THỰC HÀNH bảo DƯỠNG TÀU BAY 2 đề tài QUY TRÌNH bảo DƯỠNG TRONG BASE

BỘ GIAO THÔNG VẬN TẢI HỌC VIỆN HÀNG KHÔNG VIỆT NAM Ψ THỰC HÀNH BẢO DƯỠNG TÀU BAY Đề Tài: QUY TRÌNH BẢO DƯỠNG TRONG BASE Lớp: 18ĐHKT01 Nhóm thực hiện: Nhóm TP.HCM, ngày tháng 10 năm 2022 DANH SÁCH SINH VIÊN HỌ VÀ TÊN MSSV Võ Hữu Nguyễn Tuấn Tú 1851200020 Hoàng Bá Nam 1851200005 Nguyễn Trọng Nhân 1851200043 Võ Minh Phúc Lộc 1851200012 Trần Linh 1851200010 Bùi Tấn Phát 1851200022 Nguyễn Huy Hoàng 1851200004 Lê Minh Hiếu 1851200013 Chim Varasith 1851200058 Phan Xuân Dũng 1851200045 Nguyễn Đinh Minh Quân 1851200002 Niphaphone Tanpanya 1851200052 Nammavongsa Somchai 1851200051 MỤC LỤC COORDINATION BETWEEN AMOS WHEN USING THE SAME WIDE BODY HANGAR OR PARKING AREAS OF VAECO 1.1 Scope 1.2 Responsibility 1.3 General requirements 10 AIRCRAFT TOWING/PUSHBACK 11 2.1 Purpose 11 2.2 Definitions 11 2.3 Scope 11 2.4 Responsibility 11 2.5 Procedure 11 2.6 General requirements and safety precautions 12 CONTRACT MAINTENANCE IMPLEMENTATION 14 3.1 Purpose 14 3.2 Scope 14 3.3 Responsibility 14 3.4 Procedure 14 AIRCRAFT WORK ORDER ISSUANCE AND CONTROL 16 4.1 Purpose 16 4.2 Scope 16 4.3 Responsibility 16 4.4 Procedure 16 WORK PACK PREPARATION AND REVIEW 17 5.1 Purpose 17 5.2 Scope 17 5.3 Responsibility 17 5.4 Procedure 18 CONTROL OF WORK PROCESS AND DOCUMENT DURING MAINTENANCE PROGRESS 19 6.1 Purpose 19 6.2 Scope 19 6.3 Responsibility 19 6.4 Procedure 19 DOCK CONTROL 24 7.1 Purpose 24 7.2 Scope 24 7.3 Responsibility 24 7.4 Procedure 24 MAINTENANCE DOCUMENT COMPLETION 28 8.1 Purpose 28 8.2 Scope 28 8.3 Responsibility 28 8.4 Procedure 28 AIRCRAFT MAINTENANCE RECORD 29 9.1 Purpose 29 9.2 Scope 29 9.3 Responsibility 29 9.4 Procedure 29 9.5 Archives 29 10 ENGINE RUN-UP 30 10.1 Scope 30 10.2 Responsibility 30 10.3 Purpose 30 11 MANAGEMENT OF TOOL AND EQUIPMENT 32 11.1 Purpose 32 11.2 Scope 32 11.3 Responsibility 32 11.4 General 32 11.5 Management Procedure of T&E 32 12 RE-CERTIFYING A COMPONENT/ PART REMOVED FROM AIRCRAFT 39 12.1 Purpose 39 12.2 Scope 39 12.3 Responsibility 39 12.4 Procedure 39 13 INSPECTION OF REQUIRED INSPECTION ITEM (RII) 41 13.1 Purpose 41 13.2 Scope 41 13.3 Responsibilities 41 13.4 Required Inspection Items (RII) Definitions 41 13.5 14 Procedure 42 SUSPECTED UNAPPROVED PARTS REPORTING 44 14.1 Purpose 44 14.2 Scope 44 14.3 Responsibility 44 14.4 Investigation And Reporting 44 14.5 Product Recalled And Rework Procedures 45 14.6 Quality Control Records 46 15 CONTINUITY OF INSPECTION 47 15.1 Purpose 47 15.2 Responsibility 47 15.3 Continuity Of Inspection 47 15.4 Handover Sheet 48 15.5 Partial Inspection 48 16 REPORTING OF MANDATORY OCCURRENCES TO THE COMPETENT AUTHORITY, OPERATOR AND MANUFACTURER 49 16.1 Purpose 49 16.2 Scope 49 16.3 Responsibility 49 16.4 Procedure 49 16.5 Archives 50 17 FINAL INSPECTION 51 18 RETURN OF AIRCRAFT PART/ MATERIALS TO STORE 52 18.1 Purpose 52 18.2 Scope 52 18.3 Responsibility 52 18.4 Procedure 52 Hình 1: Quy trình bảo dưỡng Base COORDINATION BETWEEN AMOS WHEN USING THE SAME WIDE BODY HANGAR OR PARKING AREAS OF VAECO 1.1 Scope This procedure is applicable to the coordination between VAECO and customer in the following cases: ‐ A hangar lease contract (other AMO) for aircraft maintenance activities at the wide body hangar of VAECO at the same time ‐ A parking area (including engine run up area or washing area) lease contract (customer) for services/maintenance under responsibility of other AMO/Customer such as but not limited to: parking aircraft, aircraft maintenance activities, engine run-up, aircraft washing at parking areas of VAECO 1.2 Responsibility ‐ Customer is responsible for: • Inform VAECO of the specific schedule for using the hangar/ parking areas • Perform maintenance work for the customer's aircraft in specified areas in the hangar/ parking areas • Keep tool and equipment, part/ materials, barrier, signs of customer within the specified areas in the hangar/ parking areas; • Provide a list of customer maintenance staff and ensure that the maintenance staff perform maintenance work comply with VAECO's procedures about security and safety when entering and leaving the specified areas in the hangar/ parking areas • Promptly notify VAECO in situations that arisen during maintenance activities (lost of tool and equipment, maintenance event/ occurrence ) ‐ VAECO is responsible for: • Arrange hangar/ parking areas slot according to customer’s requirements; • Perform towing customer’s aircraft into the hangar or coordinating with the customer to tow the customer's aircraft into the hangar • Promptly notify Customer in situations that arisen during maintenance (lost of tool and equipment, maintenance event/ occurrence ) • Supervising security to customer maintenance staff when performing maintenance work at VAECO • Supervising the compliance of customer maintenance staff when performing maintenance work in the hangar/ parking areas with VAECO's related procedures and coordinate to handle arisen situations 1.3 General requirements ‐ BPD shall deploy training courses about VAECO's related procedures to the customer maintenance staff performing maintenance work on customers' aircraft, including: • VAECO SOP Chapter 4: General safety requirements • Procedure on fire prevention and extinguishing • Customer maintenance staff who tow customer’s aircraft into/ out the hangar/ parking areas must be trained in the VAECO SOP 6.1 ‐ The specified customer’s aircraft maintenance areas in the hangar/ parking areas flexible barriers/fances and warning signs to minimize risks ‐ Customer maintenance staff must wear labor protective clothing ‐ QC Divisions (HAN and HCM) supervise the compliance of customer maintenance staff when performing maintenance work in the hangar with VAECO's related procedures ‐ Security Division checks, supervises the security to customer maintenance staff when performing maintenance work at VAECO ‐ When situations arisen customer notifies relevant department/ center of VAECO for coordination processing, investigation ▪ Complete the Lost/ Damaged Tool/ Equipment Report and raise the Tool/Equipment Un-serviceable Tag and tag to the T&E ▪ Keep Un-serviceable T&E in separate area ‐ For torque wrenches, user must check to make sure the cap is in good condition (cap remains intact) before using ‐ Users ensure status and available of accompanied document of T&E before returning to the Tool store ‐ In case T&E have not been returned as registration, Tool keeper reports to the borrower and/or Manager of the borrower for return ‐ For the unserviceable tools/ equipment, the Tool keeper shall report to his manager to perform maintenance/ repair or damage evaluation with the attendance of staff from TD of MSC for further action ‐ All permanently lost and unrecovered damage tool/ equipment shall be enumerated by tool keeper and reported to respective maintenance director for substitution 12.RE-CERTIFYING A COMPONENT/ PART REMOVED FROM AIRCRAFT 12.1 Purpose To declare the serviceability of removed components / parts meet applicable authority regulations and customer requirements 12.2 Scope A removed component/ part which VAECO does not or retain control of the compliance with continuous airworthiness maintenance program (CAMP) 12.3 ‐ Responsibility Maintenance Director of the MCC and assigned center r have responsibility for issuance of re-certifying certificate ‐ Director of the BPD has responsibility to contact with the Customer/ Operator 12.4 ‐ Procedure It is not recommended to re-certify if the componenthas has existing defects and/ or maintenance/ inspection requirement ‐ For operators who have contracted with VAECO will responsible for checking continuous airworthiness on AMASIS to issue WO for re-certifying ‐ For other Customer, BPD shall require Customer/ Operator to provide a statement of airworthiness status of the component in Confirmation Of Component Status Form (VAECO Form 1008) ‐ send to MCs for re-certifying a removed component/ part ‐ on Type of re-certifying certificate must be specified in the WO based on customer demand condition as follow: • VAECO Form 5001 • CAAV Form • FAA 8130-3 (only applicable on U.S registered aircraft) ‐ The affected maintenance center assigns appropriate authorized staff and controls the production process to: • For serviceable component/ part removed from an aircraft • For repairable unserviceable component/ part removed from an aircraft ‐ The assigned authorized staff perform re-certifying the removed component/ part: Certify on the requested certificate or any deferred defect which has existed on the component/part to be re-certified 13.INSPECTION OF REQUIRED INSPECTION ITEM (RII) 13.1 Purpose This section provides guidance and describes procedures for conducting RII inspections in accordance with customer procedures 13.2 Scope This procedure is applied for performing RII inspection in accordance with customer procedures in case customer uses VAECO document 13.3 Responsibilities 13.4 Required Inspection Items (RII) Definitions Required inspection items (RII) are maintenance items (routine maintenance work or non-routine maintenance work), if not properly performed or if improper parts or materials are used, that could result in a failure, malfunction, or defect endangering the safe operations of the aircraft These maintenance items need to be inspected by a RII inspector who is authorized by customer and doesn’t implement this task 13.5 ‐ Procedure The RII inspector requirements: • The RII inspector must meet the customers’ requirements such as trained customer’s RII procedures and approved/accepted by customer and • The RII inspector must be CAT B authorized staff and • The RII inspector must have at least year experience for the related authorization ‐ Identify required inspection items • RII tasks include tasks are predefined by customer and additional tasks are determined based on the customer procedure by Maintenance centers/ EGD/ MCC during maintenance • Customer shall provide all RII tasks in the provided work-pack or AMS/ AMP • Maintenance centers/ EGD/ MCC assign related staff to determine maintenance items are RII based on the customer procedure during maintenance, as follows: • The RII items in EO/ SRO/ WO/ NRC… shall be created by the issuer • The EO/ SRO/ WO/ NRC with RII shall be stamped with “RII” at the right upper corner on the first page by respective TD ‐ The accomplishment of RII functions must be separated from other maintenance (inspection, overhaul, repair, preservation, and other replacement of parts), preventive maintenance, and alteration functions ‐ The performance and inspection of RII task during line maintenance that is recorded in Technical log/ Flight log page is performed in accordance with Customer’s line maintenance procedures ‐ For RII task that is not recorded in the Technical log/ Flight log page (such as NRC, EO, SRO performance) the RII task shall be signed off as specified at SOP 5.6.4.2 (5) ‐ The RII inspector shall review to make sure that required inspections are under their authorizations before conducting the required inspection ‐ After RII items is completed inspection as required, the authorized staff certifies for the performed maintenance task ‐ If Maintenance centers not have enough RII inspector to perform RII tasks, they will create a list of proposed RII inspector and send them to QAD and BPD After that, the QAD works with customer to get an approval/ acceptance of customer and inform to related maintenance center after received it 14.SUSPECTED UNAPPROVED PARTS REPORTING 14.1 Purpose To ensure compliance with the regulations and to maintain the highest level of aviation safety, the following guidance is to be followed for the detection of unapproved parts and the actions to be taken upon discovery 14.2 Scope This procedure is applied to report all unapproved suspected parts found by VAECO 14.3 Responsibility All employee VAECO 14.4 ‐ Investigation And Reporting In examining parts in inventory and/or receiving inspection the receiving inspectors shall review the item(s) receiving documentation for evidence of production approval to validate the part in accordance with “Incoming Material Inspection and Receiving Procedure” ‐ If the Staff of LGC of VAECO has found a part in inventory for which evidence of production approval is not apparent, the Director of the LGC shall request the certificate holder to demonstrate that the part is acceptable for installation on a product maintained by VAECO ‐ In the event that any part is warranted unacceptable based upon receiving inspection procedures, the Receiving Inspectors shall initiate and attach a Discrepancy Report (VAECO Form 4004) to the item(s) and place the item(s) in the quarantine area ‐ All documentation that accompanied the item(s) shall be forwarded to the QAD for future evaluation The subject item(s) shall be held until QA Director together with MCC Director and the maintenance department concerned and the FAA/ CAAV/ EASA or other competent Authority has conducted an evaluation to validate the item(s) as an approved part and returned to inventories or for installation ‐ Parts for which approval cannot be established shall be properly disposed of to prevent their installation of re-entry into inventories ‐ QAD shall investigate the origin and condition of the part When parts are considered unapproved after VAECO evaluation, the QAD promptly report them by using: • The Suspected Unapproved Parts Notification Form (FAA Form 8120-11) to the Federal Aviation Administration SUP Program Office and a copy is to be forwarded to FAA SFO-IFO and/or FSI Form 32 to CAAV • The Technical Occurrence Report to EASA ‐ Parts suspected as being unapproved that are installed on customer aircraft and listed in the customer’s approved Minimum Equipment List (MEL) authorization or Configuration Deviation List (CDL) approved procedures must be considered inoperable and deferred with the established MEL procedures The time limitations specified for removal and replacement of the part in question must be complied with ‐ If recall or rework are required for such SUP, the procedures in item shall be followed 14.5 ‐ Product Recalled And Rework Procedures Once VAECO found the deficiencies that can result the un-airworthiness of the products or violate to the current regulations, a recall and rework process must be done to prevent any possible unsafe situation ‐ If the product had been returned to service and installed on the aircraft, the recall process below shall be followed: • No Immediately risky Items VAECO shall then recall the parts according to the proposed schedule After replacement accomplished, the summary report shall be submitted to the FAA/ CAAV/ EASA and the customer • Immediately risky items VAECO shall then replace the products immediately and after replacement accomplished, the summary report shall be submitted to the FAA/CAAV/ EASA and the customer ‐ If the products had been returned to service, but not yet installed on the aircraft, the products are regarded as unserviceable and shall follow the procedures below • The Director of the QAD shall give a documented notice to the LGC for recall the product or the NHA equipped with the questionable products • The Director of the LGC shall be responsible for attaching the products with the unserviceable tag and removing them from the inventory immediately • The unserviceable parts shall then send to the related maintenance department for re-work according to the corrected method with no deficiency ‐ For the products that are not yet returned to service, the potion that involved with the deficiencies shall be subjected to rework follow the procedures below ‐ A paper notice shall be issued to the maintenance department and the inspection sections involved by the Director of the QAD requiring rework • When received the rework requirement, the inspectors of the inspection shall work with the related shop to perform the rework It is the intension of the rework to correct any portion of the work involving the deficiencies • The rework shall be clearly denoted on the maintenance record but shall not override the original record That is, both records of the original work and the rework shall be kept for future references 14.6 Quality Control Records For reference and records purposes, QAD shall maintain files of all Malfunction and Defect Reports and Suspected Unapproved Parts Reports submitted by VAECO for a period for at least two (2) years 15.CONTINUITY OF INSPECTION 15.1 Purpose To maintain the continuity of inspections and ensure that interruptions of inspections caused by shift/task handover does not adversely affect any inspection responsibility 15.2 ‐ Responsibility The Inspection personnel are responsible for full compliance with all procedures outlined in this manual and as appropriate to any item being inspected, repaired, overhauled or altered by the company ‐ The airworthiness of those items, a compliance with record requirements of the operator of those items and of the Company, depends on conformity to the procedures of this system 15.3 ‐ Continuity Of Inspection Continuity of inspection of all items or components as they progress through the various stages of work in VAECO shall include Incoming Materials, Preliminary and Hidden Damage Inspection where applicable ‐ In addition, as work progresses on a specific item, inspections shall be made as necessary so that final inspection to determine airworthiness shall not necessitate disassembly ‐ Inspections, tests, and calibrations shall be accomplished in accordance with the applicable manufacturer's recommendations and accepted/approved methods and procedures Each inspection shall be recorded by the individual accomplished the inspection 15.4 ‐ Handover Sheet Inspector handover sheet (VAECO Form 2015) shall be left by each of the inspectors leaving the job before completion of a project for information to the succeeding inspector Its purpose is to assure a continuing inspection responsibility for in-progress work inspections ‐ The Inspector handover sheet binders are located throughout VAECO and made readily available to both shift out-going and incoming inspectors to ensure the continuity for inspection completion The Inspector handover sheet binders shall be located as follows: • Dock Control Room for base maintenance; RTD for ramp maintenance • Shop office for component maintenance 15.5 ‐ Partial Inspection A partial inspection may consist of, but not be limited to, an inspection and verification of partial work completed ‐ In the event that it becomes necessary to discontinue work on a certain task or process due to the shifting, availability of material, etc., the inspector shall perform the inspection to its latest situation ‐ Once the inspection is acceptable by the inspection personnel, he/she shall make a remark on the blank area of the document stating the tasks that have been performed and inspected He/she shall sign and stamp his/her authorization adjacent to the remark to be the evidence of the acceptance 16.REPORTING OF MANDATORY OCCURRENCES TO THE COMPETENT AUTHORITY, OPERATOR AND MANUFACTURER 16.1 Purpose To ensure all mandatory occurrences found during maintenance activities are investigated and timely reported to competent authority, manufacturer and customer IAW applicable requirements 16.2 Scope This procedure is applied to report all mandatory occurrences (including but not limited to: incidents/ accidents, malfunctions and serious defects) related to aircraft/ aircraft component that are maintained by VAECO 16.3 ‐ Responsibility Maintenance staff is responsible to report all mandatory occurrences found during maintenance ‐ The related Technical Division of maintenance centre is responsible to create aircraft event on the VAECO website and initially report occurrences to the MCC and the QAD ‐ The MCC Director is responsible to initially report mandatory occurrence, malfunction and defect to Air Carrier/ Operator (as required by the contract), and QAD ‐ The QA Director is responsible for evaluating and investigating to find out the root cause of all mandatory occurrence; summarizing and reporting to Authorities, the Manufacturer and the Air carrier/ Operator as applicable 16.4 Procedure Collection and Evaluation of reports ‐ Maintenance staff immediately report occurrences (specified in 10.12.4) discovered during maintenance or reported by flight crew (applicable for VNA aircraft) to team leader and the respective Technical Division Related maintenance staff must fill Form 2035 or CAAV Form 14ab or Form of customer (as applicable) including Auth No ‐ The respective Technical Division creates an aircraft event including initial occurrence report (VAECO Form 2035) on the Technical Information module on the VAECO website If the occurrence happened during base maintenance, BMC’s TD must create separate event from the maintenance check event on VAECO ‐ MCC reports the initial information to CEO, Vice President in charge of ramp maintenance, QA Director, Operator (if required by contract) if occurrences affect the aircraft safety or flight schedule ‐ QAD evaluates the initial occurrence report from the Technical Division and aircraft technical events/ occurrences on the VAECO website to determine the necessary of occurrence investigation on daily basis QAD will put assessment into each event on VAECO Website ‐ All customer’s complain related to safety and quality of maintenance shall be reported by functional department/ centre (MCC/ Maintenance Center/ LGC/ BPD) to QAD QAD shall evaluates or investigates (if necessary) and feedbacks to related department/ centre ‐ Feedback to reporter: After QAD providing assesses for each occurrence on VAECO website, the reporter may access to see the result and feedback of the occurrence 16.5 Archives Records of all reports submitted to the authorities manufacturers and operators are maintained by QAD for at least years since occurrence identified 17.FINAL INSPECTION ‐ The certifying staff shall ensure: • All requirements of Require Inspection Item (RII) are properly conducted • All work has been inspected as required and record the result accordingly to show compliance to specific standards • Proper inspection method/techniques and standards have been utilized when conducted theaforementioned inspections • Necessary inspection buy-back has been made • The issuance of FAA Form 337 when Major alteration has been conducted • Proper installation of appliances, accessories and individual parts or components on the aircraft during aircraft maintenance or alteration, and maintenance records are completed accordingly • All process documentation has been properly completed and generated discrepancies recorded and corrected or deferred ‐ For base maintenance, the final inspection is performed as follows: • The assigned maintenance staff of each working team performs posthangar check and records in the Post-hangar Checklist (VAECO Form 6026) • B1/B2 authorised staff has to inspect and ensure that all tasks under their responsibilities had been technically carried out to the required standards • C/S CAT C with the support of B1/B2 authorised staff does the final inspection as required in para 10.5.7.3 (1) above and issues the certificate of release to service If the final inspection specifies that a maintenance task is not satisfactory, the C/S CAT C will request to rework the task and the result recorded in Non-routine Job Card (VAECO Form 6001) prior to carrying out the final inspection again ‐ For line maintenance, the final inspection is performed by appropriate certifying staff If the final inspection specifies that a maintenance task is not satisfactory, the C/S will request to rework the task and the result recorded in technical log prior to carrying out the final inspection again 18.RETURN OF AIRCRAFT PART/ MATERIALS TO STORE 18.1 Purpose To ensure the aircraft parts/ materials returned to VAECO store in compliance with applicable regulation 18.2 Scope This procedure is applied for returning of aircraft part/ materials from maintenance centers to VAECO store 18.3 Responsibility Maintenance center is responsible for returning component with attached required documents to VAECO store 18.4 Procedure ‐ Return of expendable part and materials ‐ Return of serviceable part ‐ Return of unserviceable repairable part from ramp and base maintenance centers ‐ Returning defective component from CIMC ‐ Other requirements ... Tú 185 120 0 020 Hoàng Bá Nam 185 120 0005 Nguyễn Trọng Nhân 185 120 0043 Võ Minh Phúc Lộc 185 120 00 12 Trần Linh 185 120 0010 Bùi Tấn Phát 185 120 0 022 Nguyễn Huy Hoàng 185 120 0004 Lê Minh Hiếu 185 120 0013... MATERIALS TO STORE 52 18.1 Purpose 52 18 .2 Scope 52 18.3 Responsibility 52 18.4 Procedure 52 Hình 1: Quy trình bảo dưỡng Base COORDINATION... 24 7.4 Procedure 24 MAINTENANCE DOCUMENT COMPLETION 28 8.1 Purpose 28 8 .2 Scope 28 8.3 Responsibility 28 8.4 Procedure