faa approved repair station repair station number …
TRANSCRIPT
Chapter: 0 Page: 1 Rev: V March 12, 2018
GE PROPRIETARY INFORMATION This document contains trade secrets and confidential competition sensitive commercial or financial information exempt from disclosure under the FREEDOM OF INFORMATION ACT (FOIA) 5 USC §
552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
Repair Station Manual / Quality Manual
F A A A P P R O V E D R E P A I R S T A T I O N
Repair Station Number AD12004K
Manual Number Two
General Electric Company
General Electric Aircraft Engines Peebles Operation
1200 Jaybird Road
Peebles, Ohio 45660
Telephone 937-587-2631
Chapter: 0 Page: 2 Rev: V March 12, 2018
GE PROPRIETARY INFORMATION This document contains trade secrets and confidential competition sensitive commercial or financial information exempt from disclosure under the FREEDOM OF INFORMATION ACT (FOIA) 5 USC §
552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
Table of Contents TABLE OF CONTENTS ................................................................................................................................................................................................................... 2
INTRODUCTION ................................................................................................................................................................................................... 5
A. INTRODUCTION OF REPAIR STATION MANUAL .............................................................................................................................................. 6 B. REPAIR STATION OVERVIEW .......................................................................................................................................................................... 7 E. DISPLAY OF CERTIFICATE AND OPERATIONS SPECIFICATIONS .................................................................................................................... 8 F. CHANGES TO CERTIFICATE ............................................................................................................................................................................. 8 G. PRIVILEGES AND LIMITATIONS OF THE CERTIFICATE .................................................................................................................................. 9 H. FAA INSPECTIONS ........................................................................................................................................................................................... 9
MANUAL REVISION AND CONTROL .................................................................................................................................................................................... 10
A. LISTING OF PAGE REVISIONS ......................................................................................................................................................................... 11 B. LIST OF EFFECTIVE PAGES............................................................................................................................................................................. 12
1. Manual Revision ................................................................................................................................................................................................................... 13 2. Control Process .................................................................................................................................................................................................................... 17
ORGANIZATION ............................................................................................................................................................................................................................. 19
A. ORGANIZATIONAL CHART ............................................................................................................................................................................ 20 REPAIR STATION ORGANIZATION ................................................................................................................................................................................... 22
B. ROSTER OF KEY PERSONNEL ........................................................................................................................................................................ 23 C. MANAGEMENT AND SUPERVISORY PERSONNEL .......................................................................................................................................... 26
1. Accountable Manager .......................................................................................................................................................................................................... 26 DUTIES: ..................................................................................................................................................................................................................................... 26 3. Chief Inspector ...................................................................................................................................................................................................................... 27 4. MRO Quality Lead ............................................................................................................................................................................................................... 29 5. Certified Repairman / Supervisor ...................................................................................................................................................................................... 29 6. Inspector(s) ............................................................................................................................................................................................................................ 31 7. NDT Inspector and Special Process Control ................................................................................................................................................................... 33 8. Materials Technician: .......................................................................................................................................................................................................... 33 9. Program/Test Leader(s) ...................................................................................................................................................................................................... 33 10. Technician(s)....................................................................................................................................................................................................................... 35
D. EMPLOYMENT SUMMARIES OF KEY PERSONNEL ........................................................................................................................................ 36 E. RECOMMENDATION OF A PERSON FOR CERTIFICATION AS A REPAIRMAN ................................................................................................ 36 F. PROFICIENCY OF INSPECTION PERSONNEL .................................................................................................................................................. 36 G. HOUSING, FACILITIES, EQUIPMENT AND MATERIALS ................................................................................................................................. 37
1. Floor Plan of the Facility.................................................................................................................................................................................................... 38 2. Equipment .............................................................................................................................................................................................................................. 42 3. Equivalent Tools ................................................................................................................................................................................................................... 43 4. Stock Room/Area .................................................................................................................................................................................................................. 44
H. SATELLITE REPAIR STATIONS ...................................................................................................................................................................... 46
REPAIR STATION OPERATIONS .............................................................................................................................................................................................. 47
A. REPAIR STATION OPERATIONS ..................................................................................................................................................................... 48 B. CONTINUITY OF INSPECTION RESPONSIBILITY ............................................................................................................................................. 51 C. RECEIVING INSPECTION ................................................................................................................................................................................. 51 D. HANDLING OF PARTS AND PROTECTION OF ARTICLES ............................................................................................................................... 55 E. TAGGING AND IDENTIFICATION OF ARTICLES ............................................................................................................................................. 58 F. SAFETY, SECURITY AND FIRE PROTECTION ................................................................................................................................................. 60 G. INCOMING INSPECTION OF RAW MATERIALS .............................................................................................................................................. 62 H. ARTICLE PRELIMINARY INSPECTION ........................................................................................................................................................... 62 I. HIDDEN DAMAGE INSPECTION – POST ACCIDENT ........................................................................................................................................ 64 J. IN-PROCESS INSPECTION ................................................................................................................................................................................ 64 K. FINAL INSPECTION ........................................................................................................................................................................................ 65 L. WORK SIGN-OFF ............................................................................................................................................................................................ 68 M. MAINTENANCE RELEASE – APPROVAL FOR RETURN TO SERVICE ............................................................................................................. 69 N. CALIBRATION ................................................................................................................................................................................................. 71 O. WORK PERFORMED AT ANOTHER LOCATION ............................................................................................................................................. 74
Chapter: 0 Page: 3 Rev: V March 12, 2018
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1. Special Circumstances ......................................................................................................................................................................................................... 75 2. Recurring Basis .................................................................................................................................................................................................................... 76
P. MAINTENANCE PERFORMED FOR AIR CARRIERS......................................................................................................................................... 77 1. Control of Operator Data ................................................................................................................................................................................................... 78 2. Required Inspection Item .................................................................................................................................................................................................... 78 3. Duty Time Limitations ......................................................................................................................................................................................................... 78
Q. CONTRACT MAINTENANCE ........................................................................................................................................................................... 79 1. Contract Administrative Provisions .................................................................................................................................................................................. 80 2. Contracting to FAA-certified Facilities ............................................................................................................................................................................ 80 3. Contracting to Non-FAA-Certified Facilities .................................................................................................................................................................. 81
R. CURRENT TECHNICAL DATA ........................................................................................................................................................................ 82 S. INTERNAL AUDIT PROGRAM .......................................................................................................................................................................... 84 T. PRODUCTION OF REPLACEMENT OR MODIFICATION PARTS ....................................................................................................................... 86 U. RECORDKEEPING ........................................................................................................................................................................................... 86 V. AIRWORTHINESS DIRECTIVE (AD) COMPLIANCE ........................................................................................................................................ 87 W. LIFE LIMITED PARTS.................................................................................................................................................................................... 87 X. SUSPECTED UNAPPROVED PARTS ................................................................................................................................................................. 88
TRAINING ......................................................................................................................................................................................................................................... 89
A. TRAINING PROGRAM ..................................................................................................................................................................................... 89
CORRECTIVE ACTIONS .............................................................................................................................................................................................................. 90
A. TAKING CORRECTIVE ACTIONS ON DEFICIENCIES ....................................................................................................................................... 91 1. Corrective Action Process .................................................................................................................................................................................................. 91
B. PROCEDURE REVISION .................................................................................................................................................................................. 92
SERVICE DIFFICULTY REPORTS ............................................................................................................................................................................................ 93
VOLUNTARY DISCLOSURE PROGRAM ............................................................................................................................................................................... 93
A. SERVICE DIFFICULTY REPORTS ............................................................................................................................................................ 94 B. VOLUNTARY DISCLOSURE REPORTING ................................................................................................................................................. 95
DRUG TESTING ............................................................................................................................................................................................................................ 978
Chapter: 0 Page: 4 Rev: V March 12, 2018
GE PROPRIETARY INFORMATION This document contains trade secrets and confidential competition sensitive commercial or financial information exempt from disclosure under the FREEDOM OF INFORMATION ACT (FOIA) 5 USC §
552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
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Chapter: 1 Page: 5 Rev: V March 12, 2018
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Introduction
Chapter
1
Chapter: 1 Page: 6 Rev: V March 12, 2018
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A. Introduction of Repair Station Manual
This repair station and quality manual is prepared in accordance with 14 CFR Part 145, 66 FR 41087,
effective January 31, 2004, subsequent amendments, and policies of the General Electric Company.
Additionally, this manual follows the guidance in AC 145-9, Guide for Developing and Evaluating
Repair Station and Quality Control Manuals.
The manual is set up in electronic format with hyperlinks to various procedures, process descriptions,
Quality Control Work Instructions (QCWI) and forms. All hyperlinked documents form a part of this
manual. Many hyperlinked documents are part of the General Electric Company quality system as
reviewed and approved by the FAA under the authority of Production Certificate #108. For example,
General Electric Company maintains one gage calibration system operated according to defined
quality system QCWI(s) requirements. To maintain continuity of systems within General Electric
Company, gages used during production operations and gages used during repair station operations
are calibrated per these General Electric Company system requirements. General Electric Company
has not created two separate systems, one for production operations and one for repair operations.
Notwithstanding references to quality system procedures and work instructions that are used during
production operations, those procedures form a part of this manual and when used during repair
operations are considered part of the repair station certificate. Credit for use of the General Electric
Company’s FAA-approved Production Certificate quality system is provided for in 66 FR 33142;
June 21, 1999.
Maintenance operations are performed in accordance with the current Federal Aviation Regulations
(FAR), manufacturer’s data, drawings approved as part of the type design, specifications,
Airworthiness Directives, Service Bulletins, or other technical data approved by the FAA
Administrator.
This repair station does not maintain or alter any items for which it is not rated. It does not maintain or
alter any article for which it is rated if the maintenance or alteration requires technical data,
equipment, materials, facilities or trained personnel that are not available to repair station personnel.
This manual, required for operation of this repair station, is maintained in a current status at all times.
A hard copy of this manual, maintained by the Chief Inspector, is kept at the Chief Inspector's desk.
The hard copy is maintained for the purpose of original signatures. The hard copy of this manual does
not include hard copies of all hyperlinked documents and forms. The master copy of this manual is
maintained on the Peebles Intranet and is the copy used by repair station personnel to perform repair
station operations. Each supervisor and inspector working under the authority of the repair station
certificate has electronic access to a current copy of this manual via the Intranet. Each supervisor and
inspector thoroughly understands how to access manual contents, including hyperlinked documents.
Chapter: 1 Page: 7 Rev: V March 12, 2018
GE PROPRIETARY INFORMATION This document contains trade secrets and confidential competition sensitive commercial or financial information exempt from disclosure under the FREEDOM OF INFORMATION ACT (FOIA) 5 USC §
552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
B. Repair Station Overview
The original site, consisting of approximately 4500 acres, was purchased in 1954, additional purchases
bring the current size to approximately 7000 acres. Peebles Test Operations began large-scale
development testing in the 1960s with outdoor testing and Qualification of the TF39, the General
Electric Company's first high bypass turbofan engine. In the late 1960's development test activity
increased with testing and Certification of the CF6-6 engine for the McDonnell Douglas DC10
aircraft, which entered service in 1971. Peebles continues to be instrumental in performance of FAA
Certification tests such as; water injection, cross wind, ice ball and ice slab ingestion, ice accretion,
small, medium and large bird ingestion, acoustics, dust ingestion, blade-out, aero-mechanical, etc.
These types of tests have been completed on the following commercial engine models:
CF6-6, CF6-50, CF6-80C2, CF6-80E, CFM56-2, CFM56-3, CFM56-5, CFM56-7, CF34-8C,
CF34-8E, CF34-10E, CF34-10A, GE-90, GE90-115B, GP7200, GEnx and LEAP
In 1985 Peebles Test Operation began Production Acceptance testing and Prep-to-Ship to GENERAL
ELECTRIC COMPANY customers under GE’s Production Certificate # PC108. This effort
continues with both domestic orders and exports to customers and countries around the world.
The Peebles Test facility received FAR145 “Limited” Repair Station authorization in 1991 under the
identification of CFR #AD12004K. In 1997 Peebles received a FAR145 “Class III Turbine” Repair
Station authorization with an Operations Specifications "Unlimited" rating.
The Peebles Test Operation facility currently has approximately 360 permanent employees. Repair
Station activities co-exist with PC108 and Development activities within the facility. Assembly, Prep
to Test, Test and Prep to Ship activity is completed in four (4) buildings and eleven (11) Test sites as
detailed below:
· ESC (Ed Spear Complex)/GE90 Building/Prep Building /LEPB/MMPB/PTO West:
ESC - Serves as the administrative building and contains the Calibration laboratory.
GE90 Building - Contains an engine hardware crib, 5 workstations used for assembly /
disassembly, 2 Prep to Test Stations, 1 DPREP Station.
Prep Building - Contains the Repair Station engine hardware crib, 6 workstations used
for assembly / disassembly, and Prep to Ship (as applicable).
LEPB – Contains 2 workstations used for assembly / disassembly and multiple Prep to
Test and Prep to Ship workstations primarily used for large turbofan engines.
MMPB – Contains 2 workstations used for assembly / disassembly and multiple Prep
to Test and Prep to Ship workstations primarily used for small turbofan engines.
PTO West – Contains 4 workstations used for assembly / disassembly.
Chapter: 1 Page: 8 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
· There are 11 active test sites 4 indoor (5A, 5B, 5C, 5D)7 outdoor (3B, 3C, 3D, 3E, 4D, 6A, 7).
C. Repair Station Ratings
The Repair Station currently holds two ratings.
• Limited Powerplant Rating: Limitations as defined on the Operations Specification.
• Limited Airframe Rating: Limitations as defined on the Operations Specification.
D. Operations Specifications
The Peebles Repair Station holds a Limited Powerplant Rating: Limited to GE, CFMI, and Engine
Alliance and a Limited Airframe Rating: Limited to Boeing, Airbus, Embraer, and Bombardier,
Removal, Inspection, Repair and Installation of Engine Change (QEC) Components, providing proof
of the repair station authorizations. Per FAA regulations only those engines, components and/or
accessories listed are approved for return to service. New engines, components or accessories are not
approved for return to service until the Operating Specification is revised and approved by the FAA.
Additionally the facility has a PC-108 Certificate and is ISO 9001 certified.
E. Display of Certificate and Operations Specifications
The Repair Station Certificate and Operations Specifications are available on the premises for
inspection by the public and the FAA upon request. Reference FAR 145.5.
F. Changes to Certificate
Changes that affect the Repair Station Certificate are processed through the CVG (FSDO) Flight
Standards District Office by the Peebles Repair Station AD 12004K. Reference FAR 145.57. Changes
that affect the certificate are:
• Location of the Repair Station facilities
• The addition or deletion of a rating
• The sale or transfer of assets of the Repair Station
Changes to the Repair Station Certificate will be submitted to the FSDO at least 30 calendar days prior
to the anticipated change effective date.
Chapter: 1 Page: 9 Rev: V March 12, 2018
GE PROPRIETARY INFORMATION This document contains trade secrets and confidential competition sensitive commercial or financial information exempt from disclosure under the FREEDOM OF INFORMATION ACT (FOIA) 5 USC §
552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
NOTE: Changes to housing and facilities (other than location) do not require a change to the repair
station certificate. However, if this repair station makes any changes to its housing or facilities that
could have a significant effect on the ability to perform maintenance or alterations under the certificate
and operations specification, the Chief Inspector will submit the proposed changes to the FAA for
approval. Reference FAR 145.105. A specific form is not required for submission of changes, but the
format must be acceptable to the FAA.
G. Privileges and Limitations of the Certificate
This repair station performs maintenance, preventative maintenance or alterations under the provisions
of 14 CFR Part 43 on articles for which the repair station is rated and within the limits of the repair
station operations specifications. This repair station approves for return to service only articles for
which it is rated. The Ratings and Limitations (A003) will be maintained as part of the Repair Station
Operations Specification
Revision to the Operations Specification requires a self-evaluation be conducted by the Chief
Inspector. The self-evaluation will be documented on GE Letterhead, and will address the following
items.
• Tooling / Equipment
• Facilities and Housing
• Availability of Technical data
• Material
• Process
• Availability of Trained Personnel
Completed self-evaluations will be maintained on file by the Chief Inspector.
Request for change to Ratings and Limitations (A003) list will be submitted to the FSDO by the Chief
Inspector on FAA Form 8310-3.
H. FAA Inspections
The FAA inspects the repair station operations at any time to determine compliance with the FAR.
Repair Station personnel provide full cooperation to the FAA. The repair station inserts in contracts
with non-certificated persons a clause that provides FAA access at any time to the work performed by
the non-certificated person and the facilities at which the work is performed. Reference FAR 145.223.
Chapter: 2 Page: 10 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
Manual Revision and Control
Chapter
2
Chapter: 2 Page: 13 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
C. Manual Revision and Control Process
PURPOSE: This chapter contains information regarding how this manual is revised and how
revisions to the manual are controlled to ensure only the current version of the manual is available
to repair station personnel.
SCOPE: This section is applicable to the revision and control of both electronic and hard copy
manuals maintained at this repair station.
RESPONSIBILITY: The Chief Inspector is responsible for compliance with this section of the
manual.
REFERENCE(S):
• FAR 145.209(j) & (k)
• AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control Manuals,
Chapter 1, Paragraph 1-2
• AC 120-78, Acceptance and Use of Electronic Signatures, Electronic Record keeping
Systems, and Electronic Manuals
• GE Policy 022.01 – Records and Information Management Implementing Procedure
DEFINITIONS: N/A
1. Manual Revision
Pro cedu re : Ma nual Rev i s io n
• This manual is reviewed, or revised, by the Chief Inspector at intervals not to exceed two
years. Interim requests to revise the manual are submitted to the Chief Inspector or the
Quality Manager.
o A running list of proposed changes to this manual is kept by the Chief Inspector
until such a time that it becomes practical, or necessary, to submit the proposed
changes to the CVG FSDO.
• With the exception of minor corrections, such as spelling or grammatical errors, all
requests to change the manual are submitted via e-mail, to the CVG FSDO for acceptance
prior to incorporation.
• Temporary revisions to this manual are allowed with FSDO approval. Temporary
approval consists of notification of necessary changes sent by the Chief Inspector, attached
to an e-mail that includes the "e-mail electronic" signature of the Chief Inspector, to the
Chapter: 2 Page: 14 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
CVG FSDO. A reply e-mail from the FSDO, accepting the changes, that includes the e-
mail "electronic" signature of the Chief Inspector and the FSDO e-mail address is
considered proof of acceptance of the changes. The fax machine, or on site signatures, are
acceptable alternatives.
o Documentation of FSDO acceptance via e-mail is printed and retained by the
Chief Inspector, as proof of acceptance, until finalized changes are submitted.
Finalized changes are required to be sent to the FSDO within 5 working days.
o Unless approved by the Chief Inspector, and accepted by the FSDO, on a signed
Work Request (See Forms Manual) no engine may be "Returned to Service"
(shipped) on a temporary revision. No recalls of temporary revisions are required.
Retention of temporary change "approvals" is not required once the final change is
approved.
• For final changes the Chief Inspector, or designee, prepares the proposed change in final
form on the page(s) where they occur. This includes update of the revision number and
effective date on each page being revised prior to submission for approval.
• The Chief Inspector updates the "Rev No, Rev Date and Reason for Change blocks" on
the "Listing of Page Revisions" to indicated the proposed changes. The Listing of Page
Revisions serves as a cover letter to explain the reason for the change. It is signed by the
Accountable Manager and the Facility Quality Leader to indicate approval of the changes.
Additionally, the "List of Effective Pages" is updated and signed by the Chief Inspector to
document the page(s) where changes are proposed.
o The updated manual pages, the updated "Listing of Page Revisions" and "List of
Effective Pages” are scanned, and the proposed change(s) are attached, to an e-
mail that includes the "e-mail electronic" signature of the Chief Inspector. These
are sent to the CVG FSDO for acceptance. The fax machine, or on site signatures,
are acceptable alternatives.
• Acceptance by the CVG FSDO can be in any documented form acceptable to the FSDO
including e-mail. A reply e-mail from the FSDO, accepting the changes, that includes the
e-mail "electronic" signature of the Chief Inspector and the FSDO e-mail address, is
considered proof of acceptance of the changes.
o Documentation of FSDO acceptance via e-mail is printed and retained by the
Chief Inspector, along with the "List of Effective Pages" and the "Listing of Page
Revisions" containing the original signatures.
• Once acceptance of a revision from the CVG FSDO is received, the Chief Inspector
inserts the revised pages at the points as indicated by the List of Page Revisions. The Chief
Inspector signs in the "Inserted By block" on the List of Page Revisions as proof that the
revisions are implemented.
Chapter: 2 Page: 15 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• Following update to the hardcopy manual the Chief Inspector notifies Peebles Intranet
support personnel to update the electronic copy of the manual. The electronic version of
the manual is identified with the same control number as the hardcopy master maintained
by the Chief Inspector.
o Once the electronic update is complete, the Chief Inspector is responsible to audit
the electronic manual and verify that the electronic version is the same as the
master hardcopy in his possession.
• Following the Chief Inspector's audit, changes to the manual are announced to Repair
Station personnel via e-mail. Record of this announcement is not maintained.
• The electronic version is available to all Repair Station employees via the shop computers
located at individual workstations. Repair Station personnel involved in performance of
maintenance, preventative maintenance or alterations work to the electronic version of the
manual.
• Once all approval signatures are in place a second hardcopy of the manual is made by the
Chief Inspector for distribution to the FSDO within 5 working days. This Manual cover is
identified as number ONE and the Listing of Page Revisions in that copy identifies the
FSDO as the approved manual holder and "Signatures on file" where previously approved
/ accepted.
• Training – Peebles personnel involved in, or responsible for, repair station maintenance,
preventative maintenance or alterations are provided training prior to listing on the Roster
of Authority. This training includes how to access the electronic manual on line.
• Data Archive – Prior versions or revisions of the manual are archived by the Chief
Inspector so maintenance activities are traceable to a specific manual revision. Archive
procedures are as follows:
o The replaced hardcopy pages/sections are filed by the Chief Inspector in a folder
and labeled by date replaced. These are filed, along with the original signatures or
e-mail approvals, by the Chief Inspector for 5 years minimum.
o The hardcopy records are retained on site by the Chief Inspector for 5 years
minimum as defined by General Electric Company policy 022.01 - Records and
Information Management Implementing Procedure. A record of revision to any
QCWI's referenced by the manual are automatically maintained by the General
Electric Company system.
o To prevent possible total loss Peebles Intranet support personnel will periodically
electronically backup copy the electronic manual.
Chapter: 2 Page: 16 Rev: V March 12, 2018
GE PROPRIETARY INFORMATION This document contains trade secrets and confidential competition sensitive commercial or financial information exempt from disclosure under the FREEDOM OF INFORMATION ACT (FOIA) 5 USC §
552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• The manual is written using Microsoft Word, or other Microsoft applications, for final
publication. This includes local forms utilized by repair station personnel during
maintenance activity. Attached forms that are repair station specific include instructions
for completion. Personnel responsible for completion of attached FAA forms have access
to instructions for completion of those forms.
Note: New computer systems/applications must be able to retrieve the stored data. For
example, if MSWord 2000 can’t retrieve data stored in MSWord95 then a copy of
MSWord95 must be maintained for data retrieval.
ELECTRONIC SIGNATURES – obtain FAA concurrence before implementing. FAA will
provide Letter of Acceptance. Reference AC 120-78, Acceptance and Use of Electronic
Signatures.
• Peebles is authorized to utilize e-mail as a means of electronic approval provided the
communication is between the FAA and the Chief Inspector or the Quality Team Leader
and includes the "electronic signature" of the initiating party in the reply. (VeriSign, or
similar system, digital signatures and Encryption may be required).
• Peebles is authorized to utilize e-mail as a means of electronic approval provided the
communication is between the Customer and the Chief Inspector, or a Return to Service
Certified Repairman, and includes the "electronic signature" of the initiating party in the
reply. (VeriSign, or similar system, digital signatures and Encryption may be required).
• Each page of this manual, which has been revised, will be annotated according to the page
footer of each page. Each revision will be sequentially numbered starting with revision A
as the first change to this manual. On revised pages the revision number will be entered in
the page footer. The date of the revision will also be entered in the page footer in the
month/day/year format, i.e. January 1, 2004. For the hard copy of the manual, The "List
of Effective Pages" and the Listing of Page Revisions are the only Signature pages. Once
signed or approved they are the proof of approval/acceptance.
Chapter: 2 Page: 17 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
2. Control Process
Pro cedu re : Con t ro l Pro cess
• There are two (2) hardcopies of the Repair Station and Quality Manual and one (1)
electronic copy. These are distributed as follows:
o Hardcopy (# 1) One is provided to the FAA FSDO.
o Hardcopy master (# 2) Two is printed and maintained by the Chief Inspector.
o One (1) electronic copy of the manual is maintained on the Peebles Test Operation
PTO Intranet, which is controlled and secured. The electronic version of the
manual is identified with the same Control Number as the Hardcopy Master
maintained by the Chief Inspector.
• Acceptance by the CVG FSDO can be in any documented form acceptable to the FSDO
including e-mail.
• The electronic version is available to all Repair Station employees via the shop computers
located at individual workstations. Repair Station personnel involved in performance of
maintenance, preventative maintenance or alterations are required to work to the electronic
version of the manual.
• Once all approval signatures are in place a second hardcopy of the manual is made by the
Chief Inspector for distribution to the FSDO within 5 working days.
• Changes are identified on the "List of Effective Pages" by; Section, Page number, Date
and Revision. Additionally the Revision number and Effective date on each page being
revised is updated prior to submission for approval.
RECORDS:
• Master copy of manual with original signatures
• Listing of Revised Pages
• Individual revised manual pages
• Revision acknowledgement letter (e-mail)
• Submission cover letter
Chapter: 2 Page: 18 Rev: V March 12, 2018
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Chapter: 3 Page: 19 Rev: V March 12, 2018
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Organization
Chapter
3
Chapter: 3 Page: 20 Rev: V March 12, 2018
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A. Organizational Chart
PURPOSE: This section provides an organizational chart that identifies each
management/supervisory position (by title only) with authority to act on behalf of the repair
station as well as a roster of key personnel. Additionally, employment summaries for each person
on the roster are kept at the desk of the Chief Inspector.
SCOPE: This section encompasses repair station management/supervisory personnel. Such
personnel may also be management/supervisory personnel responsible for production operations.
The organization chart clearly delineates the separation of responsibilities under repair station
operations.
RESPONSIBILITY: The responsibilities of each key person are listed within this chapter.
REFERENCE(S):
• FAR 145.151, 145.153, 145.155, 145.157, 145.159, 145.161 and 145. 209(a)
• AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control
Manuals, Chapter 3 & 4
DEFINITIONS:
• Accountable Manager – means the person designated by the certificated repair station
who is responsible for and has the authority over all repair station operations that are
conducted under 14 CFR Part 145, including ensuring that repair station personnel
follow the regulations; and serving as the primary contact with the FAA.
• Article – means an aircraft engine or component part.
• Certified Repairman / Supervisor – means a person who oversees the work performed
by any individuals who are unfamiliar with the methods, techniques, practices, aids,
equipment, and tools used to perform maintenance or alterations. Peebles Repair
Station Chief Inspector and Repairman/Supervisor(s) hold Part 65 certification.
• Chief Inspector - means a Part 65 certificate holder who provides guidance and
direction for interpretation of the FAR's under Parts 65, 91, 121, 135, and 145 as they
apply to the Repair Station. Serves as a focal point with the FAA and responsible to
control, document and approve changes to Repair Station operations.
• MRO Quality Lead- means a person who will assist the Chief Inspector and serve as a
focal point with the FAA and responsible to control, document and approve changes
to Repair Station operations as a deligate to the Chief Inspector.
Chapter: 3 Page: 21 Rev: V March 12, 2018
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• Inspector – means a person who performs inspections under the repair station
certificate or operations specifications. An inspector is thoroughly familiar with the
applicable regulations in Part 145 and with the inspection methods, techniques,
practices, aids, equipment, and tools used to determine the airworthiness of the article
on which maintenance or alterations are being performed. An inspector is proficient in
using various types of inspection equipment and visual inspection aids appropriate for
the article being inspected. Peebles Repair Station inspectors are Part 145.155
qualified.
• Material Handling Personnel - means a person(s) trained in receipt of piece parts and
components into the repair station. These persons are familiar with inspecting
material and components for handling damage, and verification that such material has
a Certificate of Conformance permitting the usage of the item by the Repair Station.
• RII Inspector - means a person trained by a specific air carrier and given written
information to each person so authorized describing the extent of his/her
responsibilities, authorities, and inspectional limitations to complete Required
Inspection Items.
• Technician - means a person(s) providing assembly and disassembly labor and
material handling general inspections. Persons working in this capacity are required to
be under direct supervision of a Part 65 Chief Inspector or a Certified
Repairman/Supervisor.
• Quality Leader – means the lead quality representative with respect to repair station
operations. Implements, manages, and oversees the operation on the General Electric
Company quality system as the system pertains to repair station operations.
Chapter: 3 Page: 22 Rev: V March 12, 2018
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REPAIR STATION ORGANIZATION
Solid line represents reporting responsibility for all maintenance activity performed under
and by the Repair Station, which this manual governs.
Dashed line establishes a line of communication and coordination activities for
scheduling, auditing, workscope development, and informational purposes associated
with Repair Station activities.
Peebles Manager / Accountable Manager
Technicians Inspectors
Including
NDT
Certified Repairman /
Supervisor
Chief Inspector
Quality Leader
Program
Leader(s)
Test Team
Leader(s)
Material
Handling
Personnel
ATO Quality Leader
MRO Quality Lead
Chapter: 3 Page: 23 Rev: V March 12, 2018
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B. Roster of Key Personnel
Pro cedu re : Ro s ter o f Key Pers onn e l
• An electronic roster of the Peebles Repair Station Key Personnel is maintained on the
Peebles Intranet by Peebles Intranet support personnel. The Roster is approved by the
Chief Inspector and accepted by the FSDO in accordance with this manual. The Roster
includes the information in Table A below. The roster is available on the Peebles Quality
Systems Home Page via the PTO Repair Station link.
• A hardcopy summary of Repair Station Key Personnel is maintained by the Chief
Inspector providing documentation of applicable personnel identification, qualifications
and their authority to act on behalf of the Repair Station as indicated by the electronic
roster.
• The hardcopy version of the Repair Station Key Personnel is kept, along with the
hardcopy of the Repair Station and Quality Control Manual, at the Chief Inspector's desk.
• The Quality Leader, following consultation with the Accountable manager and staff,
selects and recommends additions to the Roster for positions of Chief Inspector and
Return To Service Certified Repairman based on needs in the Repair Station business.
• Any application to change the Roster is made to the Chief Inspector for review prior to the
change. This includes changes caused by termination, reassignment, change in duties or
scope of assignment, or addition of personnel. Ref: FAR 145.161. Changes do not
require revision of this manual.
• Once documented and approved, all changes require CVG FSDO notification within 5
business days of the change. A record of FSDO approval is retained. This record can be
in any form acceptable to the FSDO provided it is retained.
• The Peebles Repair Station reviews overtime worked versus current staff and projected
workload to determine staffing level requirements and to determine that there is a
sufficient number of employees for the work being performed.
Personnel Back-up Roster *
Functional Responsibility Back-Up Accountable Manager Quality Leader
Quality Leader Accountable Manager/Chief Inspector
Program & Test Team Leader(s) Quality Leader/Certified Repairman
Chief Inspector Return to Service Certified Repairman
(regulatory) / Quality Leader (administrative).
MRO Quality Lead as Deligated
Chapter: 3 Page: 24 Rev: V March 12, 2018
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MRO Quality Lead Chief Inspector/Quality Leader
Return to Service Certified Repairman Chief Inspector
Certified Repairman/Supervisor Certified Repairman/Supervisor
Material Crib Technician Certified Repairman/Supervisor
Inspector Not required
Technician Not required
*Delegation of duties is handled via E-mail, which notifies the specific individual to cover in
someone’s absence.
TABLE A *
First
Name
Middle
Name
Last
Name
Badge
Number
** Title ** Area of Responsibility
Xxx Xxx Xxx Xxx Xxx As documented on separate
Tabs within the Excel File.
* Example only. Variation of Table A format permitted within the electronic file.
** Excel file "Tab" indicates Title and defines Area of Responsibility:
• Signatures for identifications of persons authorized to complete maintenance inspections or Return
to Service are maintained on the Employment Summary by the Chief Inspector.
• Accountable Manager - Is responsible for the Repair Station operations under FAR Part 145.
• Chief Inspector and Return To Service Certified Repairman - Authorized to supervise Inspectors
(as necessary) and Technicians. Authorized to claim any identified inspections, complete
Preliminary Inspections and Hidden Damage Inspections. Authorized to complete FAA Forms
that approve items for Return to Service as limited by the Roster of Authority.
• Repairman/Supervisor - Authorized to supervise Inspectors (as necessary) and Technicians.
Authorized to perform identified inspections, complete Preliminary Inspections and Hidden
Damage Inspections.
• Inspector - Authorized to claim any identified inspections, complete Preliminary Inspections and
Hidden Damage Inspections except those identified as "S" (Supervisor) or "RII" Required
Inspection Items.
CAUTION: Inspectors are made aware during training that they may work as technicians on
any given job except for those tasks that require inspection of their own work. In such cases a
technician, or another inspector, performs the task and a second inspector performs the
inspection.
Chapter: 3 Page: 25 Rev: V March 12, 2018
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• Material Handling Technician - Inspector qualified and trained to receive hardware into the Repair
Station Crib.
o Material Crib Technician training requires review and acknowledgment of SUPS training
presentation.
o A Facilities Crib Technician is trained to receive consumables into the facility under PC-
108 quality procedures. This person(s) is not listed on the Roster but records are on file
providing proof of training in receiving, labeling and storage of consumables including
Material Age Control.
• Technician - Claims work accomplished while working under direct supervision of a Certified
Repairman/Supervisor. Are required to adhere to FOD inspections but has no authorization or
qualification to claim any inspection. Not listed on the Roster but records are on file providing
proof of training for assembly techniques and are in the PTO FAR 145 Durg Pool .
• The Peebles Repair Station has no identified requirement for Required Inspection Items (RII)
Inspectors to act on behalf of the Repair Station under Part 145 authority.
When a specific air carrier request is made the Chief Inspector will create a roster listing, organized by
air carrier, which documents personnel who are authorized by the air carrier to accomplish RII
Inspections on its behalf. This RII Roster is maintained as a separate electronic appendix, along with a
hardcopy backup, and includes the following information as indicated in the RII Table below.
RII ROSTER OF AUTHORITY
Inspector
Name
Title Air Carrier
Name
Date
Authorized to
Perform RII
Signature (for
Stamp see
note below)
Items
Authorized to
Inspect
Xxx Xxx Xxx MM/DD/YY Xxx Xxx
• NOTE: Peebles will use signatures (First Initial, Last name) for identified RII Inspections.
In the event inspection stamps are issued by the air carrier the stamp is required to be in
possession of the person authorized to use it and will be documented in the Signature
(stamp) column hardcopy format as indicated above. The hardcopy RII Roster containing
signatures is maintained by the Chief Inspector at her/his desk.
• RII Roster Appendix – Electronic appendix created per above requirements for access
within the Peebles Repair Station.
Chapter: 3 Page: 26 Rev: V March 12, 2018
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C. Management and Supervisory Personnel
1. Accountable Manager
DUTIES:
• Exercises management authority over repair station operations conducted under FAR 145.
• Serves as primary contact with the FAA. At times, may delegate primary FAA contact to
other persons.
RESPONSIBILITIES:
• Ensures repair station operations are conducted in accordance with FAR 145.
• Ensures repair station employees comply with FAR 145 and other pertinent regulations
when performing maintenance or alterations under the repair station certificate.
• Ensures all tooling, technical data, facilities and trained personnel are available, as
necessary, for repair station operations.
• Coordinates new business activities.
• Provides scheduling of repair station activities.
• Reviews with the Peebles staff the needs of the business and approves addition of new
employees to the Repair Station.
In the absence of the Accountable Manager, the duties and responsibilities are delegated to Quality
Leader.
2. Quality Leader
DUTIES:
• Acts as the lead quality representative with respect to repair station operations.
• Implements, manages, and oversees the operation of the General Electric Company
quality system as the system pertains to repair station operations.
RESPONSIBILITIES:
• Ensures the overall quality of the repairs or alterations.
• Establishes the surveillance program and assures completion of internal audits of repair
station operations by approved auditors.
Chapter: 3 Page: 27 Rev: V March 12, 2018
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• Issues Corrective Action Notices to the Chief Inspector and/or Accountable Manager
where internal or external audits findings occur. These could include, but are not limited
to, Repair Station and Quality Control system audit findings, workstation related audit
findings, FAA FSDO audit findings or customer audit findings, etc.
• In conjunction with the Peebles Environmental, Health and Safety (EHS) Leader is
responsible for oversight of the facilities Anti Drug/Alcohol program.
• Assures all employees involved in maintenance work are identified to the plant Anti-Drug
Coordinator, including changes.
• Assures overall separation / segregation of Repair Station maintenance activities from
Development and New Production activities.
• Assures a Personnel Training Program is provided to all Repair Station Inspection
personnel so they are thoroughly familiar with the scope of work to which they are
assigned.
• Provides, or assures training is provided, per Parts 145.151, 145.153, 145.155, 145.157
and Parts 91, 121, 125, 135, 145 as necessary, including audits of those personnel
performing repair operations. Assure maintenance of Training Record for Repair Station
Key Personnel.
• Approves recommendations for appointment and deletion of Chief Inspector.
• Responsible for oversight of the repair station/facilities calibration program.
• Responsible for oversight of the repair station/facilities shelf-life program.
In the absence of the Quality Leader, the duties and responsibilities are delegated to the Accountable
Manager or Chief Inspector.
3. Chief Inspector
DUTIES:
• Liaison with the FAA CVG FSDO representative for such activities as periodic surveys,
coordination of issuance and revisions to the Repair Station and Quality Control Manual For
Repair Station Areas, and general administrative activities of the Repair Station operations.
• Maintains the Repair Station and Quality Control Manual and ensures the policies and
procedures outlined within are followed.
• Approves recommendations for appointment and deletion of Certificated
Repairman/Inspectors, and for application/revision to Repair Station Certificate.
Chapter: 3 Page: 28 Rev: V March 12, 2018
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• Maintains, as an attachment to, the Repair Station and Quality Control Manual a current
roster of Key Personnel.
• Ensures that only FAA certified sources are used for contract maintenance, unless approved
by the FSDO, and that inspection of items subcontracted to outside facilities is correctly
performed prior to release for reassembly of the items/engines. Oversees sub-contract
activities, including audits and maintaining the list of subcontractors.
• Ensures that inspection tools and gages utilized in the Repair Station areas are maintained
within calibration cycles and are adequate for the required measurements.
• Ensures that rejected, unserviceable, and/or non-airworthy parts are identified and tagged as
such, and that such parts have been dispositioned for return to customer, mutilate and scrap,
etc.
• Ensures that a file of current Service Manuals, instructions and Service Bulletins is
maintained in, or available to, those Repair Station areas requiring such information.
• Provides oversight to ensure current technical data is available, nonconforming material
processing is completed, shelf life and calibrated tooling programs are followed.
• Ensures preparation of historical file of Repair Orders, Build-Up Records, Inspection
Records, and other informative data pertaining to maintenance or repair of the engine and/or
components, with serial numbers of engines/parts correctly identified, and retention of such
records for the prescribed period.
• Responsible for oversight of the repair station/facility scrap program.
RESPONSIBILITIES:
• Review of work-performance records for completeness and accuracy in preparation for
items or engines being returned to the customer as airworthy.
• Reporting of Suspect Unapproved Parts FAA Form 8120-11 - Suspected / Unapproved Parts
- Exhibit Q (see Forms manual).
• Signing maintenance release tags (FAA Forms) and attaching to items/engines when the
required repair/overhaul operations have been satisfactorily performed.
• Initiation and completion of FAA Form 337 - Major Repair and Alteration - Exhibit I (see
Forms manual).
Chapter: 3 Page: 29 Rev: V March 12, 2018
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• Initiation of FAA Form 8010-4 - Malfunction and Defects as required - Exhibit D (see
Forms manual).
• Initiation and completion of FAA Form 8130-3 - Airworthiness Approval Tag - Exhibit H
(see Forms manual).
• Initiation and attachment of Repair Station Specific Release Tags - Exhibits C1 thru C4 (see
Forms Manual).
• Approval of Work Requests - Exhibit A (see Forms Manual).
• Approval of Equivalency Tooling Acceptance Form - Exhibit N (see Forms Manual).
• Completion and attachment of Carry Forward Log - Exhibit F (see Forms Manual).
• Approval of Assembly Overhaul Dispatch Order (AODO) - Exhibit M (see Forms Manual)
as authorized by Peebles AODO Quality Approval Authorization per QCWI PE-024 for the
Repair Station.
The chief inspector may delegate duties to a Certified Repairman.
In the absence of the Chief Inspector, the duties and responsibilities are delegated to a Return to
Service Certified Repairman (regulatory) or Quality Manager, and MRO Quality Leader
(administrative).
4. MRO Quality Lead
DUTIES AND RESPONSIBILITIES:
• Support the Chief Inspector duties and responsibilities limited by the roster of authority and
Chief Inspector delegation.
• Focal for regulatory agencies and certifications (create, maintain and submit
manuals/documentation for new applications).
• Calibration and Shelf Life Focal (in conjunction with the site ISO Rep)
• Internal Auditing
• MRO Operational Metrics
5. Certified Repairman / Supervisor
RETURN TO SERVICE CERTIFIED REPAIRMAN DUTIES AND RESPONSIBILITIES:
• Responsible to assist the Chief Inspector in directing the work performed under the Repair
Station Certificate and Operations Specifications. This includes supervision of work
Chapter: 3 Page: 30 Rev: V March 12, 2018
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performed by any individuals who are unfamiliar with the methods, techniques, practices,
aids, equipment, and tools used to perform the maintenance, preventative maintenance, or
alterations.
• May in the absence of, or at the request of, the Chief Inspector complete the following:
o Final approval of Tooling Equivalent Form.
o Final documentation reviews, Final Inspections, approve Return to Service including
completion of all FAA Forms and the Carry Forward Log - Exhibit F (see Forms
Manual). As limited by "Key Personnel" Roster of Authority.
o Ensuring Repair Station has access to Airworthiness directives and depending on depth
of work and work instructions ensuring compliance with applicable Airworthiness
directives.
CERTIFIED REPAIRMAN/SUPERVISOR DUTIES AND RESPONSIBILITIES:
• Responsible to assist the Chief Inspector in directing the work performed under the Repair
Station Certificate and Operations Specifications. This includes supervision of work
performed by any individuals who are unfamiliar with the methods, techniques, practices,
aids, equipment, and tools used to perform the maintenance, preventative maintenance, or
alterations.
• Reviewing incoming work instructions/quality documents for accuracy and completeness.
Drafting and/or approving Work Requests for workscope definition or clarification.
• Drafting and/or Approval of Assembly Overhaul Dispatch Order (AODO) - Exhibit M (see
Forms Manual) as authorized by Peebles AODO Quality Approval Authorization per QCWI
PE-024 for the Repair Station.
• Assuring parts used in repair/maintenance/alteration are obtained from FAA approved
sources.
• Assuring the airworthiness of items/engines being repaired, by surveillance of the repair
operations and inspections, and accompanying documentation.
• Ensuring inspections are performed on incoming repair items/engines to correctly assess
condition of such items, and that adequate reports are prepared to document findings.
• Supervising the conduct of repair/maintenance work on parts and engines in conformance to
current service manuals, instructions and Service Bulletins, and/or repair directions issued by
the Repair Station.
Chapter: 3 Page: 31 Rev: V March 12, 2018
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• Responsible to ensure all tools, materials, equipment, and parts being used are appropriate and
meet the standards and requirements set forth in this manual.
• Reviewing work-records for completeness and accuracy in preparation for Final
documentation reviews for items or engines being returned to the customer as airworthy.
• Completion of "S" (Supervisor) claims where they exist.
CAUTION: Sufficient personnel are listed on the Certified Repairman/Supervisor Roster so
that a supervisor should always be on site within the Repair Station. If the situation exists
such that no supervisor is available, no repair station work is allowed. i.e. …. No Technicians
are allowed to work, or claim, any Repair Station documentation as defined by Part 145.153.
The following regulations are recommended for review by Certified Repairman /
Supervisors via this code of federal regulations web link:
FAR Part 21 - Certification Procedures for Products and Parts
FAR Part 39 - Airworthiness Directives
FAR Part 43 - Maintenance, Preventive Maintenance, Rebuilding and
Alternation
FAR Part 45 - Identification and Registration Marking
FAR Part 65 - Certification: Airmen Other Than Flight Crew members
FAR Part 91 - General Operating and Flight Rules
FAR Part 145 - Repair Stations
FAR Part 121 - Certification and Operations: Domestic, Flag, and
Supplemental Air Carriers and Commercial Operators of Large Aircraft
FAR Part 135 - Air Taxi Operators and Commercial Operators
6. Inspector(s)
• Personnel listed as Repair Station Inspectors on the Roster of Key Personnel are
authorized to complete the inspection of engines, engine parts, sub-assemblies, and
accessories in accordance with FAA approved technical data or instructions.
CAUTION: Inspectors are made aware during training that they may work as
technicians on any given job except for those tasks that require inspection of their own
work. In such cases a technician, or another inspector, performs the task and a second
inspector performs the inspection.
CAUTION: Authorized to claim identified inspections, complete Preliminary
Inspections and Hidden Damage Inspections. They are not authorized to claim "S"
(Supervisor) or "RII" Required Inspection Items.
Chapter: 3 Page: 32 Rev: V March 12, 2018
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DUTIES:
• Responsible to complete the requirements of the workscope adhering to all work
instructions, manual sections, airworthiness directives, service bulletins, and other
technical instructions as defined in the approved workscope.
• Responsible to use appropriate inspection tools, methods and techniques called for by
the applicable Engine Manual and/or approved workscope.
• Responsible to ensure all paperwork and work package documents are accurate and all
operations are complete and up to date.
• Responsible to ensure all materials, equipment and parts being used are appropriate and
meet the standards and requirements set by the applicable Engine Manual and/or
approved workscope.
RESPONSIBILITIES:
• Responsible for, and authorized to, complete a Receiving Inspection, Preliminary,
and/or the Hidden Damage inspections. Must ensure proper segregation is maintained
between New Production, Repair Station, and Development activities. Ref: QCWI PE-
008.
• Responsible for initiating nonconforming documentation in the form of a Test Fault or a
GT2309-P "R & D" Tag as appropriate. Identification and segregation will occur where
part is removed. Ref: QCWI PE-001.
• Responsible for Nonconformance disposition where technical requirements can be met.
• May initiate a Departure Record.
• Responsible for claiming Inspector identified claims on AODO's or other documentation
where an Inspector qualification is required.
• Responsible for claiming operations or completing documentation per instructions on
work requests and other documentation. ... Field return parts change record, Test Card,
etc.
• Completion of "I" (Inspector) claims where they exist.
Chapter: 3 Page: 33 Rev: V March 12, 2018
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7. NDT Inspector and Special Process Control
DUTIES AND RESPONSIBILITIES:
• Peebles Repair Station may utilize General Electric Company Certified personnel,
provided they are trained and certified per GE POLICY 259.01, QCWI T-001 and
subsequent delineated policies, to apply Special Process defined within FAA approved
data (i.e. Manufacturers Engine or Standard Practice Manuals). Personel utilizing special
processes per 259.08 in the repair station, will be trained in the areas deamed a special
process per 259.08.
8. Materials Technician:
DUTIES AND RESPONSIBILITIES:
• Responsible to the Program Leader and Chief Inspector for maintaining the hardware crib
such that new and replacement hardware and records are always available. Responsible to
schedule shipment of conforming and nonconforming hardware as directed by the Chief
Inspector or Certified Repairman.
• Responsible for segregation and proper storage of new or replacement hardware and parts
for the Repair Station within the engine hardware crib. Ref: QCWI PE-018.
• Responsible for segregation of conforming and nonconforming hardware in the crib area.
Responsible for shipment or Scrap of Nonconforming hardware as directed by the
customer or QCWI PE-001.
• Material Crib Technician Training requires review and acknowledgment of
SUPS (Suspect Unapproved Parts) training presentation.
• A Facilities Crib Technician is trained to receive consumables into the facility
under PC-108 quality procedures. Person(s) are not listed on the Roster but
records are on file providing proof of training in receiving, labeling and storage of
consumables including Material Age Control.
In the absence of the Materials Crib Technician(s), the duties and responsibilities are delegated to a
Certified Repairman/Supervisor.
9. Program/Test Leader(s)
DUTIES:
• Assures all necessary, tooling, technical data, trained personnel, quality and workscope
planning requirements have been met and are available prior to the execution of any job.
• Assures funding is in place prior to any Repair Station activity. Assures any change in
workscope is funded prior to work activity being commenced.
Chapter: 3 Page: 34 Rev: V March 12, 2018
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RESPONSIBILITIES:
• Responsible to the Accountable Manager for the logistical operation of the repair station
and to provide direction of resources and coordination of personnel. Also serves to
coordinate and evaluate new Repair Station business.
• Responsible for the overall smooth operation of the Repair Station. Provides operational
management, including production scheduling for repair station activities as well as new
employee selection and customer interface.
• Responsible to maintain supervision over key personnel for logistical and scheduling
purposes and with the resources from the Accountable Manager provide an adequate
number of competent persons who can perform, supervise and inspect the work for
which the Repair Station is rated.
• Ensures that only those individuals who are trained and qualified are selected for various
tasks within the Repair Station. Works with Quality Manager to coordinate training
classes.
• Maintains tracking of repair station personnel days worked to ensures FAR-121
regulations are met.
• Allocates and provides proper and adequate housing and tooling and the necessary
materials and technical data for the operation of the Repair Station through the supplied
resources of the Accountable Manager.
• Maintains close surveillance to assure the highest of Quality Standards are in
conformance with current regulations and will conduct and enforce disciplinary action
when necessary to curb any wrongdoing.
• Coordinates all repair station repair program and planning activities as well as new
workscope development, review and applicability.
• Provides cost accumulation for work packages.
• Assures separation of Repair Station activities from new Production and Development
activities.
• Reviews proposals from customers to assess funding requirements and determine the
need to procure additional required tooling, equipment and material necessary for Repair
Station maintenance.
• Identifies personnel/teams to be available for Repair Station maintenance activity and
coordinates scheduling and work scope with the Chief Inspector.
Chapter: 3 Page: 35 Rev: V March 12, 2018
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• Assures all employees involved in maintenance work are identified to the plant Anti-
Drug Coordinator, including changes.
In the absence of the Program Leader, the duties and responsibilities are delegated to Certified
Repairman or the Quality Leader.
10. Technician(s)
DUTIES AND RESPONSIBILITIES:
• Responsible for proper serial/part number verification during removal or installation and
documenting any change on a Field Return Parts Change Record.
• Responsible for general inspections. …i.e. assuring that QCWI PE-010 - FOD Control
and Material Handling requirements are met.
• Responsible for engine work package upkeep and claiming of operations performed per
ODO’s, Work Requests, etc, that do not require an Inspector or other specific claim
authority.
• Responsible to ensure all tools, materials, equipment and parts being used are appropriate
and meet the standards and requirements set forth in this manual.
• Must ensure proper segregation is maintained between New Production, Repair Station,
and Development activities. Ref: QCWI PE-008.
• Responsible for initiating nonconforming documentation in the form of a Test Fault or a
GT2309-P "R & D" Tag as appropriate. Identification and segregation will occur where
part is removed. Ref: QCWI PE-001.
• Technicians can not disposition Nonconformances unless listed on Repair Station
Roster as an inspector or repairman.
• Responsible to ensure precision measuring/test equipment being used is within its posted
calibration interval and that the tool has not expired calibration. Ref: QCWI PE-004 and
QCWI PE-002.
• Completion of "A or X" (Assembler) claims where they exist.
In the absence of the Technician(s), no backup is required.
Chapter: 3 Page: 36 Rev: V March 12, 2018
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D. Employment Summaries of Key Personnel
• The Chief Inspector is responsible for maintaining the employment summaries in current
condition. The employment summaries are maintained at the Chief Inspectors desk. In the
absence of the Chief Inspector this duty is delegated to the Quality Leader.
• Employment summaries contain the following information at a minimum:
o Present title.
o Total years experience and the type of maintenance work performed.
o Past relevant employment with the names of employers and periods of
employment.
o Scope of present employment.
o The type of mechanic or repairman certificate held and the ratings on that
certificate, including the certificate number.
o Employment summaries are not required for Technicians. Personal identification
in the form of Name, Signature and badge number is the only requirement.
E. Recommendation of a Person for Certification as a Repairman
• Persons recommended for certification as repairmen meet the eligibility requirements of
14 CFR Part 65.101.
F. Proficiency of Inspection Personnel
Pro cedu re : Prof i c i en cy o f In sp ect ion Pers onn e l
• Training of repair station personnel is accomplished by classroom instruction plus factory
and on the job training as necessary. Training is documented in the approved Peebles
Electronic Database.
• The Chief Inspector or Quality Manager approves the addition of persons as Inspectors to
the Repair Station Roster of Key Personnel.
• To qualify as a Repair Station Inspector the person is required to:
PREREQUISITES:
• To maintain Repair Station Inspector status the person is required to complete
annual on-line refresher training in the approved Peebles Electronic Database.
Chapter: 3 Page: 37 Rev: V March 12, 2018
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Note: Repair Station Inspector qualification may be revoked by the Repair
Station Chief Inspector, or Quality Leader any time the Inspector's
performance is determined to be inadequate.
• Training records are maintained in the General Electric Company Electronic
Training database. New training requirements are identified by feedback from the
Staff, Certified Repairman/Supervisors as to system, or personnel failures, as well
as audit findings. New training may be added any time that the business needs
dictate. The Staff will be notified of any changes to the established plan.
• Material Crib Technician Training records are maintained in the Peebles
Electronic Database.
o Material Crib Technician training requires review and acknowledgment of
SUPS (Suspect Unapproved Parts) training presentation.
o A Facilities Crib Technician is trained to receive consumables into the facility
under PC-108 quality procedures. This person(s) is not listed on the Roster
but records are on file providing proof of training in receiving, labeling and
storage of consumables including Material Age Control.
• Certified Repairman/Supervisor training records are maintained in the Peebles
Electronic Database.
RECORDS:
• Roster of Key Personnel.
• Employment Summaries.
• Records of Training.
G. Housing, Facilities, Equipment and Materials
PURPOSE: This section provides a description of the housing, facilities, equipment, and
materials available to the repair station.
SCOPE: This section includes facilities and equipment that may not be the property of the repair
station but such facilities and equipment may be used from time to time.
RESPONSIBILITY: See individual procedures below.
REFERENCE(S):
• FAR 145.101, 145.103, 145.105, 145.109, and 145.209.
Chapter: 3 Page: 38 Rev: V March 12, 2018
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AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control Manuals,
Chapter 4.
1. Floor Plan of the Facility
The Peebles Test Operation Repair Station co-exists with new Engine Production (PC-108) activity.
Facilities, tooling, personnel and equipment are shared where possible. Peebles test operation also has
an assembly area “PTO West” located at 2564 Moores Road, Seaman, Ohio 45679.
• All areas are climate controlled by centralized heating and cooling systems. Overhead
lighting, electrical outlets and compressed air outlets are strategically located to provide
sufficient availability for Repair Station activity due to co-existence with the production
activity.
Prep To Test, Assembly/Disassembly, and Prep To Ship (See Floor Plan on next page)
• The PREP BUILDING is utilized for Repair Station activity, Development activity and
limited Production activities consisting of, but not limited to, the CF34, CFM56, and CF6
engine families. The building is constructed of pre-fabricated metal on structural beams.
• The ED SPEAR COMPLEX and GE90 BUILDING is capable of being utilized for Repair
Station activity, Development activity and limited Production activities consisting of, but not
limited to, the GEnx, GP7000 and GE90 engine families. The building is constructed of pre-
fabricated metal on structural beams.
• MMPB – Contains 2 workstations used for assembly / disassembly and multiple Prep to Test
and Prep to Ship workstations primarily used for small turbofan engines. The building is
constructed of pre-fabricated concrete on structural beams.
• LEPB – Contains 2 workstations used for assembly / disassembly and multiple Prep to Test
and Prep to Ship workstations primarily used for large turbofan engines. The building is
constructed of pre-fabricated metal on structural beams.
• PTO WEST – Contains 4 workstation used for assembly/disassembly. The building also
contains a crib area and long term storage area for equipment. The building is contrasted of
pre-fabricated metal on structural beams.
• Separation will be maintained between new Production, Development and Repair Station
activities via quarantined areas and roping off areas of existing floor space.
o Major changes to floor plan and/or facilities, which affect Repair Station Activities,
will require submittal of FAA form 8310-3 and letter explaining changes.
• Prep and Test Facilities are maintained in accordance with QCWI PE-011 - Peebles Total
Productive Maintenance.
Chapter: 3 Page: 39 Rev: V March 12, 2018
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FLOOR PLAN
PREP BUILDING
(approx.) 15,000 SQ. FT.
ED SPEAR COMPLEX
GE90 BUILDING
(approx.) 80,000 SQ. FT.
145 Engine
Hardware Crib
Calibration
Lab
Mixed Model Production
Building
Facility Crib
Shipping & Receiving
Large Engine
Production
Building
Chapter: 3 Page: 40 Rev: V March 12, 2018
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• Lighting at the "floor" work level varies between 50 to 150 foot candles. Portable
lighting is available and maintained in work areas, for use at anytime a part or
condition is suspect.
The engine hardware crib is partitioned into identified areas to provide for storage and control of
Repair Station Hardware, both conforming and nonconforming.
TEST FUNCTION:
Testing may be conducted at any Outdoor Test Site available, or any Indoor Test Site previously
correlated for the General Electric Company Production engine model/rating requiring test. Testing
can choose to use any configuration of Test hardware previously correlated.
Outdoor Test Sites:
PTO West (approx. 85,000 SQ FT)
Chapter: 3 Page: 41 Rev: V March 12, 2018
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• Site 3B
• Site 3C
• Site 3D
• Site 3E
• Site 4D
• Site 6A
• Site 7
Indoor Test Sites
• Site 5A
• Site 5B
• Site 5C
• Site 5D
• Test sites are maintained in accordance with QCWI PE-011 - Peebles Total Productive
Maintenance.
• In accordance with GE POLICY 879.15 - Test Cell Correlation, changes that may affect the
operational characteristics of any Test Site are evaluated and approved per PTC policy 7.09 -
Test Facility Configuration Control.
Chapter: 3 Page: 42 Rev: V March 12, 2018
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2. Equipment
Pro cedu re : Eq u ipmen t
• All tooling and consumable materials referenced in the applicable manual are used during
maintenance, preventative maintenance or alteration and test processes.
o The Repair Station is co-housed within General Electric Company Peebles Test
Operation, which holds PC-108 authority and General Electric Company Type
Certificate/Certification expertise. Co-housing enables the Repair Station to have
available the same assembly and test tooling used by the manufacturer for many
equivalent task(s) or operation(s) within the PC-108 or Type Certificate/Certification
processes. Where possible this tooling is considered for use by the Repair Station. If
used, these tools are approved within the customer workscope or by use of the
Equivalency Tooling Acceptance Form. This approval is required prior to use.
Where the Equivalency Tooling Acceptance Form is used a copy is filed with
approval signatures, by the Chief Inspector for 5 years minimum.
o If a need for additional tooling is identified the repair station attempts to locate and
borrow it from another General Electric Company location or GEES repair station.
Where tooling cannot be borrowed the Peebles Accountable Manager will give
instructions on leasing or purchase. Should this lease or purchase involve any
change to the Operating Specifications the Chief Inspector will contact the CVG
FSDO for direction.
• Assembly tooling is used for maintenance, preventative maintenance and alterations primarily
in the PREP BUILDING and the ED SPEAR/GE90 BUILDING. Test (cowling) and other
tooling, (blankoffs, gearbox plugs, etc,) used during Repair Station testing is the same tooling
used to support current, or prior, Production Test processes. Tooling equivalence may be
approved in the workscope for its use.
o When it is necessary to borrow tooling and equipment from a third party a
Certified Repairman or the Chief Inspector ensures that it is the proper
configuration tool and is in safe operating condition prior to use. Retention of
consideration is not required. At no time will precision measuring equipment and
tools requiring calibration be borrowed unless they are in current calibration.
o Reference GE POLICY 379.00 – Product Measurement & QCWI S-070 –
Measurement Equipment Selection Criteria for guidance.
• Precision tools and test equipment used at this Repair Station are subject to periodic cycle
checks per the Calibration Section below.
Chapter: 3 Page: 43 Rev: V March 12, 2018
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• All personnel are responsible to verify that, prior to use, each calibrated tool or device has not
exceeded its required calibration due date and that the tool is in a condition for continued use.
The use of personally owned tools is prohibited.
• This repair station plans no leasing agreements to obtain equipment. Should the circumstance
arise the Accountable Manager directs the necessary action to obtain needed equipment for the
repair station. All equipment is available when work is performed.
3. Equivalent Tools
Pro cedu re : Eq u iv a l en t To o l s
• Any tools or materials not listed in the manuals are evaluated and approved by the Chief
Inspector or a Return to Service Certified Repairman and if required the appropriate
engineering function prior to use per the Equivalency Tooling Acceptance Form.
• Locally manufactured precision measuring tools and test equipment, which is not called
out in the manual, must meet the manufactures minimum requirements to be considered
equivalent and documented on the Equivalency Tooling Acceptance Form.
• Holding, lifting, supporting, and or removal/installation tools may be used provided they
meet the intent of the tool called for in the manual.
o Tools called for by the manual may have an identifiable substitute within the
General Electric Company PC108 tooling, General Electric Company
development tooling, or be easily re-manufactured tooling. This is acceptable
granted they meet the intent of its use and are documented on the Equivalency
Tooling Acceptance Form.
• Where this form is used a copy is filed with approval signatures, by the Chief Inspector for
5 years minimum. When an equivalent tool is not specifically called out in an AODO, a
non-conformance is written against the engine stating the Tool required and the
Equivalent Tool to be used. Disposition is to obtain Equivalency Tooling Acceptance
Form, clear non-conformance when form is complete.
o The Chief Inspector will coordinate with the FAA the process for using alternate
tools and if required a listing of the tools.
Chapter: 3 Page: 44 Rev: V March 12, 2018
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4. Stock Room/Area
Pro cedu re : S t ock R o o m/ Area
• Following the Receiving Process Inspection, Repair Station parts and consumables are
stored, controlled and dispersed from Crib areas identified for Repair Station usage.
Separation of Customer owned parts are maintained on separate racks or locations,
identified with customer name. Certificates of Conformance are on file and/or attached
per the receiving process. The part, or material, is placed in storage and added to the
Repair Station inventory list.
o For engine hardware requisitioned for installation on a customer engine the
Material Crib Technician places a certificate of conformance in a folder identified
for the engine or in the engine QC book. This folder is retrieved by the Chief
Inspector or Return to Service Certified Repairman during the Return to Service
process. The Certificate of Conformances are included in the work package
delivered with the engine at Return to Service.
1. NOTE: Production hardware (PC108) can not be used on a field return
engine unless the hardware is transferred to the repair station (CofC or
8130-3). If transferred to the repair station the hardware is no longer
production hardware (and never can be).
o Where the Material Crib Technician is not available, hardware can be taken from
designated Field Return storage area(s). The item is recorded on the Crib
Withdrawal log by the person completing the withdrawal. The Material Crib
Technician follows up to assure a Certificate of Conformance is filed in the engine
folder maintained by the Material Crib Technician or placed in the engine QC
book.
NOTE: A fault must be written if no part certification is available at the time
of installation. Fault must include an equivalent statement to the following.
(Part certification required prior to engine shipment.)
o Standard hardware (bolts, nuts, washers, “O” rings, gaskets) not available within
the Repair Station Stock can be procured from PC108 stock provided the
following requirement is met.
1. Engine hardware procured in this manner requires issuance of a
Certification Statement Of Engine Hardware/Part Shipment per QCWI
PE-018 - Shipping, Receiving, and Material Handling. This
Certification Statement is required to be signed by a Materials Crib
Technician, Certified Repairman or Chief Inspector.
Chapter: 3 Page: 45 Rev: V March 12, 2018
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2. A Material Transfer Order is required where hardware other than
Standard parts and OEM bolts, nuts, washers, etc, are transferred.
Reference: GE POLICY 411.30 - Material Transfer Order.
• Additionally, for consumables (sealants (RTV), lubes, etc,) a Material Crib Technician
assures that received consumable material complies with the following:
o Consumable material certifications including shelf life data sheets are stamped (or
signed/dated) as being received and the certificate is filed for future reference.
o The cure/expiration date is transferred from the primary ship container to
individual items in instances where cure/expiration dates are not marked on
individual items as received. Reference QCWI S-041. - Control of Material with
Shelf Life or Other Special Storage Requirements.
o Consumable material received are added to the Peebles Shelf Life List
o The material cure/expiration date is monitored while the age control material is in
storage (lubricants, sealants, etc.) as follows. Per QCWI PE-012 - Peebles Internal
Audit Requirement, the Material Crib Technician completes a Weekly Operational
Checksheet to assure such items are not expired. Control is maintained for those
age control items stored. i.e. ... gaskets, "O" rings, lubes, etc, are removed before
expiration.
o That dated material includes the correct expiration/cure date marking identification
when the material is issued for use. No expired material is issued for use.
• Occasionally parts may require storage at other locations throughout the shop depending
on application, size or intended use. Any such storage requires the hardware be controlled
per QCWI PE-008. Hardware is to be identified by; R & D Tag, kit hardware containers,
or carts/tables identified by ESN (Engine Serial Number).
o Intermingling of different customer hardware in any work areas is not permitted.
Note: Signs and temporary fencing are acceptable means of providing segregation.
• Material received that is damaged, or determined to be Nonconforming, is placed in
nonconforming crib and processed per QCWI PE-001.
• The Peebles Facility Crib accepts expired age control material returned from the floor and
provides for final disposal.
• Hardware items returning from the floor require a certificate of conformance or an attached R
& D Tag providing documentation of their condition. These are delivered to the Crib
Chapter: 3 Page: 46 Rev: V March 12, 2018
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Technician or placed in the receiving area. Items that are Nonconforming are placed in the
Nonconforming Material location inside the crib.
H. Satellite Repair Stations
• This Section held in abeyance until needed.
Chapter: 4 Page: 47 Rev: V March 12, 2018
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Repair Station Operations
Chapter
4
Chapter: 4 Page: 48 Rev: V March 12, 2018
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A. Repair Station Operations
PURPOSE: This chapter describes the processes used in operation of the repair station, including
inspections and controlling and documenting the work in progress.
SCOPE: This chapter includes inspections (incoming materials, preliminary inspections, hidden
damage, final inspection), workflow, and approvals of return to service of maintained articles.
Maintenance accomplished at this repair station includes “warranty work.”
RESPONSIBILITY: The Accountable Manager is responsible for repair station operations.
REFERENCE(S):
• FAR 43.13(a), 145.109(b), 145.211(c),
• AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control Manuals,
Chapter
DEFINITIONS:
• Preliminary Inspection – means an evaluation of an article to determine customer
requested work scope and the required maintenance or alteration actions.
1. Approved Workscope
Pro cedu re : Ap prov ed Wo rks cop e
• An approved workscope must be obtained prior to the start of any work. The following types of workscopes are acceptable and considered approved when placed in the QC record book:
o Completed minimum workscope template (see forms manual)
o Purchase order
o Customer supplied workscope definition
NOTE: Email is an acceptable form of revision to the workscope and a copy of the email will be placed in the QC book with the approved workscope.
2. Workscope Definition
Pro cedu re : Wo rk sco pe D ef in i t i on
• No verbal work instructions are authorized. Prior to start of any work, the customer
furnishes documented (W/R or other) definition of how their technical information is
Chapter: 4 Page: 49 Rev: V March 12, 2018
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updated and controlled. (i.e.... how to retrieve on line manuals, temporary revisions,
consumables information, etc.).
• Maintenance instructions are provided by, or obtained from, the owner/operator of the
article being repaired and/or maintained by the Repair Station. These instructions may be
in any format and should include the following information (as applicable):
o Detailed Description of Work to be Performed
o ADN or Contract Number (Charge Number)
o Type of return to service Documentation
o Customer/Operator Name
o Engine Model Number
o Engine Serial Number
o Technical Data Requirements.
o AD/Service Bulletin Requirements
o Material Requirements
o TSN/CSN Time Since New/Cycle Since New
o Life Limited Parts Information (If Applicable)
o Required Inspection Items (If Applicable)
o Customer/Operator Approval Signature or Purchase Order Agreement (For engines
covered by service agreements such as MCPH or CSA, contact the Chief Inspector for
additional guidance)
o Long term (annual) preservation date of lube / fuel system and/or last date of engine
operation. Date of preservation of lube / fuel systems or last date of operation are required
unless otherwise approved.
o Other pertinent information required such as; 8130-3 / EASA Form 1 / AAC-038, FAA
Form 337 / AAC-085, Carry Fwd Sheets, Ship Loose/Short List, required audits of
maintenance providers, etc, as applicable.
o When the scheduled activity is Cell Correlation or Engineering Investigation testing, the
workscope may be defined using the Minimum Workscope for Cell Correlation or
Engineering Investigation template (see forms manual).
Chapter: 4 Page: 50 Rev: V March 12, 2018
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o If during cell correlation or engineering investigation testing the scheduled activity
changes to require maintenance or repair, additional approval may be required from the
owner / operator of the article. Contact the Chief Inspector or Quality Leader for guidance.
o The Chief Inspector or Certified Repairman assures that the required technical data is
available before any work is accomplished. No maintenance activity, beyond a receiving
inspection, can begin until this information is on site.
o The technical data is available at the location where work is being accomplished. Where
small sections of technical data (Manuals) are printed and provided for use, revision status
and engine effectivity for these sections is documented using the Exhibit W - Technical
Data Management Form (see forms manual). The form is maintained with sections of the
manual provided on the floor.
o Changes to or clarification of the approved workscope are documented and/or approved
by the Chief Inspector or Certified Repairman and may include PSE/ASE approval (as
required) and Source approval providing the engine.
Chapter: 4 Page: 51 Rev: V March 12, 2018
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B. Continuity of Inspection Responsibility
Pro cedu re : Con t inu i t y o f I nsp ec t io n R esp ons i b i l i t y
• Identified inspections are claimed by the Inspectors fully, or partially, completing the
directed activity. If work is partially completed, the records (documentation) will be
claimed to indicate that portion of work completed. When Assemblers/Inspectors are
working as a "TEAM", a single signature is sufficient for a claim. The
Assembler/Inspector making this claim assumes responsibility that they have verified all
items claimed are complete. An inspector may not claim the inspection where s/he has
completed the prior work that requires the inspection.
CAUTION: Inspectors are made aware during training that they may work as
technicians on any given job except for those tasks that require inspection of their own
work. In such cases a technician, or another inspector, performs the task and a second
inspector performs the inspection.
• Prior to shift changes, an appropriate entry into the Turnover “shift” Log is required for
any maintenance, preventative maintenance, etc, activity. This ensures continuity of
work/inspection is maintained. This log is maintained in the Peebles Electronic Log
program.
o Turnover "shift" log examples include, but are not limited to, turning work over to
the next shift and documenting partially completed tasks. The Turnover "shift"
log should include Date, Time, Name of Originator, Engine Serial Number and
brief description of where the work left off and what is required to do to complete
the task.
• In addition, where personnel are available to participate, a "team/crew meeting" is
conducted at shift change.
• When a “team/crew meeting” is not conducted, prior to starting any work on an engine,
engine part or component, the assigned team/crew must review the work package and
Turnover "shift" Log in order to fully understand work effort and that all completed
operations have been properly claimed and dispositioned.
• Should a Turnover "shift" Log not be available, the team/crew should consult the shift
supervisor for appropriate instructions prior to starting any work.
C. Receiving Inspection
Pro cedu re : R ece iv in g Pro cess
• Peebles receives items for assembly into engines from the following sources:
Chapter: 4 Page: 52 Rev: V March 12, 2018
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o Items are obtained from suppliers approved via the General Electric Company
Sourcing organization. These requirements are covered by General Electric
Company Policy 510.00 and flowed down per Sourcing Quality Policy S-1000.
o An air carrier may supply items provided workscope definition and Return to
Service requirements are met.
o Items are obtained from approved suppliers located in CASL.
• Dock personnel complete a visual check on incoming items/components for obvious
shipping damage per Process Instruction PI 4.05 - Receiving Engines / Engine Hardware,
& Materials External to PTO. Where no obvious damage is noted items are placed in the
Crib(s) receiving area or delivered per the Process Instruction.
o Any engine hardware items failing this check are held and the Quality Leader,
Chief Inspector or a Certified Repairman is notified and makes final
determination.
o All consumable material require listing in the MSDS file must be approved by the
Site EH & S Leader prior to distribution within the facility.
• Two crib functions are supported at Peebles:
o The Engine hardware crib(s) contain hardware, and Standard hardware (nuts,
bolts, gaskets and limited amounts of specific consumables).
o The Facility Crib contains consumables used in PC108 manufacturing. These are
available for use by the Repair Station and controlled accordingly.
• Assigned personnel are responsible to control their assigned cribs. S/he reviews items
brought into the assigned crib. Each crib has an identified receiving area. The
components and materials are allotted a Receiving Inspection (below).
CRIB RECEIVING INSPECTION:
• Assigned personnel assure that the following requirements are fulfilled when receiving
hardware, or consumables, into the engine hardware crib or facility crib.
• These personnel verify the proper amount of material has been delivered and that the
material is not damaged as a result of transit or from handling. The material has a
Certificate of Conformance.
o Hardware is checked by the Materials Crib Technician for indications of
Suspected Unapproved Parts (SUP). Reasons for suspecting a part may include
findings such as a different finish, size, color, improper (or lack of) identification,
incomplete or altered paperwork. Any SUP is isolated and processed per defined
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requirements of Suspected Unapproved Parts process as described in this manual
below.
• All packing slips and/or part or material certifications are gathered and matched with the
items received. The items are checked to ensure quantity, P/N, S/N and/or lot number
match, as applicable. The Material Crib technician (hardware) verifies that the Standard
hardware ("O" rings, preformed packing) are in their original packaging.
• For hardware, a Certificate of Conformance is required that is traceable to the OEM or to
an approved Supplier/Vendor. The Certificate can be but are not limited to:
o Certification traceable to the OEM.
o Be accompanied by an FAA 8130-3, EASA Form 1 or TC 24-0078.
Note: Where contract maintenance is involved the location supplying the item is
required to be listed in CASL.
o Be PMA with a Certificate.
o Include a Production certificate statement and number.
o Be Type Certificated with statement.
o Include Certificate of Conformance from Mfg. or be traceable to a FAA approved
certificate holder.
o Air Carrier Supplied parts need to reference the parts serviceability.
o Consumables require a Certificate from the manufacturer indicating they meet
required specification.
• With any one of the above forms properly completed and no evidence of damage the item
may be accepted into the Peebles Repair Station Crib.
o Where an approved certificate is not available, or the hardware is damaged beyond
repair it is held (placed in nonconforming crib). A Certified Repairman or the
Chief Inspector is notified to make final determination on the acceptability of the
Certificate or disposition of the damage. If determined to be unacceptable it is
returned to the supplier or processed per QCWI PE-001 - Processing Non-
Conforming & Scrap Engine Hardware.
• Once verified as meeting the above receiving inspection requirements a Exhibit C3 -
Receiving Inspection Tag (see forms manual) is completed and attached to or stored with
the item, to indicate the receiving inspection is complete.
• The part is placed in storage and added to the Repair Station inventory list. The
Certificate is filed or may remain attached to the hardware.
Chapter: 4 Page: 54 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• Additionally, for consumables (sealants (RTV), lubes, etc,) a Material Crib Technician, or
assigned person, assures that received consumable material complies with the following:
o Consumable material certifications including shelf life data sheets are stamped (or
signed/dated) as being received and the certificate is filed for future reference.
o The cure/expiration date may require transfer from the primary ship container to
individual items in instances where cure/expiration dates are not marked on
individual items as received. Reference QCWI S-041. - Control of Material with
Shelf Life or Other Special Storage Requirements.
o Consumable materials received are added to the Peebles Shelf Life list.
o The material cure/expiration date is monitored while the age control material is in
storage (lubricants, sealants, etc.) as follows. Per QCWI PE-012 - Peebles Internal
Audit Requirement, the Material Crib Technician, or assigned personnel,
completes a Weekly Operational Checksheet to assure such items are not expired.
Control is maintained for those age control items stored. i.e. ... gaskets, "O" rings,
lubes, etc, are removed before expiration.
o No expired material is issued for use. Any dated material is required to be marked
with the correct expiration/cure date marking identification when the material is
issued for use.
• Occasionally parts may require storage at other locations throughout the shop depending
on application, size or intended use. Any such storage requires the hardware be controlled
per QCWI PE-008. The hardware is to be identified by; R & D Tag, kit hardware
containers, or carts/tables identified by ESN (Engine Serial Number).
o Intermingling of different customer hardware in any work areas is not permitted.
Note: Signs and temporary fencing are acceptable means of providing segregation.
• The Peebles Facility Crib accepts expired age control material returned from the floor and
provides for final disposal.
• Stock room items are received, inspected and documented per Section 4 - Stock Room
requirements above.
• Engines are received and inspected by the appropriate Peebles Program Team.
Documentation beyond a receiving inspection is in accordance with the approved workscope.
(Engines complete a Preliminary Inspection and Hidden damage inspection per Chapter 4 H -
Article Preliminary Inspection requirements.).
RECORDS:
Chapter: 4 Page: 55 Rev: V March 12, 2018
GE PROPRIETARY INFORMATION This document contains trade secrets and confidential competition sensitive commercial or financial information exempt from disclosure under the FREEDOM OF INFORMATION ACT (FOIA) 5 USC §
552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• Certificates of Conformance are maintained within the crib until items are dispersed.
• Evidence of Engines received is maintained per QCWI PE-009 in the QC Records Book.
D. Handling of Parts and Protection of Articles
1. Handling of Parts
Pro cedu re : H andl in g o f Pa r ts
• Parts are handled in accordance with QCWI PE-010 - FOD Control and Material Handling
and GE POLICY S-009– Material Handling.
• All persons are required to inspect hardware at removal, prior to installation and prior to
storage for damage and to assure:
o Material is free from obvious rust and surface corrosion.
o Machined surfaces and hardware are generally protected from damage and hard
particle contamination and are acceptable for installation.
o Lines, tubes, hoses, and ducts are clean and uncontaminated.
o Electrostatic Discharge (ESD) protection is in place as appropriate.
• Racks, kitting carts and other areas must be clean, free of debris and loose hardware. Assure
that parts do not overhang skids or racks. In cases of exception, practical precautions will be
taken.
• During removal and/or storage prevent unnecessary contact between items. Limited metal-to-
metal or part-to-part contact of finished surfaces is permitted when:
o Mating or finished surfaces are protected and contact is minimal. Small configuration
nuts/bolts/washers can be bagged without regard for metal-to-metal contact.
o Configuration, stacking, or mass (weight) of the parts is such that no damage to
finished surfaces will occur. Heavy objects (mass weight) are on the bottom.
o Care is taken when putting items into/on carts, racks or removing them to assure that
there is no damage to finished surfaces.
o The racks, carts with this hardware are never transported by a mechanized means that
can cause vibrations and damage to finished surfaces.
Chapter: 4 Page: 56 Rev: V March 12, 2018
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• Protect mounting surfaces, external threads, splines and/or seal teeth of major modules and
components (HMU's, Lube Pump, etc,) from damage.
• Cap or cover all ports, openings and fittings.
• On major sub-assemblies where foreign material could cause contamination /FOD, the
openings will be covered with a plastic film sheet or equivalent. Grade A bearing paper is
required for bearing/sump coverage under plastic.
• Per QCWI PE-008 loose hardware in the work area will be identified by; R&D Tag, kit
hardware containers, or carts/tables identified by Engine Serial Number (ESN).
NOTE: Signs and temporary fencing are acceptable means of providing segregation.
Intermingling of different customer hardware in general work areas is not permitted.
2. Scrap Parts
Pro cedu re : S cra p Pa r t s
• The chief inspector is responsible for oversight of scrap hardware program. The quality
manager is the back-up representative. Scrap hardware is processed by PTO Crib Personnel
per QCWI PE-001 - Processing Non-Conforming and Scrap Engine Hardware. The chief
inspector will maintain a list of scrapped life limited parts.
• Appropriately marked Scrap containers will be maintained in the general work area(s) to
provide for collection and control of low cost scrap engine hardware.
3 . Pres erva t i on o f A r t i c l es / Sh e l f L i f e
Pro cedu re : Pres erv a t i on o f A rt i c l es /Sh e l f L i f e
• The Quality manger is responsible for over sight of the shelf life program. The chief inspector
is the back-up representative.
• Per QCWI PE-018 a Material Crib Technician, or assigned personnel, is responsible for
monitoring materials in storage that require shelf life control as follows:
o Item is on the Shelf Life list.
o That cure/expiration date marking identification of material is maintained while the
age control material is in storage (lubricants, sealants, etc.).
NOTE: The cure/expiration date is transferred from the primary ship container to
individual items in instances where cure/expiration dates are not marked on individual
items as received. Ref: QCWI S-041.
Chapter: 4 Page: 57 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
o That appropriate control is maintained for those age control items stored and
dispersed. i.e. ... remove and dispose of gaskets, "O" rings, etc, before expiration.
o That dated material includes the correct expiration/cure date marking identification
when the material is issued for use.
o That expired material is not issued for use.
o The Peebles Crib will accept expired age control material returned from the floor and
provide for final disposal.
• The cure/expiration date is monitored while the age control material is in storage (lubricants,
sealants, etc.). Per QCWI PE-012 - Peebles Internal Audit Requirement, the Material Crib
Technician, or assigned personnel, completes a Weekly Operational Checksheet to assure
such items are not expired.
• Engines are preserved to meet long-term storage requirement limitations (1 year) unless
otherwise specified within the approved workscope. Ref: GE POLICY 539.07.
• Peebles Certified Repairman or Chief Inspector serves as a backup for the Materials Crib
Technician at anytime.
Chapter: 4 Page: 58 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
E. Tagging and Identification of Articles
Pro cedu re : T ag g ing and Id en t i f i ca t i on
• Engines are received and unloaded by dock personnel per Process Instruction 4.05 - Receiving
Engines / Engine Hardware, Tooling, TEH, and Materials - External to PTO.
o Where the engine is to await maintenance it is stored in the Field Return storage area
by the person completing the unloading per Process Instruction 4.05.
o Where engine is to undergo immediate maintenance it is delivered to the team/area
where maintenance is to be performed.
• Once received, Repair Station parts are stored, controlled and dispersed from areas within the
engine hardware crib identified for Repair Station usage as indicated on the floor plan above.
Separation of Customer owned parts is maintained on separate racks or locations, identified
with customer name.
• Loose (conforming) hardware in the work area will be identified by; R&D Tag, kit hardware
containers, or carts/tables identified by ESN.
NOTE: Signs and temporary fencing are acceptable means of providing segregation.
o Intermingling of different customer (Field Return) hardware in general work areas is
not permitted.
• An Engine QC Book is initiated per QCWI PE-009 - Engine Record Requirements. The QC
book is used to maintain hardcopy documentation on the quality status of the engine.
o An approved workscope is required prior to any work being performed beyond a
receiving inspection. The workscope is approved by the Peebles Chief Inspector or a
Certified Repairman.
o Clarification or changes to the Approved workscope are documented and claimed
using workstation planning procedures, operation sheets or other approved work
instructions as defined within this Repair Station and Quality Manual.
o Final review of this book is completed at Return to Service by the Chief Inspector or a
Certified Repairman.
Chapter: 4 Page: 59 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• Non-conforming parts are processed per QCWI PE-001 - Processing Non-Conforming and
Scrap Engine Hardware. Once confirmed any nonconformce is identified in/on appropriate
record. i.e. ... Test Fault Sheet, R & D Tag, etc, as applicable. Any person may accomplish the
initial documentation (fault write-up). It should adequately describe (to extent practical) the
actual condition noted and the extent of departure. Disposition is provided by a "PR" qualified
Repair Station Inspector.
o For hardware assigned to an engine a Test Fault Sheet entry (see forms manual) is
generated to document the nonconformance.
o Any nonconforming part removed from the engine, or engine sub-assembly, shall be
placed on an appropriately identified (separate) nonconforming material rack in the
repair/test area. The part will have a GT2309-P "R & D" Tag (see forms manual)
initiated and attached.
o In the event the part falls outside the repair capabilities outlined in the applicable
Service Manual a Departure Record may be generated and approved for processing
the part. The General Electric Company myGEaviation Departure Record system is
the approved method.
• Where a disposition cannot be completed, that returns the part to a conforming status, the part
is returned to the engine hardware crib with an "R & D" Tag (see forms manual) attached.
o With customer concurrence such hardware is either scrapped or returned to the
customer using GT 2855-1 - Red Reject tag or R & D Tag GT2309-P. The Chief
Inspector or a Return to Service Certified repairman makes final determination.
Note: Where isolation is impractical due to size, (major module nonconforming
hardware) in process within "prep/assembly/repair locations" it will only require
attachment of the R & D Tag. i.e. .... LPT module, Core Module, Fan Blades in a box,
etc.
• Certain engine parts are used as "slave hardware" to permit testing. These parts are identified,
stored, and/or maintained separately. They are controlled by installation and removal
procedures or by painting the parts yellow. Reference 870.42 - Control of Slave Parts &
Mulitple Test Production Parts.
• In some instances, the effectiveness of this manual is enhanced by parallel subjects contained
in Peebles QCWI’s. These QCWI’s Quality Control Work Instructions are referenced within
the corresponding sections where they apply. Peebles Test Operation maintains additional
QCWI not currently referenced in the Repair Station and Quality manual that may have
application. For convenience, a link to the Peebles QCWI Index is provided below.
o Peebles QCWI Index
Chapter: 4 Page: 60 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
F. Safety, Security and Fire Protection
Pro cedu re : S af e t y , s ecu r i ty an d f i r e p rot ec t i on
• The sites safety policy and practices can be found on the Peebles EHS Practices and Policies
webpage located at: http://tewp010014.us.ae.ge.com/ehs-prac/index4.html
• As a secure facility, access is controlled at the main entrance to only those authorized to enter.
In certain cases, competitive customers are restricted from areas where proprietary
information from another customer may be present. This is controlled through escort-required
admission to the facility.
• All employees have a responsibility to be cognizant of their surroundings, aware of basic
security requirements, and to report any discrepancies immediately to their Team Leader or
Supervisor. Facility security responsibilities lie with the Security Focal Point and the security
team.
• Security requirements are periodically reviewed by a business level security audit team as well
as the site security focal point.
• The repair station assembly buildings and test sites are equipped with various types of fire
suppression systems. These systems are monitored by Security. Suppression includes the
four types of sprinkler systems (wet, dry, pre-action and deluge), CO2 under floor and
portable fire extinguishers.
• Security and Fire Protection personnel inspect the following: all fire protection system valves,
extinguishers, emergency lights, exit lights and Self Contained Breathing Apparatus. Fire
Pumps are tested weekly.
• All systems are identified per OSHA, NFPA and/or GE requirements.
• An on-site Emergency Response Team, comprised of GE employees, is Ohio State Certified
in fire fighting and Hazardous Materials emergencies. Required training is conducted through
out the year to maintain certification.
• Security and Fire personnel conduct daily inspections and enforcement. Weekly and monthly
audits help to maintain compliance.
• Any materials that may be considered hazardous are subject to OSHA Hazcom regulations
while in the workplace. All labeling and storage requirements are identified by the on site
EHS team through EHS practices as well as HAZCOM training. Shipping of hazmat
materials are controlled through the shipping & receiving department, which includes
regulatory required training and certification for those who are involved.
Chapter: 4 Page: 61 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• EH&S Practices, Health and Safety Framework programs and SRA’s help to identify the
various types of PPE required. Audits conducted by Group Leaders, Quality Teams and
EH&S reps. help to enforce PPE usage.
• All pressurized gas bottles are labeled and secured when in use. Spare bottles are stored at a
remote location according to OSHA and other regulating agency guidelines. All bottles are
capped when in transit.
• All chemicals are properly labeled and stored according to OSHA and other regulating agency
guidelines.
Chapter: 4 Page: 62 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
G. Incoming Inspection of Raw Materials
Pro cedu re : Raw Ma t er i a l In co ming In sp ec t ion
• The repair station utilizes no raw materials for processing engines during maintenance,
preventative maintenance or alterations.
Definition:
• Raw Material - Material primarily in the form of any of the following before its fabrication
into a specified part:
o Ingot Bar, Billet Slab, Sheet Plate, Forging Preforms, Pellets, Granules Powder metal,
Composite materials (other than certified materials for use in a repair), Casting,
Forging Braze material, etc.
H. Article Preliminary Inspection
Pro cedu re : Pre l i min a ry In sp ect ion
• All engines require an external Preliminary Receiving inspection and a hidden damage
(borescope*) inspection to determine the possibility of defects. Items inspected are compared
to defined Service Manual limits or approved workscope limits, as applicable.
* Note: The borescope requirement may be waived if documented within the
workscope.
Note: Photos of the engine in the "as received" condition are recommended.
Note: Clean suspect items/areas per appropriate Service Manual instructions, as
required, to complete inspections.
• Areas inspected and results of the inspection are recorded (i.e..... missing hardware, broken
clamps, dented tubing, nicked or dented blades, etc,). The PTO Inspection Observation Log
(see Forms Manual) is used where no specific document is defined within the approved
workscope.
Note: Documentation of completed inspections is required to reflect the condition of
areas inspected even if no faults are identified.
Chapter: 4 Page: 63 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
Note: Items considered in the Preliminary Inspection are listed on the attachment to
the Inspection Observation log as well as inspections required by Service Bulletin and
Airworthiness Directive compliance, teardown or disassembly work scope definition.
• Failures of hardware to meet inspection limits are recorded as a fault using a Test Fault Sheet,
or other nonconforming documentation, per QCWI PE-001.
o Disposition will be provided by a PR qualified Repair Station Inspector who is on the
repair staion roster of authority per the applicable Service Manual Limits or AWS.
o If correction cannot be approved by PR disposition the nonconformance will be
submitted on a Departure Record or contact the customer for disposition of the
hardware..
o Hardware which exceeds the above criteria is identified (i.e. ... appropriate "R & D"
Tag) as nonconforming and removed.
▪ Removed hardware identified as nonconforming is returned to the Peebles
Crib(s) for final processing per QCWI PE-001.
• Part changes that occur are recorded by person completing the change on a Field Return Parts
Change Record.
• Additionally an inspection of the engine shipping stand and engine bag is required.
Documentation of the inspection is required.
o The shipping stand is required to be checked for serviceability (caster condition, bent
or broken attach point linkages, pip pins / pinning mechanisms, etc,).
o The bag is required to be checked for holes or failed latch mechanisms, broken
zippers, etc,).
Note: Some customers may utilize other methods of protection such as wrapping in
plastic sheeting, tarpaulins, enclosed container or truck, etc. In this instance the
Repair Station will review the engine for damage during the receiving inspection.
o Failures of these inspections require notification of the customer for direction.
Maintenance is to be completed in accordance with the GMM (Part 121/135) or
General Electric Company Support manual (Part 91) as applicable.
Chapter: 4 Page: 64 Rev: V March 12, 2018
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I. Hidden Damage Inspection – Post Accident
Pro cedu re : H idd en D a ma g e I nsp ec t io n
NOTE: This procedure is only required on parts that have been involved in an aircraft accident.
• When applicable, inspection for hidden damage is performed. The scope of this inspection is
governed by the type of item involved with special consideration accorded previous operating
history, and Service Bulletins applicable to the item involved. The Chief Inspector or a
Certified Repairman identifies the areas borescoped. They may be waived if approved in the
workscope. Reference QCWI PE-008.
• If the Repair Station area is notified that the unit or components received have been involved
in an accident, fire or flood, a Work Request or the workscope designates such an event. A
thorough inspection for hidden damage (Borescope) is initiated to determine the extent of the
damage depending on the elements involved prior to any repair. Results of the inspection are
recorded on the Inspection Observation Log (See Forms Manual).
J. In-process Inspection
Pro cedu re : In - Proces s Insp ec t i on
NOTE: Ensure persons performing these inspections are listed on the Roster of Key Personnel.
• Identified inspections are performed by Repair Station Inspectors as qualified on the Roster of
Key Personnel.
• General inspections (for FOD, or potential FOD and obvious signs of damage) are required,
by all personnel, at every point in the maintenance process as indicated in the Parts Handling
section above. General inspections do not require recording except in instances where an item
is at fault or a concern is identified. These are documented on the appropriate form as a fault
per QCWI PE-001.
• Specific inspections are defined in the workscope as detailed from the Customer. These are
documented in the approved workscope in the form of an AODO(s) or Work Request(s) (See
Forms Manual).
• Hidden damage inspections are recorded on the Inspection Observation Log unless defined
otherwise in the approved workscope. All other inspections are documented by the Inspector
as defined in the approved workscope on the requesting document.
Chapter: 4 Page: 65 Rev: V March 12, 2018
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• Deviation from the work sequence requires approval of the Chief Inspector or a Certified
Repairman/Supervisor. In the event that the inspection is called out in the Prep to Ship Process
the Chief Inspector or Certified Return to Service Repairman is required to audit/check the
documentation prior to returning an item to Service.
o On occasion, steps in the approved workscope may need to be performed out of
sequence. This can occur due to workscope complexity, delays in part deliveries and
change in direction as the work is accomplished and additional information for the unit
is made available. Deviation is acceptable provided above out of sequence
requirements are met.
• Nonconformances are recorded and processed per Tagging and Identification requirements
above.
• Where any inspection is not satisfactory a disposition to reinspect is permitted. In the event,
the Technical Manual is not understood, or additional direction is required, the Chief Inspector
or a Certified Repairman/Supervisor is to be notified and s/he is required to provide specific
instructions.
K. Final Inspection
Pro cedu re : F in a l In sp ec t ion
• Engines are tested using approved software. Software is managed per QCWI PE-021 -
Software Management Program Requirements For Console & Data Systems. This includes:
o Process Instructions P/I 8.02 - Requirements for Console Configuration Files.
o Process Instruction P/I 6.15 - Automatic Data Processing Configuration Control.
o Process Instruction P/I 6.11 - Disaster Recovery of ADS System Software.
• The engines are prepared for test in cowling, and mounting systems, used to test similar model
Production Engines. A documented procedure is used for PREP TO TEST to record the setup
and DEPREP of these engines. This is required to provide for FOD inspections and control
the installation and removal of slave hardware per GE POLICY 870.42 - Control of Slave
Parts and Multiple Test Production Parts
o Additionally, the engine is prepared using form S - Engine lube/oil Record or form T -
Rake & Probe Activity, where required, to document non-maintenance activity. (See
forms manual).
Chapter: 4 Page: 66 Rev: V March 12, 2018
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• A Test Card (See Forms Manual) is issued for each engine tested. It is used to record
accomplishment of testing and preservation of the engine. The Engine Test "A" Log - Exhibit
V (see forms manual) is used to record engine starts and correlate operational power settings
and data readings. Where available this data may be recorded electronically.
• Test cell data systems are calibrated for use per QCWI PE-002. The testing is completed in a
correlated test cell per GE POLICY 879.15. Engines are tested according to the technical manual
requirements or Approved workscope.
• Records of the testing are recorded electronically in the ETDS (Engine Test Data Storage) system.
• Engines are DEPREP and inspected following test according to the approved workscope and to
the requirements of GE POLICY 889.21 Appendix A. All workscope or Technical Manual
requirements are required to be met or where a failure or nonconformance occurs it is documented
on a Test Fault Card (see Forms Manual) and processed per Section E, Tagging and Identification
of articles.
• When necessary, after repair, the engine data plate may be re-etched manually per the engine
technical data (AMM, ESM etc.)
o Engines requiring re-etching of the data plate, can be re-etched by an inspector listed on
the PTO repair station roster, with a one over one approval by an FAA repairman
supervisor.
• Additionally an inspection of the engine shipping stand and engine bag is required.
Documentation of the inspection is required.
o The shipping stand is required to be checked for serviceability (caster condition, bent
or broken attach point linkages, pip pins / pinning mechanisms, etc,).
o The bag is required to be checked for holes or failed latch mechanisms, broken
zippers, etc,).
Note: Some customers may utilize other methods of protection such as wrapping in
plastic sheeting, tarpaulins, enclosed container or truck, etc. In this instance the
Repair Station will protect and ship per customer requirements.
o Failures of these inspections require notification of the customer for direction.
Maintenance is to be completed in accordance with the GMM (Part 121/135) or
GEAE manuals (Part 91), as applicable.
o Where required maintenance is accomplished in accordance with Tooling and
Equipment Manuals.
Chapter: 4 Page: 67 Rev: V March 12, 2018
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• Prior to approval for final return to service the Chief Inspector or Return to Service Certified
Repairman as authorized for "Return to Service" by the Roster of Key Personnel completes the
following audits and inspections to determine that all work is completed and all records are
claimed.
o Audit the work package (QC Book) to determine that all work has been completed as
required for compliance with this manual and all approved technical data, and that all
required paperwork is contained within the work package.
o Review all work performed paying particular attention to the areas where work was
performed as well as all areas surrounding that area.
o Review and include the Certificate of Conformance documentation obtained from the
crib for all items installed.
▪ NOTE: For dual release (EASA) engines, 8130-3’s are required for all new
hardware installed (including hardware such as nuts, bolts etc)
o Assure that all work performed is listed in capabilities for the repair station (OPS
spec).
o Assure that all work performed meets the requirements of the workscope and that
items not performed are listed on the carry forward log.
• When approval has been given to the above audit, the Chief Inspector/Certified Repairman
proceeds to Chapter 4 Paragraph M. Maintenance Release – Approval for Return to Service.
• Reference:
o GE POLICY 949.23 -Commercial Engines and Hardware – Management of
Departures from Manuals and Service Documents
o GE POLICY 879.07 – Engine Acceptance Testing
o GE POLICY 879.15 – Test Cell Correlation
o GE POLICY 870.42 – Control of Slave Parts and Multiple Test Production Parts
o GE POLICY 879.70 – Prevention of FOD
Chapter: 4 Page: 68 Rev: V March 12, 2018
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L. Work Sign-off
Pro cedu re : Wo rk S i gn -Of f
NOTE: Stamps are not approved for use at the Peebles Repair Station.
Definition:
Claimed - Verification of work completion. Will include first initial, last name and date or the
person’s Badge # is permitted in lieu of name.
Documented Requirement - General Electric Company "Repair Station" approved workscope
requirements that define work to be completed. May include Quality System requirements,
workstation planning procedures, operation sheets or other approved work instructions.
Requirements:
• Hardcopy documentation may be either typed or hand-written in ink. It must be neat, legible,
and reproducible.
o Any voids or changes to entries are made by drawing a single line through the entry,
entering the change near the line-out and signing the correction with the first initial,
last name (Badge # permitted in lieu of signature) and date. A brief explanation of
changes or voids may be provided for clarification.
• Person(s) fully or partially completing the directed activity will claim documentation.
o If work is partially completed, the records (documentation) will be claimed to indicate
the portion of work that has been completed.
o When Assemblers/Operators are working as a "TEAM", a single signature is sufficient
for a claim. The person making this claim assumes responsibility that they have
verified all items claimed are complete.
CAUTION: Inspectors are made aware during training that they may work as technicians
on any given job except for those tasks that require inspection of their own work. In such
cases a technician, or another inspector, performs the task and a second inspector performs
the inspection.
Chapter: 4 Page: 69 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
M. Maintenance Release – Approval for Return to Service
Pro cedu re : Ma in t en an ce R el ea s e and App rov a l f o r R e tu rn t o Serv i ce
• Approval for Return to Service is accomplished by the Chief Inspector or a Return to Service
Certified Repairman as authorized by the Roster of Key Personnel. This approval is
accomplished as appropriate for the approved workscope and is exercised to comply with
FAR Part 43.
• All major repair or major alteration approvals are documented in accordance with Section 43.9
and paragraph (b) of FAR Part 43, Appendix B. FAA Form 337 - Major Repair and
Alteration is completed (in duplicate) as approval for return to service. A copy is provided
with any article that is shipped to a customer. Major repairs must have been accomplished in
accordance with data approved by the Federal Aviation Administration.
• To release components after a repair, a maintenance release (FAA Form 8130-3 -
Airworthiness Approval Tag) is used in lieu of a FAA Form 337.
o Where the work order requires a specific repair, and does not specify complete
inspection to establish airworthiness for the complete unit or component,
documentation of work performed is accomplished noting partial release on the
maintenance release tag (FAA Form 8130-3) for return to the customer. The
Maintenance Release is not used for components subjected to major alterations.
Major alterations are released on a FAA Form 337 per above.
o Where Peebles is required to document activities on Cell Correlation and Engineering
Investigation engines, and to provide this information to the customer, the Peebles
Maintenance Record Tag (see forms manual) is used. This form is used where the
Repair Station is obligated to report maintenance & test activity but is not providing a
"full" return to service. Ref: FAR 43.9 and 43.11. When available, documentation
may be made in the Maintenance Record section of the Engine Log Book in lieu of
issuing a Peebles Maintenance Record Tag
• Documentation included or provided for approval for Return to Service is required to include:
o A reference to the work accomplished, including the specific revision / date of the
technical information used.
o Appropriate certification paperwork for all parts changed/installed during maintenance
including any change of LLP's (Life Limited Parts) as required by the Customer or
Repair Station per part 91. This will include the Time Since New/Cycles Since New
(TSN/CSN).
Chapter: 4 Page: 70 Rev: V March 12, 2018
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o A listing and copies of all maintenance records and Departure records
o Copy of workscope approving alternate processes such as Prep to Test, etc.
o The date the article is approved for Return to Service, including the name of the
person approving the Return to Service.
o Open issues requiring Customer notification are communicated by use of a Carry
Forward Log. (See Forms Manual) or other suitable maintenance record explaining
any and all conditions.
o Listing of all Service Bulletins and AD’s completed
• The FAA Form 337, or the FAA Form 8130-3, is signed by the Chief Inspector or Certified
Return to Service Repairman to indicate approval.
• When the Work Scope requires a specific repair, and does not specify complete inspection to
establish airworthiness for the component a Carry Forward Log is issued to document
activities required prior to return to service and referenced in block 12 of the FAA Form 8130-
3 or on Peebles Maintenance Record Tag issued for work completed.
• The Chief Inspector or Certified Return to Service Repairman as authorized by the Roster of
Key Personnel is approved as backup for Return to Service of an Article.
Chapter: 4 Page: 71 Rev: V March 12, 2018
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N. Calibration
Pro cedu re : Ca l ib ra t ion o f Measu r ing and T es t Eq u ipmen t
• The quality manager is responsible for the over sight of the calibration program. The chief
inspector is the back-up representative.
• All personnel are responsible to verify that, prior to use, each item has not exceeded its
required calibration due date and that the tool is in a condition for continued use. The use of
personally owned tools is prohibited.
• Personnel will identify and return any calibrated equipment to the calibration lab that is
suspected of being defective. This includes any device dropped, having a broken calibration
seal or is otherwise suspect.
• The Quality Manager is responsible to assure that Precision Tools and Test Equipment used at
this Repair Station are subject to periodic cycle checks. The Chief Inspector assumes this
responsibility in the absence of the Quality Manager.
o Calibration intervals have been established through Mfg. recommendations and
General Electric Company policy. The maximum calibration interval of any piece of
test equipment is 2 years.
• Under contractual agreement with the PC-108 facility the calibration of Precision Tools and
Test Equipment are out-sourced to an on site Calibration laboratory. This laboratory is a
National Institute of Standards and Technology traceable calibration lab. This laboratory is
located in the ESC building, with some larger, more specialized equipment requiring shipment
to parent labs and facilities off-site. Precision measuring and test equipment is located
throughout each building in assigned workstations and the Test Site locations.
• The on site Calibration Laboratory is responsible to assure that Standard tools and other
devices are checked and repaired or readjusted, as necessary, at predetermined and scheduled
intervals to ensure accurate calibration. Reference QCWI PE-004 - Calibration of Standard
Tools & Other Devices.
o All Peebles tools are listed in the on site Calibration laboratory database for recall
purposes. The database displays the tool control number, location number and/or the
Tool & Gauge assigned representative (owner) and due date. Reports are generated
bi-monthly, which list all tools due for calibration. The reports are distributed to the
respective T&G representative responsible for that particular workstation. The T&G
representative is responsible for returning the tool to the calibration lab for calibration
before the calibration expires.
o Following calibration, a calibration label is affixed to each tool requiring calibration.
The Label consists of tool control number and due date. Where calibration label
Chapter: 4 Page: 72 Rev: V March 12, 2018
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attachment to the device would be detrimental to usage (i.e.… device too small,
impede device use, test cell potential foreign object damage, etc,) the label may be
displayed separately so as to be readily identifiable to the device. (i.e…. attached to
container, etc,).
o Out of Tolerance - OT reporting and investigation will be accomplished consistent
with QCWI S-080 – Measuring Equipment and local policy Reference QCWI PE-004
- Calibration of Standard Tools.
o A record of calibration history is kept in the on site Calibration laboratory database for
each piece of calibrated equipment. Calibration records are filed and retained for five
years consistent with GE POLICY 022.01 - Record Retention. The records are
maintained and updated by on site Calibration laboratory calibration personnel.
• Where new tools are acquired they are assigned a unique number and added to the Laboratory
calibration database. A calibration cycle is established per S Spec 475A requirements. ... i.e.
... based on similar type device and/or consideration of manufacturer recommendations.
• The on site Calibration laboratory is audited each year as part of ISO 9001:2001. Included
within this audit is a random check of the contractor’s records for traceability, accuracy, and
acceptability.
• Each Test Site location conducting Repair Station Testing will perform calibrations of the Site
Data Acquisition systems per QCWI PE-002 - Calibration of Data Acquisition Systems. OT
reporting and investigation is accomplished consistent with QCWI PE-002 for these systems.
• Peebles plans no lease or borrowing of calibrated tools. Should this becomes necessary, a
record of the calibration is required with the tool or authorization in a Work Request is
approved for use issued by the Chief Inspector or a Certified Repairman.
• Engine test cells are correlated using General Electric Company Procedure 879.15.
Chapter: 4 Page: 73 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• Reference:
o GE POLICY 379.00 – Product Measurement Control
o QCWI S-080 – Measuring Equipment
RECORDS
• Calibrated Records of Precision Tools are kept for 5 years consistent with GE POLICY
022.01 - Record Retention requirements. as defined per QCWI PE-004:
• Calibration records for Test Data Systems are kept by the Test Site where the calibration is
completed for 5 years consistent with GE POLICY 022.01 - Record Retention
requirements. as defined per QCWI PE-002:
Chapter: 4 Page: 74 Rev: V March 12, 2018
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O. Work Performed at Another Location
PURPOSE: This section describes how the repair station may perform work away from its fixed
location on a temporary basis under two circumstances: (a) a special circumstance such as an
aircraft on the ground arises, or (b) work is performed on a recurring basis.
SCOPE: This section describes how the FAA will be notified of the need to perform work away
from the repair station fixed location and how the repair station will not perform the work until the
operation is approved by the FAA.
RESPONSIBILITY: Describe who will be responsible for notifying the FAA of the need.
REFERENCE(S):
• FAR 145.203
• AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control Manuals,
Chapter 4-5
DEFINITIONS:
• Another location – means a location other than the location described in the repair station
manual as the repair station’s fixed base of operations. Normally, work performed at another
location does not include working outside the domicile country where the repair station is
located. Special circumstance work may be authorized by the FAA outside the domicile
country if the repair station obtains approval from the country where the work is to be
performed.
• Recurring basis – means work that is performed as part of the repair station’s everyday
business practices rather than under a special circumstance.
• Special circumstance – means a one-time circumstance arises which is out of the ordinary
business operations. Examples are: (a) aircraft on the ground needing maintenance, (b)
preparation for a ferry flight. The FAA determines a special circumstance operation.
Chapter: 4 Page: 75 Rev: V March 12, 2018
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1. Special Circumstances
Pro cedu re : Sp ec i a l Ci rcu ms tan ces
NOTE: The following information should be formulated as part of the repair station manual when
a special circumstance arises. The change to the manual must be forwarded to the FAA for
approval in each special circumstance.
Requirement:
• All maintenance activities performed by the PTO Repair Station are performed on-site at the
fixed location covered by this manual. Peebles plans no maintenance function pertaining to an
article at any off site location. In the event circumstances require such action the Peebles
Repair Station will complete the following prior to such Maintenance occurring.
• The Chief Inspector contacts the CVG FSDO for approval.
o Where FSDO approval is given, a record of the approval is maintained in the work
package for that work performed away from the Repair Station. All necessary
technical data, trained personnel and equipment will be in place prior to performing
any maintenance away from the facility.
• For work at any off site locations, the Chief Inspector, or a Return to Service Certified
Repairman, is required on site to control work performed by other Peebles Repair Station
Inspectors and Technicians. All procedures set forth in this manual, as well as specific air
carrier requirements, are to be adhered to when working away from the repair station. Contact
between repair station personnel working away from the station and the station it’s self is
maintained.
o For such maintenance the Peebles Repair Station is required to verify, by test and/or
inspection, that the work is satisfactory and that the article is airworthy before
approving it for return to service.
• For work away from the Repair Station a hardcopy of the Repair Station manuals is printed
and a Temporary Number is assigned by the Chief Inspector. It is surrendered immediately
upon return.
o Electronic Forms are printed and copies are made for use in the off site location.
These forms and the hardcopy manual are maintained off site by the Chief Inspector or
the Return to Service Certified Repairman.
• The receiving inspection of the engine is the only function that doesn't apply when working
away from the station.
Chapter: 4 Page: 76 Rev: V March 12, 2018
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• A hardcopy logbook is used to maintain shift turnover records in the event more than one shift
of activity is required.
• The parts and materials to be used at the remote work site will be drawn from the serviceable
stock at the Repair Station or supplied by the owner/operator.
o Any parts used at a remote location supplied by this Repair Station must be received
and inspected in accordance with the Repair Station receiving inspection procedure.
Parts will be afforded adequate protection from deterioration or damage or loss of
serviceable status identity. The team working away from the station will be
responsible to ensure all items shipped by the repair station to a remote location that
are not used are returned.
o The team is also responsible to ensure adequate protection against damage or
deterioration of any tool, part or material.
o All parts used require a Certificate of Conformance prior to being consumed.
• Access by the CVG FSDO is required for any maintenance activity performed away from the
Repair Station.
• Regardless of location, the same procedures, forms and materials covered by this manual are
to be used by Repair Station personnel. The Chief Inspector still holds responsibility and
authority over Repair Station activities.
2. Recurring Basis
Pro cedu re : R ecu rr in g Ba s i s
NOTE: Continuous, uninterrupted operations at another location are not authorized without the
other location becoming a certificated repair station or satellite facility.
• All maintenance activities associated with the PTO Repair Station are performed on-site at the
fixed location covered by this manual. Peebles plans no maintenance on a recurring basis
away from this location.
• The Accountable Manager, with the assistance of the Chief Inspector, will assess the need and
business impact of carrying out repair station operations at another facility. If the decision is
made to go forward with this type of operation the Repair Station manual will be amended to
address the issues listed below and forwarded to the FAA for approval.
Chapter: 4 Page: 77 Rev: V March 12, 2018
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P. Maintenance Performed for Air Carriers
PURPOSE: This section describes procedures to ensure that maintenance or alterations performed
for an air carrier are done so in accordance with the air carrier’s maintenance program and
maintenance manual. This section describes how repair station management ensures the air carrier
has provided the information necessary to ensure compliance with the applicable FAR.
SCOPE: A certificated repair station that performs maintenance, preventive maintenance, or
alterations for an air carrier or commercial operator that has a continuous airworthiness
maintenance program under part 121 or part 135 must follow the air carrier's or commercial
operator's program and applicable sections of its maintenance manual, including line maintenance.
This section addresses only operations performed at this repair station, and does not include line
maintenance.
The scope of maintenance or alterations is that which is stated on the purchase order or
other contractual document. The purchase order must state the source of the data that is
used for the repair or alteration along with any other requirements of the air carrier.
The Repair Station may issue a customer specific Peebles Process Instruction to define the
process to be used to comply with an air carrier or commercial operator’s Special
Requirements.
RESPONSIBILITY: Responsibilities for air carrier maintenance are described in each procedure.
DEFINITIONS:
• Required Inspection Item (RII): means an item of maintenance that, if not performed
properly or if improper parts or materials are used, could result in a failure, malfunction, or
defect, endangering the safe operation of the aircraft.
REFERENCES:
• FAR 145.205
• AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control
Manuals, Chapter 4-6
Chapter: 4 Page: 78 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
1. Control of Operator Data
Pro cedu re : Con t ro l o f Op era t or Da t a
• All work instructions originating from an Air Carrier per Part 145.205 are completed in
accordance with OEM and/or FAA approved data to remain consistent with the Air
Carriers continuous Airworthiness Program.
• The Repair Station plans no continuous upkeep of technical data (GMM's, Service
Bulletins, A/D's, etc,) on site for use in maintenance activities per Part 145.205. It is the
responsibility of the owner/operator to provide access to, or copies of, their GMM and
other technical data in order to accomplish the maintenance requested.
2. Required Inspection Item
Pro cedu re : R equ i red Ins pec t i on I t em
• Where RII inspections are required the air carrier provides personnel to complete the
inspection. Air carriers can elect to provide training to Peebles Repair Station personnel
selected by the Quality Team Leader thus qualifying them to complete RII inspections for that
specific air carrier.
o Where the air carrier completes such training and qualification, a Roster of RII
inspectors is maintained. This Roster is separated by air carrier RII authorization.
This list is maintained by the Quality Team Leader and is separate from the Roster of
Key Personnel.
o RII inspector status is reviewed on a case by case basis prior to the start of any work
requiring use of Peebles approved RII Inspectors.
• RII inspections are completed by RII Inspectors as defined and documented in the approved
workscope from the air carrier.
o No RII inspector having completed any portion of the work on a maintenance task
where an RII inspection is required can complete the RII inspection. In that case
another RII inspector is required to complete the inspection.
3. Duty Time Limitations
• All employees performing a function of this repair station’s inspection and maintenance
program for an air carrier are required to have at least 24 consecutive hours of off-duty
every seven days or the equivalent there of every calendar month. Travel time and waiting
at a job site prior to starting work does not meet the 24-hour requirement. Reference FAR
121.377.
Chapter: 4 Page: 79 Rev: V March 12, 2018
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• No employee works more than 16 consecutive hours in any 24 hour time period.
Q. Contract Maintenance
PURPOSE: This section describes how maintenance is contracted to another facility.
SCOPE: This section covers contract of maintenance to both certificated and non-certificated
facilities.
RESPONSIBILITY: The Chief Inspector is responsible for the contract maintenance program. A
Return to Service Certified Repairman is the backup in the absence of the Chief Inspector.
DEFINITIONS:
• Certificated facility – means a facility which posses an appropriate FAA certification.
• Maintenance function – means individual tasks that comprise the maintenance and
alterations required to return an article to service.
• Non-certificated facility – means a facility that does not possess any type of FAA
certification.
REFERENCES:
• FAR 145.209, 145.211, and 145.217
• AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control
Manuals, Chapter 4-7
Chapter: 4 Page: 80 Rev: V March 12, 2018
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1. Contract Administrative Provisions
Pro cedu re : Con t rac t Ad min i s t ra t i v e Pro v i s i on s
• The Chief Inspector is responsible for requesting approval, reviewing the Approved Sub-
contractor Source List and providing oversight (where oversight is required) of approved
vendors. This is done by assuring all utilized vendors in CASL system are “supplied” to
Peebles in the system.
• The Chief Inspector is required to notify the CVG FSDO and obtain advance approval (or
manner acceptable to the administrator) prior to changes to the Source List. This approval
may be in any form acceptable to the Administrator.
2. Contracting to FAA-certified Facilities
Pro cedu re : Con t rac t in g to FA A - cer t i f i ed f a c i l i t i e s
• ·The Peebles Repair Station may in accordance with Part 145.217 add an approved contract
maintenance provider where that contractor is a FAA Certified Repair Station. The Peebles Repair
Station will use vendors that are approved to GE-Aviation Group Procedure 522.50. The method of
approval is through a centralized database called Consolidated Approved Supplier List (CASL). Each
vendor listed in CASL must be approved, monitored and rated per GE-Engine Services Inc.
Procedure 522.50 provides for vendor auditing, rating and approval. All vendor information is
maintained in a central database, accessible through the GE Intranet, information includes
certifications, audit data and rated capabilities. Only vendors that are listed as “supplied” to Peebles in
CASL are to be used. If an additional vendor is needed and they are listed in CASL, the chief
inspector will assure that CASL is updated to add that vendor as a supplier to Peebles. The sub-
contract list of all Peebles supplied vendors can be pulled at any time at the request of the FAA.
• The Chief Inspector is required to notify the CVG FSDO prior to additions, or deletions, to the Sub-
contractor Source List. Notification for approval may be in any form acceptable to the FSDO.
• Once it is determined that the FAA Repair Station supplier is approved (and the vendor has the
appropriate rating for service to be contracted) a repair order or component WA must be generated
detailing the requested workscope and defining the associated documentation (8130-3 or equivelent)
required from the supplier for the work performed. This repair order or component WA will remain
as part of the work package from which it was generated as well as the documentation of the work
performed by the supplier. Any article being returned from contracted maintenance functions cannot
continue processing until it is checked by a Certified Repairman to verify that the work performed is
satisfactory and that the 8130-3 or equivalent documentation is acceptable. At no time is the material
crib function to release any parts made by, or parts having had contracted maintenance performed on
them by a subcontractor until a Repair Station Certified Repairman has approved the materials as
being airworthy. Two methods are acceptable for checking the hardware returned from contracted
maintenance.
Chapter: 4 Page: 81 Rev: V March 12, 2018
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o Method 1 - Once hardware and paperwork is verified as acceptable an Exhibit C3 -
Receiving Inspection Tag (see forms manual) is completed and attached to indicate the
receiving inspection is complete. A Certified repairman must sign the inspection
block on the Receiving Inspection Tag for hardware returned from contract
maintenance. The tag is required to remain attached until hardware begins installation.
If an “inspection complete” rack is utilized, the receiving inspection tag can be stored
with engine records.
o Method 2 – Hardware that is returned from contract maintenance that is tracked in the
MRO system can utilize the traveler paperwork generated from the system to
document the receiving inspection. If this method is used, the inspection block on the
paperwork must be completed by a Repair Station Certified Repairman.
• All subcontracted maintenance items shall be kept separate from regular stock until this
inspection is performed and the material is accepted for use. If for any reason subcontracted
material is rejected as being unairworthy, it is immediately identified as nonconforming and
the proper disposition made.
• A Return to Service Certified Repairman is the authorized backup in the absence of the Chief
Inspector.
3. Contracting to Non-FAA-Certified Facilities
Pro cedu re : Con t rac t in g to Non - FA A -C er t i f i ed Fa c i l i t i e s
• The Peebles Repair Station makes no provision for sub-contracting maintenance to a Non-
FAA Certified Facility.
• The Peebles Repair Station sub-contracts non-maintenance services that can impact product
maintenance. Services such as calibrations and hardware procurement may be among these.
The Chief Inspector is required to notify the CVG FSDO and obtain approval prior to
utilization of these sources.
• Prior to use of these services the Peebles Repair Station Chief Inspector is required to audit the
proposed location either in person or by e-mailing the Appendix B - Peebles Vendor Audit
Checklist. The Chief Inspector reviews the audit results and makes results of the audit
available to the CVG FSDO for review, if requested.
• Following this audit and with approval from the CVG FSDO the Chief Inspector adds the
supplier to the APPENDIX A - Approved Sub-contractor Source List. This approval may be
in any form acceptable to the Administrator provided such approval is retained by the Chief
Inspector.
Chapter: 4 Page: 82 Rev: V March 12, 2018
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• Once approved a file is maintained by the Chief Inspector for each approved vendor. This file
is required to contain:
• A copy of the vendor’s air agency certificate and operations specifications, as
applicable.
• A copy of the vendors drug alcohol program information, including Appendix D,
as applicable
• Copies of any other certifications, which may relate to the vendors’ area of
expertise, as applicable.
• A copy of the audit checklist, which has been completed by the vendor and
reviewed by the Peebles Chief Inspector and found acceptable (only required for
non FAA Repair Station maintenance services).
• Each non-maintenance vendor will be audited at least once every two years. The
follow-up audit may come in the form of a letter requesting information, which
may have changed over the last two years.
• Once approved a file is maintained by the Chief Inspector for each approved
vendor. This file is maintained at the Chief Inspector's desk.
• A Return to Service Certified Repairman is the authorized backup in the absence of the Chief
Inspector.
R. Current Technical Data
Pro cedu re : Av a i l ab i l i ty o f Cu rren t T echn ica l D a ta
• Oversite of the technical data program is the responsibility of the Chief Inspector, the quality
manager is the back-up representative.
• Current Technical data intended for use by the Repair Station is obtained at the time the data is
required. The technical data can be obtained in the following ways:
• The GE myGEaviation
• Customer or OEM websites
• Customer or OEM CD’s
• Printed hardcopy sections of the manual received from the customer.
Chapter: 4 Page: 83 Rev: V March 12, 2018
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552(b)(4). It is submitted voluntarily for the sole purpose of allowing evaluation by the U.S. Government.
• To assure the data is current a Return to Service Certified Repairman and/or the Chief Inspector
are on distribution for automatic updates from the Engine Services distribution center or GE
myGEAviation for the following:
o Standard Practices Manuals
o Consumable Product Manuals
o Tooling and Equipment Manuals
o Illustrated Parts Catalogues
o Service Bulletins
o Commercial Engine Service Memorandums
o Additional data such as Temporary revisions are checked as well.
• The Chief Inspector or Certified Repairman assures the air carriers technical data is provided as
required when performing maintenance for air carriers as defined in 14CFR Part 145.205.
• The FAA Regulations and Policies link serves as the starting location for Federal Aviation
Regulations and Technical data including, Airworthiness Directives and other information. The
Chief Inspector or Return to Service Certified Repairman checks for applicable Airworthiness
Directives and other applicable regulatory informational changes on a continuous basis.
o Any Peebles incorporated A/D's, Bulletins, or other such technical data are listed in
the Return to Service documentation issued by the Chief Inspector or Return to
Service Certified Repairman.
• The Chief Inspector or Certified Repairman assures that the required technical data is available
before any work is accomplished. They accomplished this by including the title, issue date and
revision of the required technical data in the approved workscope instructions in the form of a
Work Request (WR), AODO, or other repair station documentation.
o No maintenance activity, beyond a receiving inspection, can begin until this information is
on site.
o As required, the technical data is available at the location where work is being
accomplished. Where small sections of technical data (Manuals) are printed and provided
for use, revision status and engine effectivity for these sections is documented using the
Technical Data Management Form Exhibit W (see forms manual). The form is maintained
with the sections of the manual provided on the floor.
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o Changes to or clarification of the approved workscope are documented and/or approved
by the Chief Inspector or Certified Repairman and may include PSE/ASE approval (as
required) and Source approval providing the engine.
o If a new revision of technical data is released while an engine is in process, the repair
station can continue with the original revision that was used on the engine or change to the
new revision as long as all previous work completed complies with the new revision of the
technical data. If a new revision is utilized while the engine is in process, a review of a
new revision will be completed with supporting documentation of the review. The return
to service completed must reflect the correct revision of technical data that was used to
perform the maintenance.
o If a change request to technical data is noted, due to tech data is incorrect, additional
clarification or interpretation is needed, etc. a change inquiry is entered in an electronic
data system.
• Where a departure from the General Electric Company technical requirements is necessary
approval of PSE/ASE and a FAA DER per GE POLICY 949.23 where applicable. The Chief
Inspector or a Certified Repairman is responsible for submitting the request. Once approved the
Departure Record is filed with the engine records requiring the departure.
S. Internal Audit Program
Pro cedu re : In t erna l Aud i t P rog ra m
• Repair Station audit management is the responsibility of the Repair Station Quality Leader. The
schedule and results of these audits are documented in a General Electric Company electronic
audit schedule/tracking system.
• Repair Station "system" audits are conducted annually as part of the General Electric Company
Quality Systems audit requirements using engine services QCWI AA-007/AA-020 Exhibit A.
These audits are performed by AA-007 qualified assessors.
• Workstation audits are performed by QCWI S-026 qualified assessors. The schedule and results
of these audits are documented in an electronic audit system.
• Records of audit findings and corrective actions are entered, and issued, within the General
Electric Company electronic audit schedule/tracking system by the Quality Leader or
representative. These are issued to the Chief Inspector, Accountable Manager, Team Leader(s) or
other functions as required. The Accountable Manager is responsible to assure the Chief
Inspector, Team Leader(s) or other functions complete timely corrections.
• NOTE: Records are maintained for 5 years from the date of the corrective action report closure.
Chapter: 4 Page: 85 Rev: V March 12, 2018
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• External audit surveillance is completed bi-annually as part of the General Electric Company
Quality System audit function.
o NOTE: Reference Synop-1A for applicability matrix for the site.
Chapter: 4 Page: 86 Rev: V March 12, 2018
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T. Production of Replacement or Modification Parts
Pro cedu re : Produc t io n o f R ep la cemen t o r Modi f i ca t ion Pa rt s
• RESERVED – Contact the General Electric Company Regulatory Compliance Leader if
the repair station is engaged in this activity.
U. Recordkeeping
Pro cedu re : R eco rdk eep i ng
• Records kept by this repair station are maintained for five years from the date the article is
approved for return to service.
• This Repair Station provides a copy of the maintenance release to the owner or operator of the
article on which maintenance is performed. A duplicate is stored with the QC Book Records.
• Engine Test Records are recorded electronically in the ETDS (Engine Test Data Storage) used
to manage the engine test data.
• QC Book Records are reviewed by the Chief Inspector or a Certified Repairman. Following
review they are boxed and shipped off site to an approved General Electric Company record
storage provider per GE POLICY 022.01 and QCWI PE-009.
• CHIEF INSPECTOR 5 YEARS:
5 years 5 years 5 years 5 years 5 years Roster of Authority Records & changes
Roster of
Authority
employment
summaries
FAA FSDO
approvals for
manual
changes
Approved
Vendor/sub-
contractors
vendor list
Tool
Equivalent
approvals
Record of all
Departure
Records
RTS records FAA FSDO
approvals for
off site work
RII Roster of Authority Records
Chapter: 4 Page: 87 Rev: V March 12, 2018
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• QUALITY LEADER 5 YEARS
5 years
Audit Records
& Corrective
actions
• OTHER RECORDS
5 years (5 years
after
discharge)
5 years 5 years 5 years
Crib Records Training
Records
Calibration
Records
QC Book Engine Test
Records
REFERENCE:
• General Electric Company Procedure 022.01, Records and Information Management
Implementing Procedure
• Other procedures in this manual describe which records are kept, who keeps the records, and
where the records are physically stored.
V. Airworthiness Directive (AD) Compliance
• During maintenance or alteration, all Airworthiness Directives are complied with as requested
by the air carrier or owner/operator on the purchase order or statement of work.
• AD compliance is recorded in the maintenance record of the article to which the AD applies.
W. Life Limited Parts
• Records of life limited part updates are provided to the air carrier or owner/operator when the
scope of work involves the removal and replacement of a life limited part. This repair station
maintains a copy of the record provided.
Chapter: 4 Page: 88 Rev: V March 12, 2018
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X. Suspected Unapproved Parts
Pro cedu re : Su sp ect ed Un app ro v ed Pa r t s
• All repair station personnel are aware of Suspect Unapproved Parts (SUPS) requirements.
Material Crib Technician Training requires review and acknowledgment of SUPS training
presentation.
• Any SUPS part is reported to the Chief Inspector or the Quality Leader as soon as it is
identified. That person investigates and files an e-mail to the Regulatory Compliance Leader,
Supply Chain Quality within 24 hours as indicated below.
• The Quality Leader or Chief Inspector reports SUPS within 8 hours of discovery to the
Regulatory Compliance Leader, Supply Chain Quality, for reporting to the FAA. The repair
station will not report a SUPS directly to the FAA.
• The Regulatory Compliance Leader, Supply Chain Quality, completes reporting to the FAA
utilizing FAA Form 8120-11 - Suspected Unapproved Parts Notification.
RECORDS:
• FAA Form 8120-11 - Suspected Unapproved Parts Notification
Chapter: 5 Page: 89 Rev: V March 12, 2018
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Training
A. Training Program
The Peebles Repair Station Training Program is managed by the Quality Leader and is defined in
a separate FAA Approved Peebles Repair Station Training Manual. The Peebles Training
Coordinator maintains records of completed training in an electronic training database.
Chapter
5
Chapter: 6 Page: 90 Rev: V March 12, 2018
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Corrective Actions
Chapter
6
Chapter: 6 Page: 91 Rev: V March 12, 2018
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A. Taking Corrective Actions on Deficiencies
PURPOSE: This chapter outlines procedures repair station management uses to remedy any
undesirable condition.
SCOPE: This chapter encompasses corrective action procedures before the article is returned to
service, after the article has been approved for return to service, and revisions to procedures that
are not working as designed.
RESPONSIBILITY: The Quality Manager is responsible for the Corrective Action Program.
DEFINITIONS:
• Corrective Action – means action taken to mitigate, suppress, or eliminate the cause of a
noncompliance or nonconformance to documented requirements.
• Preventative Action – means action taken to eliminate the cause(s) of potential issues which, if
not adequately addressed, could result in non-conformances/non-compliances to documented
product or process requirements.
REFERENCES:
• FAR 145.211
• AC 145-9, Guide for Developing and Evaluating Repair Station and Quality Control
Manuals, Chapter 4-13
• GE POLICY 529.39, General Electric Company Corrective and Preventive Action
1. Corrective Action Process
Pro cedu re : Co rrect i ve A ct ion p ro cess
• This repair station adheres to GE POLICY 529.39 and AA-021 for the corrective action
process.
• The Quality Leader is responsible to assure issuance of Corrective action notices to the Chief
Inspector and/or Accountable manager where internal or external audits findings occur. These
could include, but is not limited to, Repair Station and Quality Control system audit findings,
workstation related audit findings, FAA FSDO audit findings or customer audit findings,
deviations from manual requirements during conduct of business, etc. Human factors must be
considered when developing corrective actions.
Chapter: 6 Page: 92 Rev: V March 12, 2018
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• The Chief Inspector, Quality Leader or issuer of the corrective action performs a follow-up
audit of the corrective action to ensure that it was effective.
• Status of corrective actions will be monitored by the ISO Reprenstative in conjunction with
the Chief Inspector. Any corrective actions coming due will be reported to the Quality
Manager prior to due date. The Quality Manager will communicate to management staff or
affected individuals that the corrective action must be completed. If no action is taken, the
Quality Manager will discuss with the accountable manager and take the appropriate measures
to assure correction action is completed.
• All External audit findings will be entered into electronic system used by the repair station to
assure all corrective actions are completed and effective.
B. Procedure Revision
Pro cedu re : R ev i s io ns t o Pro cedu res
• The Chief Inspector is responsible for revisions to procedures if such procedures turn out to be
non-workable, or if such procedures are revised as part of a continuous improvement effort.
• Reference Manual Revision and Control Chapter 2.
RECORDS:
• Apollo Cause and Effect Report and Diagram or similar documentation.
• The Chief Inspector maintains records of recommendations for revision until such
time as a revision is required or no more than 2 years between revisions.
Chapter: 7 Page: 93 Rev: V March 12, 2018
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Service Difficulty Reports
Voluntary Disclosure Program
Chapter
7
Chapter: 7 Page: 94 Rev: V March 12, 2018
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A. Service Difficulty Reports
PURPOSE: This section describes how the repair station will report to the FAA within 96 hours after it
discovers any serious failure, malfunction, or defect of an article.
SCOPE: This section addresses the submitting of Service Difficulty Reports. Additionally, this section
outlines notification of un-airworthy conditions to customers.
RESPONSIBILITIES: The Quality Manager or Chief Inspector is responsible for preparing and submitting a
Service Difficulty Report to the local FAA.
DEFINITIONS:
• Failure, malfunction or defect – serious defect in, or other recurring un-airworthy condition of,
an engine component or accessory, or any component of them.
REFERENCES:
• FAR 145.221
1. FMD Reporting
Pro cedu re : FMD R epo r t in g
• This Repair Station, through the Quality Leader and/or /Chief Inspector, or Inspectors will report
to the FAA, and any customer affected, within 96 hours after it discovers any serious defect in,
or other recurring un-airworthy condition of, an engine component or accessory, or any
component of them. The report will be made on FAA Form 8010-4, FAA Malfunction or
Defect Report Form, describing the defect or malfunction completely without withholding any
pertinent information. The customer will be notified utilizing a form that is in accordance with
their GMM. A copy of form 8010-4 will be utilized to notify the customer if the GMM does not
specify.
• If any defect or malfunction could result in an imminent hazard to flight, the Repair Station will
use the most expeditious method it can to inform the Administrator and all customers affected.
The Quality Manager or Chief Inspector is responsible for preparing and submitting a
Malfunction or Defect Report to the local FAA Field Office.
• The report must contain as much information required by 145.221 as is available.
Chapter: 7 Page: 95 Rev: V March 12, 2018
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B. Voluntary Disclosure Reporting
PURPOSE: This section describes the process for the repair station to report to the FAA possible non-
compliances to the FAR.
SCOPE: This section addressed reporting of possible non-compliances to FAR Part 145, any associated
FARs, and to any procedure contained in this manual.
RESPONSIBILITIES: The Chief Inspector is responsible for reporting possible non-compliances to the
FSDO. The Quality Leader is responsible to serve as an alternate in the absence of the Chief Inspector.
DEFINITIONS:
• Comprehensive fix – means an action, or actions, proposed by the Repair Station and accepted
by the FAA PMI to preclude recurrence of the apparent violation.
• Evidence – means written documents or reports that support the Repair Station’s analysis of the
disclosed apparent violation and the resulting elements of the proposed comprehensive fix.
• Satisfactory fix – means a comprehensive fix in which all corrective measures have been
completed on schedule and are satisfactory to the FAA.
REFERENCES:
• FAR 145.221
• AC 00-58, Voluntary Disclosure Reporting Program
Pro cedu re : Vo lun ta ry Di s c l osu re R ep o rt ing
• This repair station participates in the FAA’s Voluntary Disclosure Program.
• The following five conditions are met for a possible non-compliance to be covered under the FAA’s
Voluntary Disclosure Program:
1. The repair station has notified the FAA of the apparent violation immediately after
detecting it and before the FAA has learned of the violation by other means.
2. The apparent violation was inadvertent.
3. The apparent violation does not indicate a lack, or reasonable question, of the
qualification of the repair station.
Chapter: 7 Page: 96 Rev: V March 12, 2018
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4. Immediate action, satisfactory to the FAA, is taken upon discovery to terminate the
conduct that resulted in the apparent violation.
5. The repair station has developed or is developing a comprehensive fix and schedule
of implementation satisfactory to the FAA. The comprehensive fix includes a follow-
up self-audit to ensure that the action taken corrects the non-compliance.
• Reference Advisory Circular 00-58 Voluntary Disclosure Reporting Procedure for procedure on
submitting a Voluntary Disclosure.
Chapter: 8 Page: 97 Rev: V March 12, 2018
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Drug Testing
Chapter
8
Chapter: 8 Page: 98 Rev: V March 12, 2018
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A. Drug Testing Program
PURPOSE: FAR Part 120 require employees performing work for an air carrier to be under the
coverage of an approved anti-drug program. This chapter describes how the repair station administers
the program.
SCOPE: Each person who performs a safety-sensitive function directly or by contract must be tested
pursuant to an FAA-approved anti-drug program conducted in accordance with FAR 120. Persons
performing maintenance or preventative maintenance duties are covered.
• Peebles Repair Station operates under FAA approved drug plan as listed in section A449,
Table 1 of Operation Specification.
RESPONSIBILITIES: The Human Resource Manager is responsible for administration of Peebles
alcohol/substance abuse program. The chief inspector is responsible for assuring all required
individuals are in the drug pool
DEFINITIONS:
o Maintenance – means inspection, overhaul, repair, preservation and replacement of
parts.
o Safety-sensitive function – means a function listed in section FAR 120.105 &
120.215.
REFERENCES:
FAR Part 120
Policy 250.60
Peebles P.I. 9.01
P R O C E D U R E : A N T I - D R U G P R O G R A M
▪ The requirements of 14 CFR part 120 are complied with under GE Policy 250.60 and Peebles
Process Instruction 9.01 as noted below:
TESTING APPLICABLE TO ALL EMPLOYEES AND APPLICANTS:
• Applicants are informed that they are subject to drug testing as part of the
employment/placement process and that a verified negative drug test result is required as a
condition of employment.
Chapter: 8 Page: 99 Rev: V March 12, 2018
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• Prior to initial placement into a position involving performing a safety-sensitive function,
employees must provide a verified negative drug test result, and be included in the random
testing pool.
• When a supervisor, manager, Security, or medical professional suspects that an employee is
under the influence of drugs or alcohol based on observation of the employee's appearance,
behavior, speech, or body odors, the employee may be required to undergo drug and/or
alcohol testing and/or may be removed from Company property. General Electric Company
reserves the right to render judgment of reasonable suspicion/reasonable cause with or without
requiring a test.
• Return-to-duty testing may be required of employees returning from mandatory and/or
voluntary rehabilitation and will be determined on a case-by-case basis. Employees removed
from work after a verified positive drug/alcohol test result or refusal to test under federal
regulation must provide a "negative" alcohol test result and/or a verified negative drug test
result prior to returning to a safety-sensitive function.
• Upon returning from mandatory drug and/or alcohol rehabilitation, employees will be subject
to unannounced follow-up testing. Employees covered under federal regulations returning to
work from rehabilitation as a result of a positive drug and/or alcohol test result or refusal to
test are subject to unannounced follow-up testing as determined by a medical review officer
and/or substance abuse professional and will be subject to testing for at least 6 tests within 12
months and for a period of up to 60 months.
• Reference Policy 250.60 for DOD and DOT Employees.
• Changes to the anti-drug plan are submitted to the FAA by General Electric Company for
approval.
▪ Annual reports are submitted to the FAA cumulatively for the entire General Electric
Company business by March 15 of the succeeding calendar year for the prior calendar year
(Jan 1 through Dec 31). Peebles is required to submit their facility report to the business level
EHS contact in advance of the deadline.
RECORDS:
Records are maintained relating to the alcohol/substance abuse program as required by law or
regulations and the GE Workplace Information and Privacy Guidelines. Releasing them is done with
the written consent of the employee or as otherwise mandated by law, regulations, or GE guidelines.