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Model Repair Station and Quality Manual – NEW AND IMPROVED!

Submitted by Keith on Thu, 2008-05-01 11:00.

ARSA’s Model Repair Station and Quality Manual (“model manual”) was completely revised to help companies develop a repair station and quality control manual that complies with Title 14 Code of Federal Regulations (14 CFR) part 145 and the associated Federal Aviation Administration (FAA) guidance material.

The new and improved model manual addresses every paragraph of 14 CFR part 145. It contains the requirements for both a repair station manual and a quality control manual and can be customized to the particular operation with approximately 20 to 40 hours of work.

This publication is geared towards small to mid-sized companies and will prove most useful to component repair stations. Although directed at domestic repair stations, very few adjustments would be needed to show compliance with foreign repair station requirements.

ARSA first published the model manual in 2003; revision 4 is a complete re-write of the original. Specific changes include:

  • Adding an integrated Forms Manual (described below)
  • Integrating qualifications with duties and responsibilities
  • Adding provisions for hazardous material training and obligations for notification of air carrier will/will-not carry status
  • Adding provisions dealing with life-limited parts
  • Hyperlinking every section of the manual to the regulation and to internal sections and paragraphs
  • Providing detailed and more sophisticated Notes to Users for every section and paragraph to ensure proper adjustments can to be made to the manual.

The revised Model Repair Station and Quality Manual and integrated Forms Manual is available to Members who purchased the model manual before September 1, 2007, free of charge and to Non-Members who have previously purchased the manual for $1,000. When ordering the publication, please use the exact same company name so that we may verify your previous purchase and note in the "Remarks/Comments" field that you are requesting a complimentary copy based on a previous purchase. Complimentary copies will be issued via e-mail upon verification of prior purchase.

Forms Manual – NEW!

The Forms Manual provides forms, letters, lists and other documents along with instructions for their use. It is meant to support the main policies and procedures required to establish compliance with 14 CFR part 145 set forth in the model manual; however, most of the documents can be used in conjunction with any repair station manual.

This Forms Manual contains three sections:

  1. Section 1 outlines a procedure for revising the Forms Manual.
  2. Section 2 contains samples of maintenance and inspection forms and instructions for their use as required by 14 CFR § 145.211(c)(3), including the following:
    • Working Away From the Fixed Location Form and Instructions. The purpose of this form is to ensure the appropriate housing, facilities, equipment, tooling, maintenance data and personnel are available when work is performed away from the fixed location.
    • Work Order Form and Instructions. The purpose of the Work Order Form is to outline the basic requirements for work to be performed on articles received for maintenance, preventive maintenance or alteration. It is also meant to capture a general description of the work that was performed and all other forms that were used to describe that work. Stated simply, it is designed to track all the work performed, but not to describe all the work performed.
    • Repairable Tag and Instructions. The purpose of the Repairable Tag is to capture information on individual piece parts removed from a top assembly that need work before being reinstalled.
    • Continue-in-Service Tag and Instructions. The purpose of the Continue-in-Service Tag is to indicate that an individual piece part removed from a top assembly can be reinstalled without further maintenance, preventive maintenance or alteration. This tag is normally referred to as a “serviceable” tag. It indicates that the article has been inspected in accordance with data acceptable or approved by the Federal Aviation Administration (FAA) and found in an airworthy condition.
    • Rejection Tag and Instructions. The purpose of the Rejection Tag is to identify parts that are beyond economic repair or that must be scrapped.
    • FAA Form 8130-3. The purpose of FAA Form 8130-3 is to provide an approval for return to service (maintenance release) for the work performed as required by 14 CFR §§ 43.9(a)(4), 145.213(b) and 145.219(b). The Forms Manual samples provide instructions for completing this document under both 14 CFR and under the requirements for a dual release if the repair station also holds an approval from the European Aviation Safety Agency (EASA).
    • FAA Form 337: Major Repair or Alteration. The purpose of FAA Form 337 is to record major repairs or alterations in compliance with 14 CFR part 43, appendix B.
  3. Section 3 contains other forms and letters required to comply with other procedures outlined in 14 CFR part 145 and in the model manual, including the following:
    • Change Form and Instructions. The purpose of this form is to provide a method for persons to make suggested changes to manuals and forms used by the repair station.
    • FAA Form 8310-3—Application for Repair Station Certificate or Rating. The purpose of the form is to maintain compliance with 14 CFR § 145.57, which requires an amended certificate if the repair station changes its ratings, name or location.
    • Capability List Self-Evaluation Form and Instructions. The purpose of this form is to comply with 14 CFR § 145.209(d)(2), which requires repair stations with limited ratings that are keeping their own capability list under 14 CFR § 145.215(a) to perform a self-evaluation (see, 14 CFR § 145.215(c)) before adding articles to that list. This form can also be used to support a request for the change of rating if the repair station is keeping its capability list on its Operations Specifications.
    • Capability List and Instructions. The purpose of this form is to maintain the capability list required by 14 CFR § 145.215(b). That paragraph requires the article to be listed by make and model or nomenclature.
    • Repair Station Roster and Instructions. The main purpose of this form is to comply with 14 CFR §§ 145.161(a)(1)-(3) and 145.209(b). The form can also be used to assign stamps and track Required Inspection Item (RII) authorizations for inspectors.
    • Summary of Employment Form and Instructions. The purpose of this form is to establish compliance with 14 CFR § 145.161(a)(4). That paragraph of the regulations requires specific information be kept for every person assigned a management, supervisory, inspector or approval for return to service, duty, authority or responsibility.
    • FAA Form 8610-2—Airman Certificate and/or Rating Application. The purpose of this form is to apply for a repairman certificate when such a certificate is required as a qualification for an individual.
    • Will/Will-Not-Carry Notification Letter, List and Instructions. The purpose of this form is to establish compliance with 14 CFR § 145.206 as required by 14 CFR §§ 121.1005(e) and 135.505(e). The requirement only applies to repair stations that are hazardous material (HazMat) employers under the provisions of 49 CFR parts 171 through 180. Each time a part 121 or 135 carrier notifies the repair station of its status, if the repair station is a HazMat employer, it must notify its employees and sub-contractor of that carrier’s status. The letter has a form attached that will enable the repair station to track new carrier customer notifications of their carry or will-not carry status.
    • FAA Form 8120-11—Suspected Unapproved Parts Report. The purpose of the form is to report civil aviation articles that may represent a potential violation of 14 CFR.
    • Equivalency Determination Form and Instructions. 14 CFR §§ 43.13(a) and 145.109(c) require use of tools, equipment, test apparatus, materials and parts recommended by the manufacturer or otherwise found acceptable to the FAA. The purpose of this form is to provide a method for ensuring substitute tools, equipment, test apparatus and materials are equivalent to those recommended by the manufacturer. The form contains a set of instructions for establishing that substitutes are equivalent to the tools, equipment, and test apparatus recommended by the manufacturer; and a set of instructions for establishing that substitutes are equivalent to the materials and parts recommended by the manufacturer.
    • Calibration Tag and Instructions. The purpose of the Calibration Tag is to document the unique identification number of the equipment along with the calibration date and next due date.
    • Contracted Maintenance Functions Letter and Instructions. Under 14 CFR § 145.201(a)(2), a repair station may contract any maintenance for which is it rated; however, it must obtain approval of the maintenance functions it will contract and it must keep a vendor list. The purpose of this form is to ensure the maintenance functions being obtained by contract are approved by the FAA as required by 14 CFR §§ 145.209(h)(1) and 145.217(a)(2)(i).
    • Contract Maintenance Vendor List and Instructions. The purpose of this list is to establish compliance with 14 CFR §§ 145.209(h)(2) and 145.217(a)(2)(ii) and (b). These sections require the repair station keep a list of the maintenance vendors or contractors that perform maintenance functions (that have been approved by the FAA).
    • Audit and Action Form and Instructions. The purpose of this form is to address the requirements of 14 CFR § 145.211(c)(1)(ix). The form can also be used to establish compliance with the quality assurance requirements for an EASA approval.
    • FAA Form 8010-4: Malfunction or Defect Report. The purpose of this form is to establish compliance with the process for reporting a serious failure, malfunction or defect as required by 14 CFR § 145.221.
    • HazMat Training Certification Letter Instructions. The purpose of this form is to establish compliance with the 14 CFR §§ 145.53(c), 145.57(a) and 145.165(a). These regulations require a repair station to certify that its hazardous material employees have been trained in accordance with 49 CFR parts 171 through 180 when applying for a repair station certificate or for an amendment to an existing certificate.

Manual Format

The model manual and forms manual is in Microsoft Word 2003 format; editing should be accomplished by someone knowledgeable with that software.

Upon receipt of payment, ARSA will transmit the publication to you as a Zip attachment to an e-mail message. The manual is an electronic file only; no printed material or disk will be sent.

It is important that you review all requirements regarding electronic receipt of the program materials. The documents are sent electronically in a zip file. Please verify that our E-mail will not be filtered and subsequently rejected by your server. If it will be rejected, please contact us so we can find an alternative delivery method.

Disclaimer

These documents are not all-inclusive; each repair station is unique. Modifications to this model manual and Forms Manual will be required to ensure the specific procedures and forms used by the repair station will comply with the regulations. Further, the model manual does not address satellite repair stations. If your company wishes to develop a managerial repair station with satellites, please contact ARSA for assistance in modifying this document to meet those requirements.

Pricing Information

Model Repair Station and Quality Manual with integrated Forms Manual is available to Members for $750 and Non-Members for $1500.

The Forms Manual as a stand-alone document is available to members for $250 and Non-Members for $500.

Individual forms from the Forms Manual are available free of charge to Members ONLY.

NOTE: Members should read the individual form descriptions outlined above and use the publication order form to order individual forms. The individual forms include instructions, but do not include the procedure for revising the Forms Manual (Section 1 of the Forms Manual described above). Individual forms will be sent upon verification of membership status.

The revised Model Repair Station and Quality Manual and Forms Manual is available to Members who purchased the model manual before September 1, 2007, free of charge, and to Non-Members who have previously purchased the manual for $1,000.

NOTE: You may order your complimentary copy of the model manual using the publication order form. Please take care to use the exact same company name so that verification your previous purchase can be made, and note in the “Remarks/Comments” field that you are requesting a complimentary copy based on a previous purchase. Complimentary copies will be issued via e-mail upon verification of prior purchase.

Copyright Information

The Model Repair Station Manual and Quality Manual and Forms Manual are the property of the Aeronautical Repair Station Association. Unauthorized reproduction and/or distribution of any Model is an infringement of ARSA's copyright.

The Models are licensed to the purchaser's repair station location. A transmittal page containing the license accompanies each Model.

Click here to order the Model Repair Station and Quality Manual with integrated Forms Manual

Click here to order the Forms Manual ONLY

Click here to order Individual Forms