(AMC) and Guidance Material (GM) for CASR Part 145 Manual of Standards Approved ...

73 Pages·2009·0.94 MB·English

Acceptable Means of Compliance (AMC)
and
Guidance Material (GM)
for
CASR Part 145
Manual of Standards
Approved Maintenance Organisations Requirements
An Acceptable Means of Compliance (AMC) explains how the requirements contained in the Civil Aviation
Safety Regulations 1998 (CASRs) for a certificate, licence, approval or other authorisation can be met by an
applicant. Applicants are not required to comply with the AMC but if they do, CASA will issue the
authorisation. Alternatively, applicants can, on their own initiative, propose other ways of complying with
the requirements of the CASR, which CASA will assess on an individual basis.
Guidance Material (GM) provides explanations and amplification of a CASR’s policy intention, rather than
a means of complying with it. GM should be read in conjunction with the applicable CASR(s) and AMCs.
GM is identified by grey shaded text.
CONSULTATION DRAFT: November 2009
Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

Table of Contents
145.A.10 Scope.........................................................................................................................6
GM – Line Maintenance........................................................................................................6
AMC – Line Maintenance.....................................................................................................6
AMC – Base Maintenance.....................................................................................................6
GM – Small Organisations of One Person............................................................................6
5 AMC – Small Organisations of One Person..................................................................7
6 AMC – Small Organisations Up to Ten Individuals Involved in Maintenance.............8
GM 145.A.25(a) Facility Requirements................................................................................8
AMC 145.A.25(a) Facility Requirements..............................................................................9
GM 145.A.25(b) Facility Requirements................................................................................9
AMC 145.A.25(b) Facility Requirements...........................................................................10
GM 145.A.25(d) Facility Requirements..............................................................................10
GM 145.A.25(e) Facility Requirements..............................................................................10
AMC 145.A.25(e) Facility Requirements............................................................................10
GM 145.A.30(a) Personnel Requirements............................................................................10
GM 145.A.30(b) Personnel Requirements...........................................................................10
AMC 145.A.30(b) Personnel Requirements.........................................................................11
GM 145.A.30(c) Personnel Requirements............................................................................11
AMC 145.A.30(c) Personnel Requirements.........................................................................11
GM 145.A.30(d) Personnel Requirements...........................................................................12
AMC 145.A.30(d) Personnel Requirements.........................................................................12
GM 145.A.30(e) Personnel Requirements – Employee Qualifications................................13
AMC 145.A.30(e) Personnel Requirements – Employee Qualifications.............................13
Training syllabus for initial human factors training............................................................15
GM 145.A.30(f) Personnel Requirements............................................................................16
Specialist Services Maintenance Certification....................................................................16
Non-Destructive Testing.....................................................................................................17
AMC 145.A.30(f) Personnel Requirements.........................................................................17
Non Destructive Testing (NDT)..........................................................................................17
Organisations...............................................................................................................18
Personnel.....................................................................................................................18
Recording of NDT Test Results..................................................................................18
Visual Acuity...............................................................................................................19
Welding...............................................................................................................................19
Engine Ground Running; Borescope Inspection; Flight Control Rigging...........................19
AMC 145.A.30(h)1-2. Personnel Requirements..................................................................19
GM 145.A.30(j)1-3. Personnel Requirements......................................................................19
GM 145.A.30(j)4. Personnel Requirements.........................................................................20
AMC 145.A.30(j)4.(i) Personnel Requirements...................................................................20
AMC 145.A.30(j)4.(ii) Personnel Requirements..................................................................21
AMC/GM for CASR Part 145 2
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Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

GM 145.A.35(a) Certifying and Support Staff.....................................................................21
GM 145.A.35(b) Certifying and Support Staff.....................................................................21
GM 145.A.35(b)3. Certifying and Support Staff..................................................................21
GM 145.A.35(c) Certifying and Support Staff.....................................................................22
GM 145.A.35(d) Certifying and Support Staff............................................................................22
GM 145.A.35(d) Certifying and Support Staff.....................................................................22
AMC 145.A.35(e) Certifying and Support Staff..................................................................23
AMC 145.A.35(f) Certifying and Support Staff...................................................................23
AMC 145.A.35(j) Certifying and Support Staff...................................................................23
GM 145.A.37 Training.........................................................................................................24
GM 145.A.40(a) Equipment Tools and Material..................................................................24
AMC 145.A.40(b) Equipment Tools and Material...............................................................24
GM 145.A.40(d) Equipment Tools and Material.................................................................24
AMC 145.A.40(d) Equipment Tools and Material...............................................................24
GM 145.A.43 Fabrication in the Course of Maintenance (FITCOM)..................................25
AMC 145.A.43 Fabrication in the Course of Maintenance (FITCOM)...............................25
Inspection and Identification.......................................................................................26
GM 145.A.43(b) Fabrication in the Course of Maintenance (FITCOM).............................26
AMC 145.A.43(b) Fabrication in the Course of Maintenance (FITCOM)..........................26
GM 145.A.45(a) Maintenance Data..........................................................................................27
AMC 145.A.45(a) Maintenance Data........................................................................................27
GM 145.A.45(b) Maintenance Data.....................................................................................27
AMC 145.A.45(b) Maintenance Data..................................................................................27
GM 145.A.45(d) Maintenance Data.....................................................................................28
AMC 145.A.45(d) Maintenance Data..................................................................................28
GM 145.A.45(e) Maintenance Data.....................................................................................29
AMC 145.A.45(e) Maintenance Data...................................................................................29
GM 145.A.47 Production Planning......................................................................................29
AMC 145.A.47 Production Planning...................................................................................29
GM 145.A.50 Certification of Maintenance.........................................................................30
System of Certification....................................................................................................30
Table 1 – Maintenance Verification and Certification Overview............................31
GM 145.A.50(a) Certification of Maintenance....................................................................32
AMC1; 145.A.50(a) Certification of Maintenance...............................................................32
AMC2; 145.A.50(a) Certification of Maintenance...............................................................32
AMC 145.A.50(d) Certification of Maintenance.................................................................34
Internal Release Documentation..........................................................................................34
GM 145.A.60 Occurrence and Major Defect Reporting......................................................34
AMC/GM for CASR Part 145 3
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Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

AMC 145.A.60 (a) Occurrence and Major Defect Reporting..............................................34
AMC 145.A.60 (b) Occurrence and Major Defect Reporting..............................................35
GM 145.A.65 Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................35
Organisational Management Systems.................................................................................35
AMC 145.A.65 Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................36
Quality Management Systems.............................................................................................36
Organisational Management Structure – Summary.........................................................38
Figure 145.A.65.1   Organisational Management System Structure.......................39
GM 145.A.65(a) Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................39
AMC 145.A.65(a) Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................39
Sample Safety Policy Statement......................................................................................40
Topics Acceptable for Inclusion in a CEO Statement of Corporate Safety Commitment40
GM 145.A.65(b) Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................42
Drug and Alcohol Management Plan (DAMP)...................................................................42
Fatigue Risk Management Systems for Maintenance Organisations..................................42
Background.....................................................................................................................42
Guidelines for ‘Good Practice’........................................................................................42
Underlying Principles..................................................................................................42
AMC 145.A.65(b) Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................44
Fatigue Risk Management Systems.................................................................................44
GM 145.A.65(b)8. Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................44
GM 145.A.65(c)1. Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................44
AMC 145.A.65(c)1. Safety and Quality Policy, Maintenance Procedures and
Management Systems..............................................................................................................45
GM 145.A.65(c)2. Safety and Quality Policy, Maintenance Procedures and
Management Systems..............................................................................................................46
AMC 145.A.65(c)2. Safety and Quality Policy, Maintenance Procedures and
Management Systems..............................................................................................................46
GM 145.A.65(d) Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................46
AMC 145.A.65(d) Safety and Quality Policy, Maintenance Procedures and Management
Systems....................................................................................................................................46
GM 145.A.70(a)10. Maintenance Organisation Exposition.................................................47
AMC 145.A.70(a)10. Maintenance Organisation Exposition..............................................47
AMC 145.A.70 Maintenance Organisation Exposition........................................................47
GM 145.A.75 Privileges of the Approved Maintenance Organisation.................................47
Sub-contracting Maintenance..........................................................................................47
AMC/GM for CASR Part 145 4
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Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

Appendix I Safety Management Systems................................................................................49
1 Safety Management Process....................................................................................49
Collect the Data...........................................................................................................49
Figure SMS.1 Safety Management Process..........................................................50
Analyse the Data..........................................................................................................50
Prioritise Unsafe Conditions........................................................................................50
Develop Strategies.......................................................................................................50
Approve Strategies......................................................................................................50
Assign Responsibilities and Implement Strategies......................................................50
Re-evaluate Situation...................................................................................................51
Collect Additional Data...............................................................................................51
2 Safety Management System Implementation Plan..................................................51
Small Organisations.....................................................................................................51
3 The Components of a Safety Management System (SMS).....................................51
GM – Safety Policy, Objectives and Planning............................................................52
GM – Safety Risk Management..................................................................................59
Figure SMS.3 Tolerability of Risk (TOR) Triangle..................................................60
Figure SMS 4 Risk Management Processes..........................................................63
Risk..........................................................................................................................63
Risk Assessment.......................................................................................................63
Figure SMS.5 Example Risk Assessment Matrix...................................................64
AMC- Safety Risk Management.................................................................................66
Figure SMS.6 Risk Management Process – Overview  
Source:  AS/NZ 4360 (2004).....................................................................................66
GM – Safety Assurance Processes..............................................................................67
Systems to Achieve Safety Oversight:......................................................................67
Safety Performance Monitoring and Measurement.................................................68
Internal Safety Investigation....................................................................................68
Investigation Management......................................................................................68
Scope of Safety Investigations.................................................................................69
Figure SMS.7 Internal Safety Investigation Process.............................................70
Change Management...............................................................................................70
Continuous Improvement of the Safety System........................................................71
Management Review................................................................................................71
AMC –Safety Assurance Processes – Small Organisations........................................72
GM – Safety Promotion...............................................................................................72
Training and Education...........................................................................................72
Safety Communication............................................................................................73
AMC – Safety Promotion – Small Organisations........................................................73
AMC/GM for CASR Part 145 5
CONSULTATION DRAFT
Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

145.A.10 Scope
GM – Line Maintenance
1 Where aircraft are to be maintained in accordance with progressive type programmes or for
temporary and occasional cases (AD’s, SB’s) under a Line Maintenance approval in accordance
with a control procedure as mentioned above, the particular check or task should be individually
assessed.
AMC – Line Maintenance
1 Line Maintenance should be understood as any maintenance that is carried out before flight to
ensure that the aircraft is fit for the intended flight.
2 Line Maintenance may include:
(cid:190) Trouble shooting.
(cid:190) Defect rectification.
(cid:190) Aeronautical Product replacement with use of external test equipment if required.
Aeronautical Product replacement may include products such as engines and propellers.
(cid:190) Scheduled maintenance and/or checks including visual inspections that will detect obvious
unsatisfactory conditions/discrepancies but do not require extensive in depth inspection. It
may also include internal structure, systems and powerplant items which are visible through
quick opening access panels/doors.
(cid:190) Minor repairs and modifications which do not require extensive disassembly and can be
accomplished by simple means.
3 For the carrying out of Aircraft Maintenance in accordance with Progressive type programmes or for
temporary and occasional cases (AD’s, SB’s) by an AMO that holds Line Maintenance approval only,
it is acceptable for the AMO to have a control procedure in its exposition for the assessment of the
organisation’s capability to complete all tasks within the particular check safely to the required
standards at the designated line maintenance station and where the Quality Manager approves the
assessment.
AMC – Base Maintenance
Maintenance tasks falling outside the criteria for Line Maintenance above are considered to be Base
Maintenance.
Where the AMO uses facilities either inside or outside Australia such as satellite facilities, sub-
contractors or line stations, such facilities may be included in the approval without being identified on
the approval certificate, if the AMO’s exposition identifies the facilities and contains procedures to
control such facilities and CASA is satisfied that they form an integral part of the AMO.
GM – Small Organisations of One Person
1 This Guidance Material (GM) provides guidance on how the smallest organisations satisfy the
intent of Part-145:
2 By inference, the smallest Part-145 AMOs would only be involved with a limited number of light
aircraft, or aeronautical products used for large aircraft or aircraft operated in Passenger Service
operations. It is therefore a matter of scale; small AMO’s maintaining a small number of light
aircraft do not demand the same level of resources, facilities or complex maintenance procedures
as a large organisation.
AMC/GM for CASR Part 145 6
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Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

3 A Part-145 approval may be required by two quite different types of small organisations; the first
being the light aircraft maintenance hangar, the second being the aeronautical product
maintenance workshop maintaining such products as small piston engines, radio equipment etc.
4 Where only one person is employed (in fact having the certifying function and others), the AMOs
approved under Part-145 may use the alternatives provided in this Guidance Material limited to
the following:
(a) For Class ‘Aircraft’ maintenance;
(cid:190) A2 Rating, Base and Line maintenance of aeroplanes of 5700 kg and below (piston
engines only.
(cid:190) A3 Rating, Base and Line maintenance of single engined helicopters of less than 3175 kg.
(cid:190) A4 Aircraft other than A1, A2 and A3.
(b) For Class ‘Engine’ maintenance;
(cid:190) B2 Rating, Piston engines with a maximum output of less than 450 HP.
(c) For Class ‘Aeronautical Products’ maintenance, ‘C’ Ratings.
(d) For Class ‘Specialist Services’ maintenance;
(cid:190) D1 Rating (Non-Destructive Testing);
(cid:190) D2 Rating (Welding);
(cid:190) D3 Rating (Other Specialist Service as specified).
5 AMC – Small Organisations of One Person
(a) The minimum acceptable means of compliance to MOS paragraph 145.A.30 (b) is for one full-
time person who holds the position of ‘Accountable Manager’, maintenance engineer and is also
the Certifying Employee, meeting the requisite Part-66 requirements. No other person may issue a
Certificate of Release to Service and therefore if absent, no maintenance may be released during
such absence.
(b) The quality and safety monitoring functions under MOS paragraphs 145.A.65 (c) and (d) may
be contracted to an appropriate organisation approved under Part-145 or to a person with
appropriate technical knowledge and extensive experience of quality audits employed on a
part-time basis, with the agreement of CASA.
Note: Full time for the purpose of Part-145 means not less than 35 hours per week except
during vacation periods.
(c) For a small organisation where one individual uses a contracted quality and safety monitoring
arrangement, the requirement of MOS paragraph 145.A.35(i) is satisfied by the submission to
and acceptance by CASA of the nomination of that individual as the Accountable Manager,
where the individual is also responsible for Quality and Safety issues and for Maintenance
Certifications and Certificates of Release to Service. In this situation it is not necessary for
the individual to issue authorisations for him or herself. The individual’s authorisations will
be limited by his or her qualifications, which are required to be specified under paragraph
145.A.30(e) and may be referred to in a description of the AMO’s capability in the
Exposition.
(d) For acceptable means of compliance to MOS paragraphs 145.A.65(c) and (d) the contracted
quality or safety monitoring organisation or person should make a minimum of 2 visits per 12
months and it is the responsibility of this organisation or person to carry out such monitoring
on the basis of 1 visit pre-announced and 1 visit unannounced to the organisation.
(e) With only one person as in 5(c) above, the requirement for a separate record of authorisation under
paragraph 145.A.35(j), may be satisfied by a description of the individual’s authorisations or
qualifications to be included in the AMO’s exposition.
AMC/GM for CASR Part 145 7
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Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

(f) The AMO is responsible to comply with the findings of the contracted quality or safety
monitoring organisation or person.
(g) Under the intent of CASR 145.010(3)(c), if the organisation or person contracted for quality
monitoring loses or relinquishes its approval; or if the AMO wishes to change the contracted
provider of this function, then the AMO must apply to CASA for a significant change
approval with a proposal for new quality monitoring arrangements.
6 AMC – Small Organisations Up to Ten Individuals Involved in
Maintenance
(a) For acceptable means of compliance to MOS paragraph 145.A.30(b), the normal minimum
requirement is for the employment on a full-time basis of two persons who meet CASA’s
requirements for certifying employees, whereby one holds the position of "maintenance
engineer" and the other holds the position of "quality audit engineer". Either person could
assume the responsibilities of the accountable manager providing that they can comply in full
with the applicable elements of MOS paragraph 145.A.30(a), but the "maintenance engineer"
should be the certifying person to retain the independence of the "quality audit engineer" to
carry out audits. Nothing prevents either engineer from undertaking maintenance tasks
providing that the "maintenance engineer" issues the Certificate of Release to Service.
(b) The "quality audit engineer" should have similar qualifications and status to the "maintenance
engineer" for reasons of credibility, unless he/she has a proven track-record in aircraft quality
assurance, in which case some reduction in the extent of maintenance qualifications may be
acceptable.
(c) In cases where CASA agrees that it is not practical for the organisation to nominate a post
holder for the quality monitoring function, this function may be contracted in accordance with
paragraph 5(b), but if the AMO is approved on this basis, then paragraphs 5(f) and 5(g) are
also applicable.
GM 145.A.25(a) Facility Requirements
Where the hangar is not owned by the organisation, it may be necessary to establish proof of tenancy.
Protection from the weather elements relates to the normal prevailing local weather elements that are
expected throughout any twelve month period. Aircraft hangar and component workshop structures should
prevent the ingress of rain, hail, ice, snow, wind and dust etc. Aircraft hangar and component workshop
floors should be sealed to minimise dust generation.
For line maintenance of aircraft, hangars are not essential but it is recommended that access to hangar
accommodation be demonstrated for usage during inclement weather for minor scheduled work and
lengthy defect rectification.
Employees involved in aircraft maintenance should be provided with an area where they may study
maintenance instructions and complete maintenance records in a proper manner.
AMC/GM for CASR Part 145 8
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Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

AMC 145.A.25(a) Facility Requirements
Where the AMO uses facilities either inside or outside Australia such as satellite facilities, sub-contractors or line
stations, such facilities may be included in the approval without being identified on the approval certificate, if the
AMO’s exposition identifies the facilities and contains procedures to control such facilities and CASA is satisfied
that they form an integral part of the AMO.
An acceptable means of compliance to the requirement for segregation of specialist workshops will be
segregation to the extent that sensitive equipment is not contaminated in areas where they are to be
maintained. For example workshops where composite repairs and sanding is performed should be
segregated from electronic, hydro mechanical component or hydraulic component workshops.
Segregation may be by physically isolating workshops with solid walls or by a combination of distance
and less substantially partitioned bays with adequate environmental control. Additionally, similar
segregation should be provided where sensitive tooling and equipment is used for maintenance.
Facilities including aircraft hangars, Aeronautical Product Maintenance workshops and office
accommodation may be provided that are appropriate for the tasks carried out in them to the extent that:
1 Employees can carry out required tasks without undue discomfort because of temperature (for
example, there may be adequate heating and cooling); and
2 Airborne contamination, including dust, is kept to a minimum and below a level in the work task
area where visible aircraft or aeronautical product surface contamination cannot be seen.
3 Lighting allows each maintenance task to be carried out properly or effectively; and
4 Noise does not distract individuals from carrying out maintenance tasks.
Where facilities cannot ensure these criteria or for maintenance that must be performed outside any
hangar, workshop or office as mentioned above such as for line maintenance, a Part 145 organisation may
comply with this requirement by:
1 Providing Personal Protective Equipment and clothing;
2 Having procedures that identify when and under what conditions maintenance may be performed,
for example;
(cid:190) If the facilities cannot provide adequate heating and cooling, procedures may define the
conditions under which maintenance may be performed; and.
(cid:190) If it is impractical to control noise during maintenance tasks, individuals involved in the tasks
may be provided with equipment that will prevent excessive noise from causing distraction;
and
If airborne contamination results in visible surface contamination, all systems that could be affected by the
contamination are sealed until the contamination and the source of the contamination are removed.
Aircraft hangar and component workshop floors should be sealed to minimise dust generation. The degree
to which floors should be sealed depends upon the approved scope of maintenance for the facility. An
acceptable standard for a workshop that overhauls intricate avionic components will be more stringent than
for an aircraft hangar that is approved for line maintenance and defect rectification. As a minimum, for
hangar floors to be sealed means that they should not be dirt or gravel floors where dust and dirt may
contaminate aircraft or aeronautical products. The outcome required is that where systems or components
are open they should not be subjected to dust and contamination due to environmental factors.
GM 145.A.25(b) Facility Requirements
This provision is intended to provide for adequate office accommodation for:
1 maintenance planning functions; and
2 task research, maintenance data and instruction research and reading; and
AMC/GM for CASR Part 145 9
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Acceptable Means of Compliance (AMC)
Guidance Material (GM) CASR Part 145

3 certification and coordination requirements of maintenance employees for:
(a) normal scheduled maintenance; and
(b) the rectification of defects that could normally be expected in the AMO’s maintenance
facilities and locations.
AMC 145.A.25(b) Facility Requirements
It is acceptable to combine any or all of the office accommodation requirements into one office subject to
employees having sufficient room to carry out assigned tasks. Office accommodation may be provided for
the processing and management of check sheets and task cards and their certification management, as well as
for the research and reading of maintenance tasks, maintenance instructions and other maintenance data by
maintenance employees.
GM 145.A.25(d) Facility Requirements
Having storage facilities for serviceable aeronautical products, tools and equipment that are clean, well
ventilated and maintained at a constant dry temperature to minimise the effects of condensation will be an
acceptable means of compliance. Manufacturer’s storage recommendations will be followed for those
aeronautical products, tools and equipment identified in such published recommendations.
Storage racks should be strong enough to hold aeronautical products and provide sufficient support for
large aeronautical products such that the product is not distorted during storage.
All aeronautical products, wherever practicable, should remain packaged in protective material to
minimise damage and corrosion during storage.
GM 145.A.25(e) Facility Requirements
Sufficiency of hangar space to carry out planned base maintenance may be demonstrated by the
preparation of a projected aircraft hangar visit plan relative to the maintenance programme. The aircraft
hangar visit plan should be updated on a regular basis.
AMC 145.A.25(e) Facility Requirements
An acceptable hangar visit plan will be one that is described in the exposition as a document that is
regularly updated and used as a reference for projected planning of hangar utilisation. The hangar visit
plan by virtue of its continual changeability needs only to be included in the exposition by reference, with
the description and procedures for control to be included in the exposition.
GM 145.A.30(a) Personnel Requirements
With regard to the Accountable Manager, it is normally intended to mean the Chief Executive Officer of
the AMO, who by virtue of the position has overall (including in particular financial) responsibility for
running the organisation. The Accountable Manager may be the Accountable Manager for more than one
organisation and is not required to be necessarily knowledgeable on technical matters as the AMO’s
exposition defines the maintenance standards to be adhered to. When the Accountable Manager is not the
Chief Executive Officer (or equivalent), or where the finances of the organisation may be controlled by a
board of directors, CASA will need to be satisfied that such an Accountable Manager has direct access to
chief executive officer and has a sufficiency of ‘maintenance funding’ allocation to support the scope of
maintenance proposed for approval.
GM 145.A.30(b) Personnel Requirements
The Quality Manager’s responsibilities are outlined in MOS paragraph 145.A.30(c).
The Safety Manager’s responsibilities are outlined in AMC paragraph Safety Responsibilities.
AMC/GM for CASR Part 145 10
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