FAA APPROVED REPAIR STATION Repair Station Number …

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




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




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




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Introduction

Chapter

1




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.




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.




· 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.




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.




Manual Revision and Control

Chapter

2




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




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.




• 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.




• 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.




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




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Organization

Chapter

3




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.




• 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.




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




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

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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.




• 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.




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.




• 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.




• 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).




• 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

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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.






• 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.

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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.




7. NDT Inspector and Special Process Control


• 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:


• 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.




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.




• 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)


• 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.




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.




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


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


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.




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.




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




• 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)




• 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.

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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.




• 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.




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.

http://wsp04.ae.ge.com/wls-ewcp/corp/AEDMSDoc?docNumber=PE-018EXB




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




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.




Repair Station Operations

Chapter

4




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),


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




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).




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.




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:




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




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.




• 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:




• 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.




• 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.




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.




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.




• 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

http://genet.ae.ge.com/ORG/QSA/tbq/peebles/pe-qcwis/pe-index.htm




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.




• 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.




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.




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.




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.




• 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).




• 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.




• 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




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.




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).




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.




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




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.

http://genet.ae.ge.com/ORG/QSA/tbq/peebles/pe-qcwis/pe002.htm




• 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:




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


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.




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.




• 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.




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


Manuals, Chapter 4-6




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.




• 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






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.




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.




• 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.




• 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.

http://www.faa.gov/regulations/index.cfm




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.




• 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.




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




• 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.




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




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




Corrective Actions

Chapter

6




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



• 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.




• 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.


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.

Service Difficulty Reports

Voluntary Disclosure Program

Chapter

7




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.




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.




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.




Drug Testing

Chapter

8




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.




• 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.

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