufacturing organization should establish its production procedures taking into consideration: D24.1.2.1.1 The establishing of appropriate inspection stations and programmes.
D24.1.2.1.2 The arrangement of production areas to provide segregation of manufacturing processes or operations which may adversely affect other operations. D24.1.2.1.3 D24.1.2.1.4 A system to control the integrity of all special processes and services. The identification and control of products and controlling documentation.
D24.1.2.2 example: D24.1.2.2.1 D24.1.2.2.2 D24.1.2.2.3 D24.1.2.2.4 D24.1.2.2.5 D24.1.2.2.6 04/04/2011
The process control procedures would include, for a non-destructive inspection as an
The operator qualifications required by the manufacturer. The currency requirements for an operator by the manufacturer. Inspection procedures in specifications that are approved as part of quality control data. Inspection and calibration of equipment. The establishment of realistic, current acceptance criteria. The recording and retention requirements for records. Page 13 of 33 ANO-002-AWRG-2.0
Note:
Any subcontracted work is considered to be an extension of the manufacturers organization and should be controlled by the manufacturers procedures.
D24.1.3
TESTING AND INSPECTION:
D24.1.3.1 The manufacturer should establish and comply with test and inspection procedures applicable to the products. These procedures should include: D24.1.3.1.1 D24.1.3.1.2 D24.1.3.1.3 An inspection planning system Production testing requirements Final testing requirements
D24.1.3.2 The holder of a manufacturing certificate should establish procedures for dealing with materials and parts not conforming to the type design or specifications. These procedures should enable the manufacturing organization to:D24.1.3.2.1 Control the identification, rework, and use of non-conforming parts, including the isolation and scrapping of unusable parts. D24.1.3.2.2 Ensure that any parts which will not conform to the type design are not used until the necessary design changes have been approved. D24.1.3.2.3 Provide for corrective action with regard to discrepancies in manufacturing procedures, processes, designs, or any other condition which caused the non-conforming parts, to ensure that all affected and subsequent products will be in conformity with the type design. D24.1.3.2.4 Maintain charts or records to show the effectiveness of the corrective action program and to reveal problem areas as they arise. D24.1.3.2.5 Ensure that only those parts and processes which have been accepted and found to conform to acceptable design data are used in the product.
D24.1.4
STORES:
D24.1.4.1 Stores are generally referred to in relation to those activities where items move within the organization. The stores system in many manufacturing organizations is linked closely to the supply system. The stores system is generally the internal supply processes controlling product and material distribution and flow through the organization. The latest version of Airworthiness Notice AWNOT-006AWXX may also be referred to as a guide line.
D24.1.5
VERSION:
D24.1.5.1 Although normally associated with the completed product, a manufacturing organization may version products from one production area to another, either directly or through a stores control mechanism. D24.1.5.2 At each stage where a product leaves a production area the version may be controlled by a statement of compliance. This is the confirmation by an authorized company person that the product, whether complete or at a step in the process: D24.1.5.2.1 D24.1.5.2.2 D24.1.5.2.3 04/04/2011 Has been checked Complies with the airworthiness requirements Is acceptable for approval Page 14 of 33 ANO-002-AWRG-2.0
D25.
CONTINUED AIRWORTHINESS:
D25.1 The manufacturing organization has a responsibility to ensure that the products manufactured are monitored and supported. These include monitoring of investigations and analysis defects, which if corrected may aid production or make the item easier to use, resulting in an economic advantage to operating and maintenance organizations. The term Defect as stated in latest version of Airworthiness Notice No. AWNOT-009-AWXX, means, any failure or malfunction of an aircraft component or aircraft equipment whether found in-flight or on the ground. As per notice, every operator shall supply information of Abnormal Defects to the manufacturer. Defects that may result in injury, accidents, or hazards to other aviation activities are considered abnormal defects. D25.2 Under this rule, the manufacturing organization has a responsibility to keep the users of products which they manufacture and the designer of those products informed of abnormal defects. The defect reporting responsibility of a manufacturing organization will generally cover those product features that are causing a problem that are introduced by poorly controlled manufacturing processes and poor material performance rather than design faults or maintenance practices. Defect reporting to the PCAA is covered in the latest version of Airworthiness Notice No. AWNOT-009-AWXX. D25.3 For in-service products, the holder of a manufacturing certificate should establish procedures for recording, investigating cause, and assuring corrective action of all known or reported failures, malfunctions, and defects. Procedures should ensure that: D25.3.1 In-service problems are investigated and prompt corrective action is taken on all affected products as appropriate. D25.3.2 Users of the product are informed of the service difficulties and resultant changes through Service Bulletins (Refer Para D26). D25.3.3 practicable. Feedback on service problems is received from the users of the products to the extent
D25.4 The procedures required may form part of a totally integrated quality control system.
D26.
SERVICE BULLETINS (SBs):
D26.1 After receiving feedback on service problems from the user of the product, it will be the responsibility of the manufacturer to analyze the problem of the repetitive abnormal defects and inform the user for any modification or inspection that is required to be embodied on the product. This is to be informed through service bulletins. The service bulletins are to contain the following information / topics:
D26.1.1 D26.1.2 D26.1.3 D26.1.4 D26.1.5 D26.1.6 D26.1.7 D26.1.8 D26.1.9
Service Bulletin Number Service Bulletin Date Title / Subject Models Affected (that should include Model No., Year of Manufacturer, and Manufactures Serial Numbers, MSN) Purpose Time of Compliance Approval Man-Hours Accomplished Instructions
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D27.1.9.1 D27.1.9.2 D27.1.9.3 D27.1.9.4 D27.1.9.5 D27.1.9.6 D27.1.9.7 D27.1.9.8 D27.1.9.9
Description Reference Change in Weight and Balance Accomplishment Instructions Material Tools to be used Parts required Drawing / Diagrams / Pictures Any other instructions that may be considered necessary be the manufacturer
D26.2 Keeping in view of the type of mod or inspection, the SB maybe categorized such as Mandatory SB, Critical SB, Alert SB, etc. The categorization is to be defined in the company exposition manual. D26.3 After every 01 year, a Service Bulletin index containing a list of all the pervious SBs is to be sent by the manufacturer to all the operators and to the authorities where the aircraft has been registered including PCAA.
D27.
AIRCRAFT FABRIC:
D27.1 This will be applicable if the product manufactured is an aircraft - The manufacturer has to prove that the aircraft fabric meets the requirements mentioned in the current version of Airworthiness Notice No. AWNOT-029-AWXX
D28.
PRODUCTION TEST FLIGHT:
D28.1 This will be applicable if the product manufactured is an aircraft - A production test flight will be carried out after completion of each product and a certificate of compliance (CAAF-022-AWXX and CAAF-023-AWXX) will be issued. The procedures of the production test flight are to be laid down in the company exposition manual. Note: When an aircraft is to be exported from Pakistan, Airworthiness will version an Export Certificate of Airworthiness (Refer latest version of ANO-004-AWXX).
D29.
WEIGHT AND BALANCE:
D29.1 This will be applicable if the product manufactured is an aircraft - To determine the basic weight and center of gravity, the aircraft is to be weighed after its final assembly.
D30.
PUBLICATIONS AND INFORMATION:
D30.1 The Organization holds and makes available to both, personnel and PCAA, all technical publications appropriate to the class of work covered by the Approval. Suitable arrangements are made to ensure that these documents are kept amended and up-to-date. Necessary procedures for developing maintenance manuals, wiring diagram manual, flight manual, structural repair manual, etc are to be stated in the exposition manual.
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D31.
RECORDS:
D31.1 Manufacturing records - The holder of a manufacturing certificate should provide procedures that ensure correct technical data control, including: D31.1.1 Only applicable drawings, drawing change notices, engineering data, and quality control data are available to production and inspection personnel. D31.1.2 That unauthorized, inappropriate, and obsolete drawings and data are promptly removed from production areas. D31.1.3 Prior to final acceptance of products or parts, all changes to the type design are either incorporated in the applicable drawings, or described in change notices attached to such drawings. D31.2 For airworthiness certification and recording compliance with the airworthiness requirements, all significant inspection and test records attesting to the conformity and safety of the completed part or product are required to be retained. D31.3 The procedures should detail the method of identification of records that are no longer current, but are required to be held for research or other purposes. D31.4 As the records should be legible and of a permanent nature, the retention of facsimile paper records should be avoided due to its likelihood of fading. D31.5 Records can be kept electronically but systems should ensure the information security, integrity, and retrieval. A system of backing up electronic data would be considered appropriate. Procedures for electronic record and document keeping should consider: D31.5.1 D31.5.2 D31.5.3 D31.5.4 D31.5.5 D31.5.6 information D31.5.7 D31.5.8 D31.5.9 D31.5.10 D31.5.11 Avoidance of data loss in the event of power interruptions Software control, including amendments and prevention of corruption Unauthorized access Audit trail facilities Archiving of data in a similar manner to hard copies, and for a similar period Backup of critical information, preferably once a day, with storage for that backup Data verification, on entry and retrieval. Publication provision Staff training Amendment of stored data Problem report register including the problem details and solutions
D31.6 For ease of access records may also be computerized but the original documents should be retained in a secure environment. The rule requires the ideal retention of records to be 2 years from the date of the withdrawal of the last example of the product from service. This is a very onerous requirement but ensures that the information is available no matter how long the product remains in service. The rule recognizes the need for varying this time limit in special cases. The cases that may support the reduction of this period will vary considerable but may include, but not be limited to, the following: D31.6.1 The only examples of the product being used are installed on aircraft limited to experimental operations.
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D31.6.2 The number of products is finite and the necessary information can be provided to each owner for inclusion in the products service records. D31.6.3 Although products still exist, the likelihood of restoring an operating example of the product is considered extremely rare. D31.6.4 The supplemental type certificate is cancelled and the owners of each example of the product informed as to the non-type certificated nature of the product.
D32.
PERSONNEL RECORDS:
D32.1 A certificated manufacturing organization must establish procedures to ensure records are kept of all staff authorized to certify under its authority. The following minimum information should be kept in respect of each certifying person: D32.1.1 D32.1.2 D32.1.3 D32.1.4 D32.1.5 D32.1.6 D32.1.7 D32.1.8 D32.1.9 D32.1.10 D32.1.11 Name Date of birth Qualifications Initial training Continuation training Experience Qualifications relevant to the authorization Privileges of the authorization Date of first version of the authorization The expiry date of the authorization Identification number of the authorization
D32.2 The records may be kept in any format but must be controlled by the organizations quality assurance senior person. Safeguards must be put in place to ensure that the records cannot be altered in an unauthorized way. Personal information must not be accessible to unauthorized persons. Organizations should take account of Privacy of Information legislation in the management of personal information. D32.3 The persons to whom the records relate should be given access, on request, to his or her own records. The PCAA is an authorized person in respect of any aviation documents and records. When the PCAA is assessing eligibility for initial or continued approval, or when it has cause to doubt the competence of a particular certifying person, it may access those records. D32.4 An organization should keep the records for at least five years after the individual has ceased to be in its employment, or after withdrawal of the authorization, whichever is sooner. In addition certifying persons, on leaving an organization, must be provided with a complete record of company certification authorizations which they have held. D32.5 An organization shall ensure that the following records are kept as detailed below, where applicable: D32.5.1 D32.5.2 D32.5.3 D32.5.4 Customer's order. Aircraft, engine or part. Relevant standards / specifications. Stores records.
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D32.5.5 D32.5.6 D32.5.7 D32.5.8 D32.5.9
Test and inspection records including a record of each identified (i.e. by serial number) component and item of equipment. Certificates of release to service. Outgoing authorized release certificate / airworthiness approval tag. The current status of compliance with all mandatory continuing Airworthiness information; Weight and balance record;
D32.6 Records shall be made available to the operators. D32.7 Procedures of maintaining records will be stated in the company exposition manual. While developing the procedures, traceability, preservation and neatness of record are to be included.
D33.
HUMAN RESOURCES AND FATIGUE FACTOR:
D33.1 According to recent publications, reports, etc, on aviation safety, between 70 and 80 per cent of aircraft accidents are due to human factors. Many of these accidents could have been avoided if basic human factors concepts had been observed. Several incidents have a contributing factor fatigue due to excessive hours of work. Excessive hours of work and constant pressure are two vital factors that lead to errors. To reduce the contributing factor fatigue due to excessive hours of work and constant pressure, the organization should employ sufficient personnel to plan, supervise and inspect the activities included in the approval. Keeping the above points in view, the organization is required to: D33.2 Have sufficient personnel employed to plan, supervise and inspect the activities, and D33.3 Control hours of service and duty timings.
D34.
TRAINING POLICY:
D34.1 The organization shall ensure that all personnel receive initial and refreshers training appropriate to their assigned tasks and responsibilities. The organization shall also ensure that all personnel are instructed regarding the manufacturing methods to be employed, in particular when new or unfamiliar equipment is introduced into service. The training program established by organization shall include training in knowledge and skills related to human performance including co-ordination with other personnel. D34.2 The organization shall also arrange familiarization factory training courses for at least four airworthiness officials (02 Aerospace and 02 Avionics) as to provide continued airworthiness surveillance of the product manufactured. The expenditures on the training will be at no cost to PCAA. Factory training courses may also be arranged for operators, for which the latest version of ANO-008-AWXX maybe referred.
D35.
QUALIFICATION OF CERTIFYING PERSONNEL:
D35.1 The organizations personnel levels should ensure that a sufficient number of suitably qualified people are available to carry out the manufacturing task. As part of these levels, a sufficient number of qualified inspectors are required to ensure that all parts, processes, and procedures, are inspected for conformity to technical data, specifications, and procedures specified in the appliance or part design. D35.2 The competence of all staff should be determined on the basis of: D35.2.1 Academic qualifications.
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D35.2.2 D35.2.3 D35.2.4
AME licenses, certificates or approvals held. Employment records. Written, oral, or practical examination.
D35.3 The organization should provide for the assessment and maintain the levels of competency of all personnel. D35.4 A product cannot be released to service unless certifications are made by appropriately approved personnel that the tasks have been completed in accordance with the manufacturers and Airworthiness Directorates requirements. D35.5 In case the organization does not have its own approval system duly approved and monitored by the Airworthiness Directorate, the requirements for shop approval are provided in the latest version of Airworthiness Notice AWNOT-025-AWXX. D35.6 The competence of personnel shall be established in accordance with a procedure and to a level acceptable to the Airworthiness Directorate. The person signing a release to service shall be qualified in accordance with this ANO.
D36.
FACILITY REQUIREMENTS:
D36.1 Office accommodation should provide for the management, planning, records, quality, production, and other staff. The offices should be sufficient to meet the requirements for the scope of manufacturing work. Working and environmental conditions shall be controlled as necessary to ensure compatibility with the work undertaken. D36.2 Adequate office facilities are to be provided for personnel engaged in the management of quality, planning and technical records as there is an ongoing requirement to retain production records the provision of storage and the methods of cataloguing and preventing deterioration of this material. D36.3 Testing facilities may include calibrated and critical equipment and this test and measurement equipment should have adequate protection and control. D36.4 The manufacturing organizations arrangement of production areas should: D36.4.1 Provide for the segregation of manufacturing processes or operations which may adversely affect other operations. D36.4.2 Provide for the storage of equipment, tooling, material and components.
D36.5 Specialized workshops are to be segregated to avoid environmental or work area contamination. The separation of precision inspection areas from each area where, for example, grinding, cutting, sanding, or painting operations are performed allows for compliance with the applicable process specifications. D36.6 Suitable storage areas provide the manufacturing organization with control over the deterioration of, damage to, and acceptability of those items stored. Correct storage of inspection tooling, for example, ensures accurate checks to be carried out on the manufacturing process. D36.7 Storage facilities will be provided for parts, equipment, tools and material. Storage conditions shall be such as to provide security and prevent deterioration / damage to stored items. There should be a complete segregation of serviceable and unserviceable parts.
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D37.
EQUIPMENT, TOOLS, AND MATERIAL:
D37.1 The organization must show that all tools and equipment, necessary to accomplish the approved manufacturing instructions, must either be permanently on hand or available as required in accordance with documented arrangements in the exposition. D37.2 This rule requires the manufacturing organization to not only have the necessary equipment but to also have the procedures to ensure control of the process. D37.3 The requirements extend to the provision of: D37.3.1 Production data from organizations such as libraries, standards organizations, the Civil Aviation Authority, and other manufacturing organizations D37.3.2 D37.3.3 Tools and testing facilities requiring workshop, or other specialized environments Equipment including measurement, drawing, and computer support equipment.
D37.4 The procedures should ensure that each process is performed by trained and qualified personnel in accordance with acceptable specifications containing definitive standards of quality. D37.5 The procedures would provide for periodic inspection of gauges, solutions, or any critical equipment including the associated documentation. Special processes and services, such as welding, brazing, heat treatment, and plating, would include the close control of factors such as temperature, curing time, and solution. D37.6 In undertaking manufacturing work the organization should ensure that it identifies, in its exposition, the processing and testing locations it intends to use regularly. If tools, equipment, or special processes are located at these other premises then controls should be in place to ensure the equipment is controlled and calibrated as necessary. D37.7 Outside organizations, or organizations certificated under other Civil Aviation Rules, may be acceptable to provide the equipment, tools, and manufacturing facilities. In these instances a contractual arrangement would be expected and this agreement should be referenced in the exposition. D37.8 As an example of tool or equipment control, a procedure may require that: D37.8.1 Equipment and tooling would have the capability and reliability to ensure production of uniform duplicate parts and products conforming to the type design D37.8.2 D37.8.3 D37.8.4 D37.8.5 The acceptance of non-conforming parts, or rejection of conforming parts, due to improperly controlled tools and gauges, be avoided by: Inspecting and calibrating the equipment to appropriate measurement standards Inspecting tools, gauges, and testing equipment, as well as production jigs, fixtures, and templates which are depended upon as means of inspection Establishing inspection intervals on the basis that such tools and gauges would be inspected prior to their becoming inaccurate, or requiring adjustment, replacement, or repair A records system is provided to ensure that each piece of equipment, tooling, or storage container is: Checked prior to first usage and at the proper periodic interval. Marked to indicate the date that the next inspection is due.
D37.8.6 D37.8.7 D37.8.8
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D37.8.9
Removed from inspection and shop areas, or conspicuously identified, to prohibit usage after expiration of the inspection due date. The material used for manufacturing of aircraft parts, which are essential for its safe operation shall conform to approved specifications.
D37.8.10
D38.
QUALITY CONTROL AND QUALITY ASSURANCE:
D38.1 The system for quality control and quality assurance set up shall be such that the prime objective is to maintain a continuous check on the effectiveness of the manufacturing organization and on the procedures and systems employed to ensure that all PCAA Airworthiness Directorate requirements as well as those of the Organization itself are met. D38.1.1 The following definitions shall apply:-
D38.1.1.1 Quality: The quality of a product or service is the degree to which it meets the requirements of the customer including the relevant airworthiness requirements. D38.1.1.2 Quality Control: A management system for programming and coordinating the on-going quality manufacturing and improvement efforts of the various groups in an organization, so as to permit the completion of aircraft maintenance in compliance with any specific requirements laid down by the airworthiness directorate, organization or customer affecting airworthiness. D38.1.1.3 Quality Assurance: The quality assurance is the overall authority for the supervision of quality standards, enabling those standards set by the system of quality control to be enforced. D38.1.2 The implementation of the quality control requirements should normally be assigned to a quality manager who will be responsible for the operation of quality assurance tasks utilizing, as necessary, a staff of quality assurance engineers, who shall be appropriately qualified and experienced, and in sufficient numbers, to properly undertake the work performed by the quality department. Moreover it will be ensured that only AME license holders (appropriately qualified and experienced) shall be deputed in quality section of the organization. D38.1.3 The quality control system should include formal procedures for notifying the results of quality assurance tasks to those persons required and empowered to provide corrective action, as appropriate. Such persons should also be required by the system to inform the quality manager of the corrective action taken, or to be taken. D38.1.4 Various methods can be employed by which effective quality control and quality assurance can be achieved, and these depend, in part, upon the size, scope and complexity of the organization concerned and the amount and level of work undertaken. In recognition of this, the PCAA considers that an organization shall develop internal audit system / procedures of manufacturing facilities including shops on regular basis. This may include system for follow up of non conformities observed. D38.1.5 Quality assurance division is headed by chief engineer quality assurance and reports to an accountable manager (managing director / chief executive) to ensure manufacturing / airworthiness standards.
D39.
CONTRACT AND SUB-CONTRACT:
D39.1 The requirements for contract and sub-contract have been laid down in the latest version of AWNOT-068-AWXX.
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D40.
CHANGES TO CERTIFICATE HOLDER'S ORGANIZATION:
D40.1 An organization should always ensure that its exposition remains an accurate description of the organization and its activities. When there are changes to staff, structure, location, or documented procedures organization should ensure the exposition reflects these changes. Prior acceptance by the Director is required for certain changes including: D40.1.1 D40.1.2 D40.1.3 D40.1.4 The Chief Executive The listed senior persons The manufacturing activities The locations at which work is carried out, including testing and inspection locations.
D41.
TYPE EVALUATION COMMITTEE (TEC):
D41.1 A type evaluation committee is to be established by the organization, which will consist of members from the manufacturing organization and two members of the airworthiness directorate, PCAA (01 Aerospace and 01 Avionics). The functions and frequency of meeting shall be mentioned in the exposition manual.
D42.
AMENDMENTS AND MODIFICATIONS:
D42.1 Any subsequent amendments or modifications to this ANO may be processed and incorporated through Airworthiness Directorate, HQ CAA, in consultation with Chief Legal Services, HQ CAA as and when required or deemed expedient or appropriate.
E.
E1.
EVIDENCES (ACRONYMS / RECORDS / REFERENCES):

ACRONYMS:
ANO ACTA CARs 94 CTA DGCAA DY DG GM HR PCAA PCTA STC TAC TCDS TRG & DEV AIR NAVIGATION ORDER AMENDED CERTIFICATE OF TYPE APPROVAL CIVIL AVIATION RULES 1994 CERTIFICATE OF TYPE APPROVAL DIRECTOR GENERAL CIVIL AVIATION AUTHORITY DEPUTY DIRECTOR GENERAL GENERAL MANAGER HUMAN RESOURCE PAKISTAN CIVIL AVIATION AUTHORITY PROVISIONAL CERTIFICATE OF TYPE APPROVAL SUPPLEMENTAL TYPE CERTIFICATE TYPE ACCEPTANCE CERTIFICATE TYPE CERTIFICATE DATA SHEET TRAINING & DEVELOPMENT
E2.
RECORDS:
CAAF-001-AWXX CAAF-002-AWXX CAAF-004-AWXX CAAF-022-AWXX CAAF-023-AWXX CAAF-101-AWXX CAAF-102-AWXX CAAF-105-AWXX
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E3.
REFERENCES:
Civil Aviation Rules, 1994 ANO-008-AWXX ANO-004-AWXX ANO-010-AWXX AWNOT-003-AWXX AWNOT-006-AWXX AWNOT-009-AWXX AWNOT-025-AWXX AWNOT-029-AWXX AWNOT-063-AWXX AWNOT-068-AWXX
IMPLEMENTATION:
This Air Navigation Order shall be implemented with effect from 4th April, 2011 and supersedes / repeals / cancels ANO 92.0002 issue-1 dated 10th July, 2004.
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INDEX Sr. No.

1. 2. 2. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Authority Purpose Scope Description Definitions Approval procedure Grant of approval Manufacturing organization exposition manual Making of exposition manual Exposition acceptance Multiple certification Privileges of the Approval Scope of approval Renewal of approval Extension of approval Manufacturing certificate amendments Organizational changes Safety audit and inspections Issuance of certificates of type approval, supplementary type certificate and production certificate Design Approval Issuance of Production Certificate Notification of ceasing manufacturing Liaison Office Authorizations for manufacturing personnel Nominated personnel Senior persons responsibility Identification of products Production control procedures Continued airworthiness Service Bulletins (SBs) Aircraft Fabric Production test flight Weight and Balance
Contents
Page No.
1 1 1 1 1 2 3 4 4 5 5 6 6 6 6 7 7 7 8 9 9 9 9 9 10 11 13 13 15 15 16 16 16
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32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 47.
Publications and information Records Personnel records Human resources and fatigue factor Training policy Qualification of certifying personnel Facility requirements Equipment, tools, and material Quality control and quality assurance Contract and sub-contract Changes to certificate holder's organization Type evaluation committee (TEC) Evidences (Acronyms / Records / References) Implementation
16 17 18 18 18 18 19 21 22 22 23 23 23 24
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APPENDIX A Checklist
CHECK LIST (as applicable)

1. 2. History of the organization. Review of approved Exposition Manual for applicability, approval status, completeness and conformance with the regulations. Organization Structure (Specify Engineering executive positions, their interrelation, duties & responsibilities). Qualification/ experience requirements for different engineering executive posts. Number and experience of engineering staff, both departmentally and in total. Working hours of the engineering staff with reference to their task. Technical work area available for the operator against its requirements (this should include information pertaining to floor areas(s) of business etc.). Details of facilities & equipment (this should also include details of ground support equipment). Confirm available of special tools & equipment, as recommended by the manufactures, for accomplishing maintenance/repair/ overhaul work on different aircraft/accessories. (In the case of operator/owner of aircraft not exceeding maximum certificated take-off weight of 5,700 kg, an itemwise list of special tools and equipment is to be attached). Details of special support equipment e.g. non-destructive testing etc. & system of their inspection & manufacturing. Procedure & arrangement for calibration of test and standard master & equipment. Details of storage facilities for aircraft parts and related details. Procedure for spares acquisition disposition, and details of quality control arrangements and procedures for parts and material control including source, inspection, certification of foreign purchase etc. Details of fire fighting, first aid & other emergency handling equipment. Availability and planning of manufacturing manpower allocation & control. Details of training facilities, if any.
3.
4. 5. 6. 7.
8. 9.
10.
11. 12. 13.
14. 15. 16.
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APPENDIX A Checklist
17.
Procedure for grant of approval to technical personnel by approved inspection organization, related training program, required standards, record & control, and system by which such approvals are assessed/revoked. Quality control and/or assurance system with working methodology, if applicable and implementation of quality audits procedure (in house and sub-contractors etc). Procedure for control, filing of reportable defects, incidents and accidents. Details of aircraft and its component reliability program, its management and implementation. Procedure for concession assessment &implementation. Procedure for implementation of work cards/sheets pertaining to maintenance schedule & methods applied for its review and amendment. Procedure for preservation and retention of technical records. Complete list of technical literature (manuals etc.), documents (check cards etc.) maintenance schedule or any other document related to approval required and procedures for updating. Procedure for procurement, assessment and incorporation of service bulletins, modifications, manufactures technical information etc. Specimen copies of all tags, forms, certificates, etc., used by the applicant pertaining to aircraft, its components and the personnel. Fuel / Lubricant quality control arrangements. Details of weight and balance control system, if any. Details of sub-contracting arrangements for aircraft work, if any. Any additional information relevant to the approval requested. Manufacturing contract arrangements with respect to repair and overhaul of aircraft components etc. Control and procedures for certification of components both in country and at foreign repair facilities.
18.
19. 20. 21. 22.
23. 24.
25.
26.
27. 28. 29. 30. 31.
32.
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APPENDIX B Exposition manual details 1. 1.1 Guide to compilation of the company exposition manual (as applicable) This Appendix is intended as a general guide to the compilation of company exposition manual.
1.1.1 Minimum acceptable requirements for compiling an exposition are not prescribed in this Appendix, but an exposition based on the content of this Appendix, would be acceptable to the CAA Airworthiness Directorate. The Exposition Manual should be produced in a concise form, and its scope, insofar as it applies to the approval sought, should include:
(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) A general description of the scope of the work authorized under the organizations terms of approval; A description of the organizations procedures and quality or inspection system; Number and experience of engineering staff, both departmentally and in total. Working hours of the engineering staff with reference to their task. A general description of the organizations facilities; Names and duties of the person or persons required by this ANO; A description of the procedures used to establish the competence of manufacturing personnel; A description of the method used for the completion and retention of the manufacturing record; A description of the procedure for preparing the maintenance release and the circumstances under which the release is to be signed; The personnel authorized to sign the maintenance release and the scope of their authorization; A description, when applicable, of the additional procedures for complying with an operators maintenance procedures and requirements; A description of the procedures for complying with the service information reporting requirements given in latest version of airworthiness notice no 9; and A description of the procedures for receiving, amending and distributing with in the maintenance organization all necessary Airworthiness data from the type certificate holder or type design organization.
1.1.2
1.1.3
Exposition Manual should be presented in loose leaf form, so that it may be readily amended by the operator, as necessary to keep the information contained therein upto date. Where an Organization desires to use an exposition to satisfy requirements other than those of the CAA Airworthiness Directorate, the CAA Airworthiness Directorate has no objection to the inclusion of this additional information provided that the CAA Airworthiness Directorate requirements are fully satisfied. An Exposition Manual cannot be completed until the relevant approval requirements of manufacturing organization have been satisfied, and it must be in its final draft before agreement by the CAA Airworthiness Directorate,
1.1.4
1.1.5
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APPENDIX B Exposition manual details

and before terms of approval can be granted. CAA Airworthiness Directorate will discuss the Organizations preliminary drafts during their visit(s) in order to agree the final content. 1.1.6 The Exposition Manual will form the basis of CAA Airworthiness Directorate approval of the Organization.
2. 2.1
Basic requirements for a company exposition manual (as applicable) Identification: The Exposition Manual should be identified as follows:(a) (b) (c) (d) (e) (f) Company name, document title and reference number. Amendment standard by version number / date / amendment record. Approval by Chief Executive. Holders of the Exposition Manual, i.e. distribution list. Official title of person responsible for administration of the Exposition Manual. Contents List or Index.
2.2
Introduction: The Introduction should explain the purpose of the document for the guidance of the Organizations own personnel, and should give general information concerning the Organizations history and development, in order to provide background information to the CAA Airworthiness Directorate. Where appropriate. Relationships with other Organizations, forming part of the same group, should be mentioned. Organizations Premises and Undertakings: Brief details of premises should be included quoting addresses, approximate floor space, and types of buildings. The scope of the Organizations aerospace undertakings, at the addresses of the various premises, should be defined. Terms of Approval: The Exposition Manual will form the basis of CAA Airworthiness Directorate Approval. A concise definition of the work authorized will be prescribed in the CAA Airworthiness Directorate terms of approval. It is recommended that the CAA Airworthiness Directorate Certificate and schedule of approval are reproduced and included in the Exposition Manual. The Schedule of Approval may, in some cases, be supplemented by Capability Lists. A Capability List must bear an version number and date and may not be amended without the agreement of the CAA Airworthiness Directorate. A note to this effect should be included at the bottom of the page. Personnel: This Section of the Exposition Manual should nominate the persons required under this ANO (grant of approval), giving their terms of reference within the Organization, and, in particular, outlining responsibilities for liaison with CAA Airworthiness Directorate.
2.3
2.4
2.5
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2.5.1 A diagram, or diagrams, showing chains of responsibility of nominated departmental heads, and senior technical personnel up to the Chief Executive should be included. These diagrams should also indicate, by suitable means, and / or written description, how technical co-ordination throughout the Organization is affected. In some cases, the Organization may wish to include more information, concerning personnel and their responsibilities, than is required by the Airworthiness Directorate, but amendments to the Exposition Manual which affect nominated staff, must not be made without Airworthiness Directorate concurrence.
2.5.2
2.6
Facilities: This Section should provide information concerning the Organizations technical facilities and associated essential equipment, which will vary according to the type(s) of activity involved and the specific terms of approval sought.
2.6.1 In the Section devoted to facilities, information under the headings given below should be included, where applicable. If there is a good deal of detailed information the use of Appendices is recommended.
(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) Research. Design/Drawing office. Development. Type Testing. Planning. Manufacture and/ or Process. Overhaul and Repair. Routine Testing. Storage * facilities for parts, equipment, tools and materials. Quality assurance and / or Inspection. Metrology and Standards. Specialized Facilities e.g. NDT, Spectrograph, Publications and Technical Library. Technical Records (Traceability, preservation and neatness) Product Support. Training.
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Storage condition shall provide security and prevention from deterioration and damage.
Note: All shops undertaking inspection / overhaul of instruments, Avionics etc. shall ensure dust free environment. 2.6.2 The headings should be varied to suit the size of the organization and its activities.
2.7
Procedures: A concise description is required of the Organizations technical procedures covering all aspects of work conducted within the CAA Airworthiness Directorate Terms of Approval; this should show how matters affecting airworthiness are controlled, by references, where appropriate, to existing internal instructions. In order to meet the Requirements, Organizations may select to establish a Quality Control system. The system adopted will, obviously, depend on the size and complexity of the Organization and the nature of the work undertaken.
2.7.1 The headings below are examples of the procedures which may need to be covered in the Exposition Manual:(a) (b) (c) (d) (e) Quality program, policy and administration, including the Quality Audit system. Product design and development control. Modification and repair procedures. Concession procedure. Product evaluation, including product approval, field responsibility and defect
investigation. (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) Reliability programs and its implementation. Control of bought out items, including Quality Control Surveillance of sub-contractors. Manufacture and process control. Control of stock, including procedures for handling non-conforming parts. Tool, metrology and test equipment control. Process Control. Technical records. Technical publications control, including Service Bulletin evaluation procedures. Equipment overhaul, modification and repair procedures, including certification. Test flight procedures. Training.
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APPENDIX B Exposition manual details (q) Appendices, giving examples of :
(i) (ii) (iii) (iv)
Standard forms, cross-referenced to the written procedures section; Tags indicating the purpose and use of each; Inspection stamps, and other identification symbols used to indicate status of part; Approved certificate and / or test certificate.
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Ano-002-Awrg-2.0 DT 4th April 2011

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APPROVAL OF ORGANIZATION (MANUFACTURING)

AIR NAVIGATION ORDER

VERSION : DATE OF IMPLEMENTATION : OFFICE OF PRIME INTEREST : 04/04/2011

2.0 04-04-2011 AIRWORTHINESS DIRECTORATE ANO-002-AWRG-2.0

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

D3.1.9 D3.1.10 D3.1.11 D3.1.12 D3.1.13

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

MANUFACTURING ORGANIZATION EXPOSITION MANUAL:

MAKING OF EXPOSITION MANUAL:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

EXPOSITION MANUAL ACCEPTANCE:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

PRIVILEGES OF THE APPROVAL:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

MANUFACTURING CERTIFICATE AMENDMENTS:

SAFETY AUDIT AND INSPECTIONS:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

ISSUANCE OF PRODUCTION CERTIFICATE:

NOTIFICATION OF CEASING MANUFACTURING:

AUTHORIZATIONS FOR MANUFACTURING PERSONNEL:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

SENIOR PERSONS RESPONSIBILITY:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

INSPECTION AND TESTING:

INTERNAL QUALITY ASSURANCE:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

PRODUCTION CONTROL PROCEDURES:

D24.1.2.2 example: D24.1.2.2.1 D24.1.2.2.2 D24.1.2.2.3 D24.1.2.2.4 D24.1.2.2.5 D24.1.2.2.6 04/04/2011

The process control procedures would include, for a non-destructive inspection as an

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

TESTING AND INSPECTION:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

SERVICE BULLETINS (SBs):

D26.1.1 D26.1.2 D26.1.3 D26.1.4 D26.1.5 D26.1.6 D26.1.7 D26.1.8 D26.1.9

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

D27.1.9.1 D27.1.9.2 D27.1.9.3 D27.1.9.4 D27.1.9.5 D27.1.9.6 D27.1.9.7 D27.1.9.8 D27.1.9.9

PRODUCTION TEST FLIGHT:

WEIGHT AND BALANCE:

PUBLICATIONS AND INFORMATION:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

D32.5.5 D32.5.6 D32.5.7 D32.5.8 D32.5.9

HUMAN RESOURCES AND FATIGUE FACTOR:

QUALIFICATION OF CERTIFYING PERSONNEL:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

D35.2.2 D35.2.3 D35.2.4

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

EQUIPMENT, TOOLS, AND MATERIAL:

D37.8.6 D37.8.7 D37.8.8

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

QUALITY CONTROL AND QUALITY ASSURANCE:

CONTRACT AND SUB-CONTRACT:

APPROVAL OF ORGANIZATIONS (MANUFACTURING)

CHANGES TO CERTIFICATE HOLDER'S ORGANIZATION:

TYPE EVALUATION COMMITTEE (TEC):

AMENDMENTS AND MODIFICATIONS:

EVIDENCES (ACRONYMS / RECORDS / REFERENCES):