APPROVED MAINTENANCE ORGANISATION
Maintenance
Procedures Manual
Bush Pilots Aviation
Sub H, Farm 1892
Chisamba
Zambia
Tel: 0978972043
Version: BPA-MPM-01 30/AUG/2021
Manual Copy No: 1
Bush Pilots Aviation
i.
Maintenance Procedures Manual
Approval Page
Maintenance Procedures Manual compiled by:
_________________________
Chantel Myburg
Maintenance Procedures Manual accepted by:
__________________________
Neil McGreevy
Accountable Manager
___________________
Date
Maintenance Procedures Manual
Approved by Director General of Zambian Civil Aviation Authority.
_________________________
Name
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__________________________
Signature on behalf of
Z/AMO/99/2017
____________
Date
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Maintenance Procedures Manual
Revision Record Sheet
Issue
No.
Nature of Change:
1
First Issue (original)
2
Revision of Management Organisation
Chart
Revision of Index and Minor Editorial
Corrections
Addition of Rest and Duty Limitations
Addition of Refueling Procedures
Addition of Prohibition of Smoking
Change of Management Personnel
Change to Company Information
Change of Distribution List
Addition of Bonded Store Facility
Reformat of manual to ZCAA requirements
2
2
2
2
2
2
2
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3
4
5
6
7
8
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Actioned By:
Date:
Signature:
20th Oct 2017
Mulipa John
Banda
Neil McGreevy
30th August 2021
Neil McGreevy
30th August 2021
Neil McGreevy
Neil McGreevy
Neil McGreevy
Neil McGreevy
Neil McGreevy
Neil McGreevy
Neil McGreevy
Neil McGreevy
30th August 2021
30th August 2021
30th August 2021
30th August 2021
30th August 2021
30th August 2021
30th August 2021
8th October 2021
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Maintenance Procedures Manual
List of Effective Pages
Page no:
Revision No:
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Maintenance Procedures Manual
Company Information
Company Name:
Bush Pilots Aviation Ltd.
Registration no:
119971
Approval no:
Z/AMO/99/2017
Physical address:
Sub H, Farm 1892
Chisamba
Zambia
Postal address:
P O Box 13
Fringilla
Chisamba
Zambia
Telephone no:
+260978972043
Cell No:
+260978972043
E-mail:
bushpilotsaviation@outlook.com
Airfield:
Otago, Chisamba (FLOT)
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Maintenance Procedures Manual
Table of Contents
i.
Approval Page.............................................................................................................................................. 1
ii.
Revision Record Sheet ................................................................................................................................. 2
iii.
List of Effective Pages. .............................................................................................................................. 3-4
iv.
Company Information ................................................................................................................................. 5
v.
Table of Contents. .................................................................................................................................... 6-8
vi.
Glossary of Abbreviations and terms .......................................................................................................... 9
vii.
Distribution List. ........................................................................................................................................ 10
viii.
Introduction. .............................................................................................................................................. 11
Part 1 - Management. ....................................................................................................................................... 12
1.1
Corporate Commitment. ........................................................................................................................... 12
1.2
Management Personnel. ........................................................................................................................... 13
1.3
Duties and Responsibilities of Management Personnel............................................................................ 13
1.4
Management Organisation Chart .............................................................................................................. 18
1.5
Authorised Personnel. ............................................................................................................................... 19
1.6
Rest and Duty Limitations for persons performing maintenance functions in the AMO. ........................ 19
1.7
Human Resources. ..................................................................................................................................... 19
1.8
Procedure for Company Authorisation. .................................................................................................... 21
1.9
Control of Authorisation Stamps. .............................................................................................................. 21
1.10
Competency to Perform Special Maintenance Functions. ........................................................................ 21
1.11
Description and Layout of Facilities. ......................................................................................................... 21
1.12
Organisations Approved Scope of Work. .................................................................................................. 22
1.13
Privileges of the AMO Under the Approved Scope of Work. .................................................................... 22
1.14
Special Circumstances. .............................................................................................................................. 23
1.15
Validity of the Approval. ............................................................................................................................ 23
1.16 Notification Procedure to The Director General Regarding Changes in The Organisation’s Activities/
Approval/ Location/ Personnel. ............................................................................................................................ 24
1.17
2
Maintenance Procedures Manual Amendment Procedure. ..................................................................... 25
Part 2 - Maintenance Procedures..................................................................................................................... 26
2.1
Purchasing Procedure................................................................................................................................ 26
2.2
Supplier Evaluation Procedures. ............................................................................................................... 26
2.3
Receipt Inspection and Identification of Serviceable Parts. ...................................................................... 27
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2.4
Storage of Aircraft Components and Materials and Issue from Stores. ................................................... 28
2.5
Acceptance of Tools and Equipment ......................................................................................................... 29
2.6
Calibration of Tools and Equipment .......................................................................................................... 29
2.7
Use of Tooling and Equipment by Personnel ............................................................................................ 30
2.8
Cleanliness Standards of Maintenance Facilities. ..................................................................................... 31
2.9
Maintenance Operations........................................................................................................................... 31
2.10
Control of Airworthiness Data. .................................................................................................................. 34
2.11
Aircraft Maintenance Program, AD Procedures, Modification Procedures and Technical Record Control.
35
2.12
Maintenance Documentation and Completion of Records. ..................................................................... 36
2.13
Rectification of Defects. ............................................................................................................................ 38
2.14
Release to Service Procedure. ................................................................................................................... 38
2.15
Records for The Operator.......................................................................................................................... 38
2.16
Defective Aircraft Components ................................................................................................................. 39
2.17
Special Aircraft Maintenance Procedures ................................................................................................. 39
2.18
Refueling of Aircraft. ................................................................................................................................. 40
2.19
Prohibition of Smoking. ............................................................................................................................. 40
Part 3 Quality Assurance System. ................................................................................................................... 42
3.1
Objectives of the Quality Assurance System. ............................................................................................ 42
3.2
Quality Audit of the Organisation. ............................................................................................................ 42
3.3
Quality Audit of Aircraft. ........................................................................................................................... 42
3.4
Quality Audit Remedial Action. ................................................................................................................. 43
3.5
Occurrence Report. ................................................................................................................................... 43
3.6
Client Complaints. ..................................................................................................................................... 43
3.7
Management Analysis and Overview. ....................................................................................................... 44
3.8
Certifying Personnel Competence and Training. ....................................................................................... 44
3.9
Certifying Personnel records. .................................................................................................................... 44
3.10
Quality Audit Personnel............................................................................................................................. 44
3.11
Deviation/Concession control. .................................................................................................................. 44
3.12
Exemption control ..................................................................................................................................... 44
3.13
Specialised activities. ................................................................................................................................. 44
Part 4 – Documentation (Air Operators).......................................................................................................... 45
4.1
Not applicable to this facility ..................................................................................................................... 45
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Maintenance Procedures Manual
Part 5 – Appendices .......................................................................................................................................... 46
5.1
Appendix A - Floor Plan ........................................................................................................................... 46
5.2
Appendix B - List of Certifying Inspectors ................................................................................................ 47
5.3
Appendix C - Work Pack – Single Engine .................................................................................................. 48
5.4
Appendix D - Work Pack – Twin Engine .................................................................................................... 49
5.5
Appendix E - Log Book Entry ..................................................................................................................... 50
5.6
Appendix F - Job Card ............................................................................................................................... 51
5.7
Appendix G - Defect Sheet ....................................................................................................................... 52
5.8
Appendix H - Labels .................................................................................................................................. 53
5.9
Appendix I - Certificate of Release to Service .......................................................................................... 54
5.10
Appendix J - Arrival Inspection Form ....................................................................................................... 55
5.11
Appendix K - Certificate of Fitness for Flight ............................................................................................ 56
5.12
Appendix L - Inspection Reminder............................................................................................................ 57
5.13
Appendix M - Post Inspection Check Sheet .............................................................................................. 58
5.14
Appendix N - CAA Operations Specifications for Aircraft Maintenance Organisations ........................... 59
5.15
Appendix O - Occurrence Report/ Client Complaint Report .................................................................... 60
5.16
Appendix P - List of Approved Suppliers .................................................................................................. 61
5.17
Appendix Q - Rules for the Issue of a Competency to Perform Special Aircraft Maintenance Procedures
62
5.18
Appendix R - Audit Schedule ................................................................................................................... 63
5.19
Appendix S - Audit Findings ...................................................................................................................... 64
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Glossary of Abbreviations and Terms.
AD
Airworthiness Directives
AIC
Aeronautical Information Circular
AME
Aircraft Maintenance Engineer
AMO
Approved Maintenance Organisation
AMS
Approved Maintenance Schedule
AOC
Air Operator’s Certificate
CATS
Civil Aviation Technical Standards
CRS
Certificate of Release to Service
DG
Director General
ICAO
International Civil Aviation Organisation
MCM
Maintenance Control Manual
NDT
Non-Destructive Testing
SB
Service Bulletin
SEL
Service Letter
SI
Service Instruction
TSO
Technical Standard Order
ZCAA
Zambia Civil Aviation Authority
ZCAR’s Zambia Civil Aviation Requirements
Maintenance
Means all work done in accordance with manufacturers recommendations and
approved maintenance schedules and includes inspection, adjustment,
replacement, rectification, repair, modification, overhaul, manufacturing, and
testing.
Competent Authority
Any Civil Aviation Authority which is a member of ICAO and is responsible for
the geographical area under consideration.
Direct Supervision
Means, in relation to the maintenance of an aircraft, that the person exercising
the supervision personally maintains such surveillance of all maintenance being
performed, as is necessary to ensure that it is being properly carried out, and
that this person is readily available for consultation with the person doing the
work.
Approved Maintenance Organisation
Airworthiness Data -
Means an organisation approved by the Director General in
terms of the ZCAR’s Part 6, or by a Contracting State, to perform
maintenance of aircraft or parts thereof, and operating under
supervision of the appropriate authority.
Refer to 2.10.1
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Distribution List
Manual No
Zambia Civil Aviation Authority (ZCAA)
Airworthiness Department
1
Accountable Manager
N. McGreevy / D. West-Mace (Alternate.AM)
2
Quality Assurance Manager
C. Willis-New
3
Administration Manager
C. Myburg
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Maintenance Procedures Manual
Introduction
The procedures set out herein forms the Maintenance Procedure Manual required by
the Civil Aviation Requirements August 2015, Part 6 as amended.
The approval holder will ensure that all members of the staff are familiar with every
procedure that relates to their duties, and that such procedures are followed at all times.
The approval holder will also ensure that in exercising the privileges of its Approved
Maintenance Organisation Licence:
-
The provisions of the Civil Aviation Requirements, Aug 2015, as amended, are
always complied with.
-
Only aircraft or aircraft components and equipment for which the organisation is rated
are maintained.
-
The privileges of such ratings on the approval are not exercised unless the necessary
facilities, current technical data, tools, equipment, materials, and competent personnel
to perform the maintenance, in accordance with all the current requirements regarding
the maintenance and airworthiness of that particular type of aircraft, airframe, engine,
aircraft component or other equipment are available.
Note:
No amendments shall be made to this Maintenance Procedures Manual without the written
approval of the Director General of the ZCAA. When approved, such amendments shall be
incorporated immediately.
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1 Part 1 - Management.
1.1 Corporate Commitment.
1.1.1
The Accountable Manager and the organisation have committed themselves to comply with the
airworthiness requirements as set out in this document and approved by the Director General.
1.1.2
All maintenance carried out by this organisation shall be strictly in accordance with the Zambia
Civil Aviation Requirements, Part 6, Aug 2015, as amended, and in compliance with this
approved Maintenance Procedures Manual, as well as all amended to date, aircraft, component
and equipment Manufacturer's Manuals and Instructions.
1.1.3
The organisation shall only perform work within its scope of approval and only when the facilities,
specialised equipment, tooling, amended to date airworthiness data and certifying personnel to
perform the work are available.
1.1.4
Should any new or amended regulations, published in the Zambia Civil Aviation Requirements,
part 6 Aug. 2015, as amended, and/or any other instructions issued by the ZCAA, and/or any
instructions issued by the aircraft, component and/or equipment manufacturer from time to time,
conflict with this Maintenance Procedures Manual, the former provisions shall prevail.
1.1.5
It is further understood that the ZCAA reserves the right to suspend, withdraw and/or amend the
approvals of the Approved Maintenance Organisation, should the organisation not comply with
the conditions and requirements of the approval.
1.1.6
The procedures contained in this manual are accepted and approved by the undersigned and
must be always adhered to.
____________________________
Neil McGreevy
Accountable Manager
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1.2 Management Personnel.
1.2.1
The following key management personnel of the AMO are responsible for ensuring that this AMO
complies with the requirements of the ZCAR’s Part 6:
Position
Name
Accountable Manager
Neil McGreevy
Quality Assurance Manager
Catherine Willis-New
Aviation Safety Officer
Derek West-Mace
1.3 Duties and Responsibilities of Management Personnel.
1.3.1
Authority of the Accountable Manager.
The Accountable Manager is the executive member of the closed corporation and as such has full
control of the maintenance organisation.
Contractual authority has been granted to the Accountable Manager to ensure that all activities
undertaken by the organisation are carried out in accordance with the applicable requirements
prescribed in the regulations.
The following powers have been vested in the Accountable Manager:
1.
Unrestricted access to work performed or activities undertaken by all other persons as employees of,
and other persons rendering service under contract with, the organisation.
2.
Full rights of consultation with any such person in respect of compliance by him or her.
3.
Powers to order cessation of any activity where such compliance is not affected.
4.
Powers to report directly to the Chief Executive Officer on any matter or concern regarding
airworthiness, safety and/or compliance with the regulations.
The Accountable Manager may delegate duties to any competent person. However, this does not relieve
him from his overall responsibility and accountability.
1.3.2
Duties and Responsibilities of the Accountable Manager.
The Accountable Manager shall ensure the following:
1.
That the approval is displayed in a prominent place, generally accessible to the public and at the
organisation’s principal place of business and, if a copy of the approval is displayed, he shall produce
the original approval to an authorised officer, inspector, or authorised person if so, requested by such
an officer, inspector, or person.
2.
That any advertisement indicating that the Organisation is an Approved Maintenance Organisation
reflects the number of the Maintenance Organisation’s approval and contains a reference to the
category or categories for which the Organisation is rated.
3.
That any ZCAA authorised officer, inspector or authorised person is permitted to carry out such safety
inspections and audits which may be necessary to verify the validity of an application, including safety
inspections and audits of any partners or subcontractors to determine compliance with the appropriate
requirements as prescribed.
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4.
That the privileges of such ratings on the approval are not exercised unless the necessary facilities,
current technical data, tools, equipment, materials, and competent personnel to perform the
maintenance in accordance with all the current requirements regarding the maintenance and
airworthiness of the particular type of aircraft, airframe, engine, aircraft component or other equipment
are available.
5.
That only aircraft or aircraft components and equipment for which the organisation is rated, will be
maintained.
6.
That the Quality Assurance System for the control and supervision of the maintenance of aircraft and
aircraft equipment is established and maintained.
7.
That liaison be established and maintained between the Director General and the organisation with a
view to ascertain correct manners of compliance with the ZCAA requirements, and interpretations of
such requirements by the Director General.
8.
That the Quality Assurance Manager has direct access to the Accountable Manager and the Chief
Executive Officer on matters affecting airworthiness and safety.
9.
That any significant change to the Quality Assurance System is submitted to the Director General for
approval.
10.
That a procedure is established and implemented for initially assessing and for maintaining the
competence of those personnel involved in planning, performing, supervising, inspecting, or certifying
the maintenance undertaken by the organisation.
11.
That adequate and competent personnel are employed to plan, perform, supervise, inspect, and certify
all maintenance carried out by this organisation.
12.
That all persons who are directly in charge of any maintenance or inspection and all personnel who
are authorised to issue a release on behalf of this Approved Maintenance Organisation are
appropriately licensed and/or rated in terms of Part 6 of the Zambia Civil Aviation Requirements, Aug
2015, as amended, or have been issued by him or her with a certification authorisation with the
appropriate rating, as provided for in this manual of procedures.
13.
That personnel in all technical departments are of sufficient numbers and experience and have been
given appropriate authority to be able to discharge their allocated responsibilities.
14.
That there is full and efficient co-ordination between departments and within departments in respect of
airworthiness matters.
15.
That tools, equipment, and materials necessary to perform adequately the approved scope of work are
available, controlled and maintained, where necessary, calibrated at a frequency and to an approved
national standard to ensure serviceability, accuracy, and traceability.
16.
That at least one complete and current copy of the Maintenance Procedures Manual is held at each
separate workplace specified in the Maintenance Procedures Manual, and that each applicable part is
made available to the personnel who require those parts to carry out their duties and to assure that
compliance is met.
17.
That certifying personnel are provided with evidence of the scope of their authorisation.
18.
That records are held of all certifying personnel and maintenance engineers. The records shall include
particulars of the scope of their authorisation. The records shall be kept for a period of five years after
the date on which the certifying member ceases to be authorised by the organisation.
19.
That adequate records are kept of all maintenance performed by the Approved Maintenance
Organisation. These records must indicate the name of each person who performed on, and/or
inspected the aircraft and shall be kept for a period of at least five years from the date on which the
aircraft, component, or equipment to which the maintenance relates, was released to service.
20.
That a copy of each Certificate of Release to Service is provided to the operator of the aircraft, together
with a reference to any specific airworthiness data used for major repairs and modifications carried out.
21.
That any defect or condition of equipment or a component which may hazard an aircraft be reported to
the Director General within 48 hours (from the moment the defect or condition is identified) and that
the operator or owner of the aircraft is informed of any such defect or condition.
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Maintenance Procedures Manual
22.
That all amended to date airworthiness data necessary to support the maintenance performed by the
Approved Maintenance Organisation is kept and made available to all personnel who need access to
such data to discharge their allocated responsibilities. This shall include all relevant data issued or
classified as mandatory by the Director General, the holder of the type certificate or an appropriate
authority.
23.
That a procedure is established to control and amend the data referred to in the above-mentioned
paragraph.
24.
That application for renewal of the Approved Maintenance Organisation approval is made to the
Director General at least sixty days before expiry date of such approval on the appropriate form,
accompanied by the appropriate fee.
25.
That, when required, application for the amendment of the approval be made to the Director General
on the appropriate form, accompanied by the appropriate fee and the amendment pages to the
Maintenance Procedures Manual.
26.
That the Quality Assurance and inspection personnel are authorised to carry out their duties as
required.
27.
Should the approval be suspended in accordance with Part 6 of the ZCAR’s, that the Accountable
Manager may appeal against such suspension to the Director General within 30 days after becoming
aware of the suspension and deliver the appeal in writing stating the reasons why the suspension
should be varied or set aside.
28.
The appellant shall submit a copy of the appeal and any documents or records supporting such appeal,
to the authorised officer, inspector or authorised person concerned and shall furnish proof of such
submission for the information of the Director General.
29.
The holder of an approval which is suspended, shall forthwith produce the approval upon suspension
thereof, to the authorised officer, inspector or authorised person concerned for the appropriate
endorsement.
30.
The holder of an approval which is cancelled, shall, within 30 days from the date on which the approval
is cancelled, surrender such approval to the Director General. Should the approval be allowed to
expire, the approval shall be surrendered.
Duties and Responsibilities of the Alternate Accountable Manager.
The Alternate Accountable Manager shall be responsible for the duties and responsibilities of the
Accountable Manager in his absence.
1.3.4
Duties and Responsibilities of the Quality Assurance Manager.
1.
To perform regular and independent internal audits, in order to monitor and report to the Accountable
Manager, the level of compliance with the ZCAR’s, the AMO’s and general airworthiness
requirements.
2.
To monitor and review the corrective actions taken with respect to non-conformities identified and to
monitor and review the implementation of preventative actions taken to prevent the recurrence of such
non-conformities.
3.
To monitor any amendments to the Maintenance Procedures Manual and any associated manuals and
submit proposed amendments to the ZCAA.
4.
To present to the Accountable Manager, for the purpose of review and implementing of corrective and
preventative actions, quality indicators such as:
-
Audit Feedback Reports.
-
Defect Reports.
-
Client Complaint Reports.
-
Incident Reports.
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Maintenance Procedures Manual
Duties and Responsibilities of Certifying Personnel.
The principal duties of each Company Authorisation holder are the following:
1.
To maintain the validity of his/her AME license or other approval (if he/she is holder of such an
approval).
2.
To ensure that maintenance is performed only if the adequate approved accommodation and facilities,
and that current technical data, tools, special equipment, test apparatus and materials are available.
3.
Only to perform and/or certify maintenance within his/her own authorisation and within the scope of
this Approved Maintenance Organisation’s license approval.
4.
To ensure that all maintenance is carried out in accordance with Part 6 of the ZCAR’s, this approved
Maintenance Procedures Manual, and the approved Aircraft Maintenance Schedule.
5.
To ensure that only methods, techniques, and practices which are prescribed in the current
Manufacturer's Maintenance Manuals, or any instructions approved by the ZCAA for the safe operation
and continued airworthiness of the aircraft, engine, components, or equipment are used.
6.
To use only tools, equipment, and test apparatus necessary to ensure that the maintenance is carried
out in accordance with the appropriate manufacturer’s requirements or standard practices approved
by the ZCAA.
7.
On completion of the maintenance, he/she shall ensure that the condition of the aircraft, engine,
component, or equipment is satisfactory for release to service and is at least equal to its original or
properly modified condition with regard to:
-
Aerodynamic function.
-
Structural strength.
-
Resistance to vibration and deterioration.
-
Performance.
-
Other qualities affecting airworthiness.
8.
To complete the required maintenance records accurately and completely.
9.
To complete and certify the release documentation before the aircraft is returned to service.
10.
Altimeter System Tests and Inspections shall be carried out in accordance with the ZCAR’s Part 6 and
for the altimeter tests, record on the altimeter case, the date on which the altimeter has been tested.
11.
ATC Transponder Tests and Inspections shall be carried out in accordance with the ZCAR’s part 6.
12.
Emergency Location Beacon Tests and Inspections shall be carried out in accordance with ZCAR’s
Part 6, Aug 2015 as amended.
13.
If any inspections are carried out, he/she shall ensure that the aircraft, engine, module, component, or
equipment under inspection complies with all appropriate airworthiness requirements as prescribed in
Part 6 of the Zambia Civil Aviation Regulations, Aug 2015 as amended, and use a checklist which
includes the scope and detail of the tests and inspections referred to in the regulations.
14.
All maintenance carried out on an aircraft, engine, module, component, or equipment shall be recorded,
on completion as follows:
-
Details of the maintenance including, where applicable, the type of inspection and any approved
data used to include revision status.
-
For a Progressive Inspection, whether a detailed inspection or routine inspection of the component
or areas of the aircraft was carried out.
-
The Serial Numbers, if any, Total Time and/or Cycles Since New and/or Overhaul of components
or equipment removed or fitted.
-
Details of measurements or test results obtained, including the results of any ground or air tests.
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-
For an altimeter system test and inspection, the date on which and maximum altitude to which the
altimeter has been tested.
-
The date of completion of such maintenance.
-
The name of the person completing such maintenance, if other than the person certifying the release
to service.
-
The location and, if applicable, the name of the facility where such maintenance was carried out.
-
Where such maintenance has been carried out because of the failure of any component or
equipment, or damage caused by forced landing or accident, the reasons for carrying out the
maintenance.
15.
The person who carries out the maintenance shall:
-
Record the details referred to in the paragraph above, in the appropriate logbook or in a
maintenance record approved by the ZCAA.
-
Record the details legibly and in ink or other permanent material.
-
Where worksheets or other associated maintenance records are used to document the details of
the maintenance;
- Reference those records in the logbook, or in the maintenance record approved by the ZCAA.
- Retain the records for the appropriate period prescribed in the regulations.
16.
Modifications shall not be carried out unless they are done in accordance with ZCAR’s Part 6, Aug.
2015.
17.
After any major repair or major modification to an aircraft, engine, module, component or equipment,
test flights shall, if required by the ZCAA, be carried out of the aircraft under such conditions and in
such manner as the ZCAA may determine and no passengers, cargo or mail shall be transported in
any aircraft undergoing test flights.
18.
Any temporary or permanent repair to an aircraft, engine, module, component, or equipment which has
been damaged after an accident or an incident shall be carried out in accordance with the requirements
as prescribed in the ZCAR’s Part 6, and the Manufacturers’ Manuals and recommendations.
19.
Any compass fitted to an aircraft, shall be swung, and maintained in accordance with the requirements
as prescribed in the ZCAR’s Part 6.
20.
If the aircraft, engine, module, component, or equipment is not released to service, he/she shall:
21.
-
provide the owner or operator with a signed and dated list of the discrepancies, including any
equipment which is marked "inoperative" in terms of paragraph (2), if he/she is satisfied that the
aircraft:
-
Is not airworthy.
-
Does not comply with the applicable Type Certificate Data, Airworthiness Directives, Mandatory
Service Bulletins, or other approved data upon which the airworthiness of such aircraft is affected.
-
For those items which appear to be inoperative, place a label on each inoperative instrument and
the cockpit controls, marking each item "inoperative".
-
Enter the appropriate statement as prescribed in ZCAR’s Part 6, in the appropriate logbook and /or
Aircraft Technical Log.
-
Enter his/her signature, license or authorisation number, and the date of the entry.
If the approved data for a repair or a modification to an aircraft, engine, module, component, or
equipment include changes to the Operating Limitations, or Flight Data in the aircraft Flight Manual,
the Certifying Inspector shall not certify the Release to Service until the approved changes have been
incorporated into the Flight Manual and/or Aircraft Operating Manual.
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1.4
Maintenance Procedures Manual
Management Organisation Chart
Accountable
Manager
N.McGreevy
Hangar Manager/
Alternate
Accountable
Manager
D.West-Mace
Safety Manager
D.West-Mace
Quality Assurance
Manager
C.Willis-New
Planning/
Library
Workshop
Assistants
J.Chiwara
M. Tembo
A. Lubinda
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C. Myburg
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Certifying
AMEs
M.Lusambo
D.West-Mace
R.Chanda
P.Mutale
M. Chirwa
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1.5 Authorised Personnel.
1.5.1
List of Authorised Certifying Personnel.
The list of authorised personnel is published in Maintenance Procedures Manual Part Five, refer to
Appendix B “List of Certifying Inspectors”.
A revised copy of the list of authorised personnel will be provided to the ZCAA within 14 days of any
amendment.
1.6 Rest and Duty Limitations for persons performing maintenance functions in the AMO.
1. No person may assign, nor shall any person perform, unless that person has had a minimum rest
period of 8 hours, prior to the beginning of duty.
2. No person may be scheduled to perform any aircraft maintenance functions, for more than 12
consecutive hours of duty.
3. In situations involving unscheduled aircraft unserviceability, persons performing maintenance
functions for aircraft may continue on duty for up to:
-
16 consecutive hours
-
20 hours in 24 consecutive hours
4. Following unscheduled duty periods, persons performing maintenance functions for aircraft shall
have a mandatory rest period of 10 hours.
5. The AMO shall relieve the person performing maintenance functions from all duties for 24 hours
during any 7 consecutive day period.
1.7 Human Resources.
1.7.1
1.7.1.1
Adequacy of Human Resources.
It is the policy of this Approved Maintenance Organisation to ensure that:
1.
The personnel in all technical departments are of sufficient numbers and experience and have been given
appropriate authority to be able to discharge their allocated responsibilities; and
2.
There is full and efficient co-ordination between the Accountable Manager and staff in respect of airworthiness
matters.
1.7.1.2
Maintenance work shall either be performed or directly supervised by Authorised Maintenance Engineers.
(Refer to page 9 for the definition of ‘direct supervision’). Unqualified personnel considered for
employment by this organisation shall only perform maintenance work under the direct supervision of an
Authorised Maintenance Engineer.
1.7.1.3
Initial qualification as Aircraft Maintenance Engineer with Release Authority:
1.
In order to be authorised as an Aircraft Maintenance Engineer with release authority, the applicant must
be the holder of a valid AME license with the appropriate training.
2.
In order to be authorised as an Aircraft Maintenance Engineer with authority to perform duplicate inspections,
the applicant must be the holder of an AME license with an A and C category.
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1.7.1.4
1.7.1.5
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In addition, the candidate shall have an adequate understanding of the Civil Aviation Requirements, and
this Maintenance Procedures Manual.
1.
A person qualifies as a mechanic when he/she has completed the appropriate training test specified in
ZCAR’s Part 6 as amended. Such a qualified mechanic may be authorised to perform maintenance on an
aircraft independently but subject to inspection and release by the Authorised Certifying Engineer.
2.
In the case where a person is utilized only to perform certain specified tasks as part of a maintenance program
a person may be authorised to perform such work independently, but subject to inspection and release by a
Certifying Engineer, on the proviso that the person has successfully completed basic training in the
maintenance practices as relevant to the person’s particular responsibilities.
3.
Personnel who have not been trained in accordance with the above shall only perform maintenance work
under the direct supervision of one of this AMO’s Authorised Certifying Engineers.
Continuation Training
Another form of continuation training is provided through the exposure to Airworthiness Directives and
Service Bulletins, and the involvement in implementing those on the aircraft.
Continuation training also includes training on new or amended regulations, as well as the manual of
procedures.
1.7.1.6
1.7.1.7
Recurrent Training
1.
Recurrent training includes training on new or amended regulations as well as the maintenance procedures
manual.
2.
Should it become evident through observation in the job environment, or as a result of audit findings or
incident investigations, that any person needs to be retrained, such recurrent training is provided either
formally or informally.
Training Plan
Training needs shall be reviewed annually in accordance with the requirements of ZCAR’s Part 6, and a
training plan shall be established (where such training needs have been identified).
1.7.1.8
Training Record
Records shall be kept of the technical training and experience of personnel. All such records will be kept
up to date with the following information:
1.
Copy of AME license (where applicable).
2.
Record of experience.
3.
Copy of ID/Passport (if no AME license).
4.
Copies of certificates of courses attended (where relevant).
5.
A copy of the company authorisation statement.
All the above information shall be kept on file for a period of 5 years after the person has left the
company.
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1.8 Procedure for Company Authorisation.
1.8.1
Company authorisation may be awarded to an applicant complying with the requirements of
section 9.5 if both the Accountable Manager and Quality manager agree. Authorisation awarded
is indicated in Part Two of this Maintenance Procedures Manual.
1.8.2
Company authorisation may be withdrawn:
1.
Upon request of the Accountable Manager or;
2.
When the candidate no longer meets the requirements or;
3.
When the conduct of the authorised person does not justify continued authorisation, the Quality Assurance
Manager’s decision in this regard will be considered as final.
1.9 Control of Authorisation Stamps.
1.9.1
An authorisation stamp is issued to an appointed candidate. Each stamp is identified by the AMO
designation and a unique stamp number.
1.9.2
The issue of the stamps will be controlled by the Accountable Manager.
1.9.3
When the term of an authorisation comes to an end, the stamp shall be returned to the
Accountable Manager.
1.9.4
In the case of a lost stamp, this shall be reported to the Accountable Manager who will record this
in the appropriate register. Another stamp may be issued if the Accountable Manager and the
Quality Assurance Manager considers the authorised person to be worthy
1.9.5
Only work authorised by the Accountable Manager and carried out under AMO shall be released
to service using these stamps.
1.10 Competency to Perform Special Maintenance Functions.
1.10.1 A certificate of competency to perform special maintenance functions such as engine running,
aircraft towing, and aircraft taxiing may be issued by the Accountable Manager if the candidate
complies with Appendix Q of Part Five of the Maintenance Procedures Manual.
1.11 Description and Layout of Facilities.
1.
The maintenance facilities of Bush Pilot Aviation Ltd are situated at Farm 1892, Chisamba, as indicated
in Section 4.
2.
The Approved Maintenance Organisation’s hangars are of metal construction, have concrete floors
adequately sealed against dust generation, and can be sealed off from the elements by means of
hangar doors. A floor plan of the facilities is contained in Part Five, Appendix A.
3.
These facilities provide adequate accommodation for all maintenance to be performed by the Approved
Maintenance Organisation, ensuring protection from the weather.
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4.
Specialised work areas are segregated as appropriate to ensure that environmental and work area
contamination does not occur.
5.
Appropriate office accommodation is provided for the administration of the maintenance performed
and, in particular for the administration of the organisation’s quality, planning and technical records.
6.
The working environment provided is appropriate for each task carried out and complies with any
special requirements specified in the applicable airworthiness data.
7.
Storage facilities are provided for parts, equipment, tools, and materials required by the organisation.
These storage facilities provide security for serviceable parts and the segregation of serviceable from
unserviceable parts. Provision is made to control deterioration of and damage to stored items.
1.12 Organisations Approved Scope of Work.
1.12.1 Scope of Work.
The intended scope of approval of Bush Pilots Aviation Ltd, under the ZCAA Approved Maintenance
Organisation License No. Z/AMO/99/2017, is as listed below:
(Refer to the ZCAA approved Operations Specification for the actual approval.)
Category A
Restricted: Class 1 – Composite construction of small aircraft.
Class 3 – All metal construction of small aircraft.
Category C
Restricted: Class 1 – Piston Engines of 400hp or less.
Category X
Restricted: Class 1 – Fixed pitch and ground adjustable propellors, of wood, metal or
composite construction.
Class 2 – Other propellors by make.
Note The above privileges include the servicing of airframe, engines and propellor components in
accordance with the servicing information, which is available in the respective Maintenance
Manuals.
1.13 Privileges of the AMO Under the Approved Scope of Work.
1.13.1 The privileges of this Approved Maintenance Organisation approval under the Category A rating,
shall be limited to aircraft for which approval is granted in the ZCAA Operations Specification,
and shall be;
1.
To release to service an aircraft, excluding its engine or engines.
2.
To certify in the manner prescribed in the regulations;
3.
-
Work which the maintenance schedule relating to an aircraft authorises the holder of the approval to
certify.
-
The assembly of an aircraft and any adjustment or minor modification of an aircraft; and
-
The installation or replacement of completed sub-assemblies, equipment, instruments and minor
components of an aircraft, excluding its engine or engines.
To release to service an aircraft, excluding its engine for engines, for a test flight.
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1.13.2
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The priveleges of the Approved Maintenance Organisation approval under the Category C rating shall
be limited to aircraft for which approval is granted in the ZCAA Operations Specification, and shall be;
1.
To release to service an engine installed on an aircraft.
2.
To certify in the manner prescribed in the regulations:
- Work which the maintenance schedule relating to an aircraft authorises the holder of the approval to
certify.
- The installation of an engine on an aircraft.
- Any adjustment or minor modification of an aircraft engine and the replacement of external components
and of piston and cylinder assemblies.
- The overhaul and testing of spark plugs; and
- Any installation and maintenance, other than the overhaul, major modification or major repair, of
propellers and the re-assembly of variable pitch propellers which may have been dismantled for transport
purposes; and
- To release to service an aircraft engine for a test flight.
1.14 Special Circumstances.
1.14.1 Notwithstanding anything to the contrary contained in the regulations, the holder of an approval
with the appropriate rating may, in circumstances where;
1.
No appropriately licensed and rated aircraft maintenance engineer; or
2.
No other approved and appropriately rated Approved Maintenance Organisation is available, rectify any defect in
a similar type of aircraft for which the approval is rated.
1.14.2 Where such a defect is rectified, the holder of the approval shall notify the Director General in
writing, within 48 hours from the moment the defect is rectified, of the reasons for, and nature of
such rectification.
1.14.3 Where a defect in an aircraft which is not similar to the type of aircraft for which the approval is
rated is rectified, the holder of such approval shall obtain the prior written permission from the
Director General to effect such rectification.
1.15 Validity of the Approval.
1.15.1 This AMO is aware that the AMO approval cannot be transferred to another organisation.
1.15.2 An Approved Maintenance Organisation approval shall be valid for the period determined by the
Director General, which period shall not exceed one year (12 months) calculated from the date of
issuing or renewal thereof.
1.15.3 The approval shall remain in force until it expires or is suspended by an authorised officer,
inspector, or authorised person, or cancelled by the Director General, in terms of the regulations.
1.15.4 An authorised officer, inspector or authorised person may suspend for a period of not exceeding
30 days, an Approved Maintenance Organisation approval issued under this part, if;
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1.
After a safety inspection and audit carried out in terms of regulation, it is evident that the holder of the approval
does not comply with the requirements prescribed in this part, and such holder fails to remedy such noncompliance within 30 days after receiving notice in writing from the authorised officer, inspector, or authorised
person to do so; or
2.
The authorised officer, inspector or authorised person is prevented by the holder of the approval, or any of its
partners or subcontractors, to carry out a safety inspection and audit in terms of the regulations; or
3.
The suspension is necessary in the interests of aviation safety.
1.15.5 If the holder of an approval allows the approval to expire, the approval shall be surrendered to the
Director General.
1.15.6 The holder of an approval which is suspended, shall forthwith produce the approval upon
suspension thereof, to the authorised officer, inspector or authorised person concerned for the
appropriate endorsement.
1.15.7 The holder of an approval which is cancelled, shall, within 30 days from the date on which the
approval is cancelled, surrender such approval to the Director General.
1.16 Notification Procedure to The Director General Regarding Changes in The Organisation’s
Activities/ Approval/ Location/ Personnel.
1.16.1 When any change to the organisation is considered or when any change occurs as a result of
unforeseen circumstances, the Accountable Manager shall immediately liaise with the Quality
Assurance Manager, in order to find the best strategy to implement the planned or unforeseen
change within the requirements of the regulations. Any changes which may affect the original
approval, shall be communicated to the Director General within 14 days.
1.16.2 Application to the Director General shall be made and prior approval shall be obtained before
effecting any changes to the following-:
1.
Any change in ownership.
2.
The management personnel or structure.
3.
Certifying, planning or library staff.
4.
The accountable manager.
5.
The maintenance ratings.
6.
The procedures for changing the scope within a rating.
7.
The locations at which maintenance is carried out or:
8.
The procedure for authorising persons to certify maintenance.
9.
Failure to renew subscriptions to maintenance manuals or other airworthiness data.
1.16.3 Any change to the approved location or the addition of the other locations shall be notified to the
Director General in writing and an inspection of the new premises by the Director General shall
be arranged prior to any maintenance being commenced in the new facilities.
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1.16.4 An application for an amendment of the approval shall be submitted to the Director General
(together with the appropriate fee and the Maintenance Procedures Manual amendments) when
an amendment to the scope of approval is required.
1.16.5 Any changes in the Quality Management System which are of significance to the showing of
compliance with the appropriate requirements shall be submitted to the Director General for
approval accompanied by an application form.
1.17 Maintenance Procedures Manual Amendment Procedure.
1.17.1 This document constitutes the Maintenance Procedures Manual required by ZCAR’s and is
binding on all personnel performing maintenance for and on behalf of this organisation.
1.17.2 Any proposed amendment to this Maintenance Procedures Manual and any associated
document authorised by this Manual will, before internal distribution thereof, be submitted to the
Quality Assurance Manager to check compliance with the regulations before incorporation and to
the Accountable Manager for his approval. Subsequently, the Manual will be submitted to the
Director General for his approval and any amendments required by the Director General will be
implemented.
1.17.3 Upon approval by the Director General, the internally distributed copies will be amended as
follows:
-
Obsolete pages will be removed.
-
Amended pages will be inserted.
-
Pages will be checked against the list of effective pages.
-
Amendment record will be signed by the person inserting the amendment.
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2 Part 2 - Maintenance Procedures.
2.1 Purchasing Procedure.
2.1.1
The part number and/or specification of the part required for maintenance will be determined by
the assigned Certifying AME and recorded on the Job Card.
2.1.2
All parts and materials shall be purchased/obtained from reputable suppliers, who are able to
provide traceable maintenance/manufacturing histories and appropriate release certificates with
the consignment.
2.1.3
A purchase order for aircraft related parts and materials may only be placed with suppliers whose
names appear on the approved suppliers list (Part Five Appendix P).
2.1.4
The purchase order shall contain all the necessary data to completely define the product or
service and should state what deliverable documents are required. An order for specialised
functions such as NDT, plating or welding will specify the OEM (Original Equipment
Manufacturer) process required where applicable.
2.2 Supplier Evaluation Procedures.
2.2.1
The Accountable Manager is responsible to establish and maintain a list of approved suppliers.
The following criteria shall be applied:
1.
Only reputable suppliers, capable of supplying the required documentation will be used for the procurement of
parts or components. The parts they supply must be obtained from sources approved by the OEM, the Aviation
Authority of the country of origin, or the Director General.
2.
Aircraft equipment to be repaired or maintained by organisations outside of Zambia will only be contracted to
Maintenance Organisations with ZCAA approval. Evidence of their approval (and continued validity thereof)
will be kept on file.
3.
Any subcontractor approved to perform calibration on inspection, measuring and test equipment must be the
holder of ZCAA accreditation.
2.2.2
Review of Approved Suppliers List.
The approved suppliers list shall be reviewed annually to check that the suppliers still meet the
requirements of an approved supplier. Any information about the quality performance of the suppliers’
products may be used in the decision to remove a supplier from the approved suppliers list.
This may include:
- Non supply of the required documentation.
-
Any other supply problem leading to rejection or a long delay.
-
Poor performance of the product as evidenced by unscheduled removals, accidents, or incidents.
Based on poor performance, a supplier can be removed from the approved suppliers list at any time.
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2.3 Receipt Inspection and Identification of Serviceable Parts.
2.3.1
2.3.2
Receipt Inspection.
1.
All items are inspected upon receipt to ensure that they are properly packed, free of damage and
accompanied by the required Release Certificates.
2.
The receiving inspection will be performed by an authorised inspector.
3.
Parts will remain in the Quarantine Store until inspected and will not be issued if not accepted.
4.
Upon passing inspection, a batch number is recorded on the part or batch of parts. This batch number is
used to uniquely identify the part or batch to its release certificates and the supplier’s documentation. The
order number will be used as batch number.
5.
Where applicable, the remaining shelf life and service life data is checked. If the remaining life period is
inadequate, the item(s) are referred to the Accountable Manager to decide if the item(s) should be accepted.
6.
Should any suspected bogus (unapproved) parts be discovered during receipt inspection, the matter shall be
referred to the Accountable Manager to report to the ZCAA. An occurrence report (Part Five Appendix O) will
be used to refer the matter to the Accountable Manager.
7.
Should a part or component fail the inspection, the inspector shall immediately complete and attach an
Unserviceable Label to the part or component and place the part or equipment in the Quarantine Store. An
Occurrence report will be used to refer the matter to the Accountable Manager.
8.
Parts or components that have failed the inspection are reported to the Accountable Manager who shall
investigate the cause of failed inspection and decide upon relevant action to be taken, including the
disposition of the part or component.
9.
Parts that have passed inspection are transferred to the appropriate shelf in the Bonded Store or to the job
where they are required.
Acceptance Criteria.
The following inspection and certification requirements must be met for a part to be accepted:
1.
New parts:
Original Release Certificates showing the part is supplied by a Type Certification holder and/or supplier approved
by the Type Certificate holder.
The certificate must be correctly completed, certified, and accompanied by any further required documentation.
Acceptable forms are:
-
FAA Form 8130-3
EASA Form One; or
Original Export Certificate of Airworthiness for Class I products. (Note that, for an engine or propeller, FAA
Form 8130-3 is considered to be an export C of A).
Standard parts and materials should be accompanied by either:
-
A certificate of conformance of the manufacturer or;
The part number and manufacturer’s batch number or;
The supplier’s batch number which can be traced to the manufacturer.
In the case of critical materials, a test report is also required.
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2.
Maintenance Procedures Manual
Used, overhauled, or remanufactured parts or components.
Used, overhauled and/or remanufactured parts or components shall only be accepted if released by an appropriate
Approved Maintenance Organisation or Repair Centre.
Acceptable release certificates are:
-
CRMA or CRS
FAA Form 8130-3
EASA Form One; or
Original Export Certificate of Airworthiness for Class I products. (Note that, for an engine or propeller, FAA
Form 8130-3 is an export C of A).
Traceable history documents (in the form of logbooks, log cards and/or strip and repair reports) are also required for
used aircraft, engines, propellers, or components.
2.4 Storage of Aircraft Components and Materials and Issue from Stores.
2.4.1
Quarantine Area
The Quarantine Store in the administration office serves as the quarantine area, where a receiving
inspection is performed. Items are not issued to the bonded Store until the receiving inspection is
completed.
2.4.2
Bonded Store
1.
Access to the Bonded Store is controlled by the Accountable Manager, or the allocated administrative person.
2.
Parts that have been allocated to a specific aircraft but not yet fitted are stored
on the ‘serviceable’ shelf of the Bonded Store.
2.4.3
Repairable Items
Repairable items will normally be dispatched for overhaul/repair without delay. Where the need arises to
store repairable items for a short period, they will be stored on the
‘Repairable’ shelf in the Bonded Store.
2.4.4
Scrap Items
Scrap items are items that cannot be repaired. They are to be marked with a Scrap label, and kept in the
Bonded Store, until they are able to be safely disposed of.
2.4.5
Flammable Store
The Flammable Store is a separate building, located away from the other facilities.
2.4.6
Tool Store
All tools will be stored in the workshop, either in lockable steel cabinets, or on the “shadow board”.
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Equipment Storage Area
All general hangar equipment such as stands, jigs, jacks etc. shall be placed in this area when not in use
at the back right hand corner of the hangar. This area shall be kept orderly to ensure proper control over
this equipment.
2.4.8
Packaging and Preservation of Aircraft Components
Components that have been received awaiting installation will remain in their original packaging.
Components and parts to be transported will be packaged in a manner appropriate to the intended
transport and storage. Components disassembled in the workshop will be adequately protected to prevent
deterioration and marked with appropriate tags.
2.5 Acceptance of Tools and Equipment
2.5.1
All special tools and equipment as required by the manufacturers to carry out scheduled
maintenance shall be available to cover all the ratings on this Organisation’s Approved
Maintenance Organisation License. In addition, other standard equipment and hand tools
required to perform aircraft maintenance functions shall be supplied.
2.5.2
In the event that certain special tools are not available, prior arrangements shall be made to loan
such tools from another organisation.
2.5.3
Where applicable, the Operating Instructions and Calibration Certificate shall be available for
tools and equipment.
2.5.4
All tools and equipment shall be listed in an Equipment Register, which is controlled by the
Accountable Manager. The Equipment Register must contain the following information:
2.5.5
-
Description.
-
Company allocated identification number.
-
Calibration period and due date (where applicable).
A storage position shall be allocated to each tool or piece of equipment, i.e., on a shadow board,
in a toolbox or in a position on the hangar floor.
2.6 Calibration of Tools and Equipment
2.6.1
Any inspection, measuring or test equipment which is used to make a measurement to release
an item shall be subject to calibration. This inspection, measuring and test equipment shall be
recorded and closely monitored by the Accountable Manager. The calibration control list shall
contain the items in 14.5.3.
2.6.2
All new or incoming equipment shall be calibrated or inspected to ensure compliance has been
met, before being placed in its allocated storage area.
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2.6.3
Any tools, special equipment and/or test apparatus detected which exceeds its calibration period
shall immediately be identified, removed from service and either sent for calibration or locked in
the quarantine store.
2.6.4
All tools, special equipment and/or test apparatus which require calibration shall have a placard
(or sticker) indicating date of last calibration and date due for next calibration, attached.
2.6.5
All Calibration Certificates issued shall be available at the Approved Maintenance Organisation.
These Certificates (Records) shall be kept for a period of 5 years.
2.6.6
All measuring or test equipment shall be calibrated once a year or as required by the
manufacturer.
2.6.7
The calibration certificate will remain valid till the end of the calendar month in which it expires.
2.6.8
Any measuring equipment that does not need calibration because it is not used to make a
measurement required for an inspection or release, shall be marked “not subject to calibration”.
2.7 Use of Tooling and Equipment by Personnel
2.7.1
Special tools are stored in the tool store. The issue from the tool store will be recorded in the
Tools issue book.
2.7.2
The tools and equipment shall be returned to the allocated storage area when not in use.
2.7.3
At the completion of each job, the tools are checked, and the tool check recorded on the job card.
2.7.4
Missing tools shall be reported to the Accountable Manager. Damaged tools or those that
malfunction shall be repaired or replaced.
2.7.5
Whenever the use of tools or test equipment is required, the relevant Aircraft Maintenance
Manual shall be consulted by the Certifying Inspector or AME to ensure the correct tool and/or
test equipment is used.
2.7.6
Prior to use, all gauges and indicators on the equipment identified as being calibrated shall be
checked by the competent store person, certifying inspector or AME to ensure that they are
within their calibration period.
2.7.7
Personal Tools
2.7.8
1.
Hand tools may be kept in the personal toolboxes. These toolboxes shall be kept orderly, and no unused spares,
lubricants or sealants shall be kept in the toolboxes.
2.
Each toolbox shall be identified to link it to a specific person.
3.
An inventory of these tools shall be kept by the individual, and daily visual tool checks shall be carried out.
Equipment used for measuring purposes shall be selected with consideration to the accuracy of
the measurement to be made.
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2.8 Cleanliness Standards of Maintenance Facilities.
2.8.1
The maintenance facilities shall be kept in a clean and orderly state. All components removed
from the aircraft shall be appropriately identified and stored on appropriate racks/stands provided
for this purpose. The rack/stand shall be identified to the aircraft by means of the registration
number.
2.8.2
Parts and/or components and/or equipment stored for a long period shall be covered to prevent
dust contamination.
2.8.3
Empty containers and used cleaning materials shall be disposed of immediately after completion
of each maintenance task.
2.8.4
Unused spares (including bolts, washers, and rivets) shall be returned to the store on completion
of the task for which they have been obtained.
2.8.5
Mandatory replacement parts removed shall be disposed of. Used surplus parts may be
inspected by an AME and returned to service. Otherwise, these used parts shall be disposed of.
2.8.6
The floors shall be swept regularly, and all rubbish removed by the appointed cleaning staff, to
ensure that a high standard of cleanliness is maintained.
2.8.7
Any spills of lubricants, fluid or any other debris resulting from the maintenance, shall be cleaned
regularly.
2.8.8
Work areas that produce dust or any form of pollution shall be separated (screened off) from
other working areas.
2.9 Maintenance Operations
2.9.1
Receive Booking.
The maintenance process is normally initiated by the customer’s booking. A credit worthiness check is
made before booking is accepted. A maintenance slot is determined, based on current workload and
availability of personnel and space.
2.9.2
Maintenance Planning.
A work pack is compiled by the assigned Maintenance Planner/AME. The contents of the work pack depend
on the type of aircraft.
The maintenance schedule is selected according to the criteria of Section 14.11.1. An AD/SB compliance
checklist is added as required by section 14.11.2.
The Job Card number, Defect Sheets, Stores Requisition Forms, and appropriate checklists are added as
required by the task.
The work pack is issued to the assigned AME.
2.9.3
Receipt of Aircraft for Maintenance.
Upon receipt of the aircraft, a receiving inspection is conducted, and the results are recorded on the Arrival
Inspection Sheet. Should anything untoward be discovered, this is reported to the Accountable Manager
and brought to the attention of the customer.
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2.9.4
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Defect Reporting and Failure Investigation.
The organisation shall ensure that all items undergoing failure investigation, are inspected to determine the
cause of failure of the item concerned.
When a major defect or condition is identified that may pose a hazard to flight safety, the defect or condition
shall be reported to the Director General within 48 hours from the moment the defect or condition has been
identified.
The maintenance organisation will collect, investigate, and analyze information relating to such a defect or
condition in the aircraft or component maintained by the AMO. This information will be distributed to the
applicable design organisation, the owner/operator of the aircraft or component and the Director General.
2.9.5
Inspection for Hidden Damage.
Prior to the commencement of any maintenance, all airframe, engine, or other components that have been
involved in an accident or any other incident that may affect its serviceability, shall be given a thorough
inspection for hidden damage. This shall include areas adjacent to the obviously damaged members or
components and the findings shall be recorded.
2.9.6
Unusual Flight Occurrences.
Inspections are required if any of the following conditions have occurred:
-
Hard/overweight landings.
-
Operations outside the normal flight envelope.
-
Severe air turbulence or severe maneuvers.
-
Lightning strikes.
-
Foreign object damage.
-
High drag/side loads due to ground handling.
-
Propeller strikes.
The manufacturer’s recommendations must be followed if any of the above has occurred. An appropriate
AIC applies to propeller strikes.
2.9.7
Aircraft Inspection Procedure.
1.
The aircraft is inspected in accordance with the appropriate inspection check sheet that was selected at the
maintenance planning phase.
2.
The check sheet is followed, and the maintenance manual is consulted. The results of the inspection are
recorded on the check sheet.
3.
The check sheets in the work pack are completed as the work progresses. In this way a continuous record of
progress is maintained and hand-over to another responsible person is facilitated, should this become
necessary.
4.
All parts or components removed from the aircraft are identified and stored on suitable racks or containers.
Parts that are removed to provide access need not be identified individually by a label but may be identified
through the label on the shelf or container.
5.
Unserviceable parts shall be segregated from serviceable parts. Defective parts or components that are
repairable shall be labeled as repairable and kept separate for routing to the appropriate maintenance area.
(Refer to Part Five Appendix H for labels in use by this AMO).
6.
Defects are identified by the maintenance engineer in charge of the check and recorded on the Defect Sheet.
Where necessary, these defects are reported to the customer for authorisation.
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7.
The Part Number/Serial Number and/or specification of any parts or materials required for maintenance shall
be determined by the assigned Maintenance Engineer and recorded on the Parts Requisition/Order Form
8.
Parts and materials are drawn from the store and must be accompanied by appropriate release
documentation. Upon receipt, the Maintenance Engineer inspects the item for eligibility before use. The
release documentation is appended to the work pack.
9.
ADs and SBs are complied with as required by the checklists. AD and SB status is recorded in the respective
AD and SB compliance checklists.
10. An engine, propeller or component may be shipped to an approved supplier for Maintenance. Similarly, an
approved service provider may be called in to perform work on the aircraft.
11. When work in an area is completed and before the area is closed, a final inspection is made to ensure that all
the required work was done and that the defects recorded have been cleared. A check is also made for loose
articles or any tools that may have been left behind. An authorised inspector is invited to perform any stage
inspection, any duplicate inspection, and any final inspection before the closure of any area.
12. Duplicate inspections are required whenever a control has been disturbed. A duplicate inspection is first
performed by an authorised release inspector and is subsequently inspected independently by another
authorised release inspector. In the event that such an inspection is required away from the main AMO base,
the holder of a CPL with the appropriate rating may perform the second leg of the duplicate inspection.
13. No inspection is considered to be complete before all the paperwork has been signed by the maintenance
engineers as required by the work pack
14. After the work pack has been signed, the aircraft is cleaned.
15. Should a flight test be required, this is arranged, and the results are recorded.
16. The work pack is finally checked for completeness by the assigned inspector and the logbook entries are
made. Finally, the Release Certificate is prepared and signed, and the inspection reminder is attached to the
aircraft.
17. After the invoices have been raised, and payment was received, or, alternatively, after credit arrangements
have been approved, the aircraft is released to the customer.
2.9.8
Aircraft Modifications.
Implementation of modifications shall be carried out in accordance with the ZCARS’s Part 6.
These rules on modification or repairs to aircraft can be summarised as follows:
1.
All modifications require prior approval from the ZCAA, prior to the modification being embodied. An
application shall be made on the appropriate ZCAA form, and an approval number shall be allocated for
the modification prior to the work being initiated.
2.
A minor modification can be classified as minor by either the ZCAA Certification Department or a ZCAA
approved design organisation. The organisation that classifies the modification as minor may also approve
the data, If classification and approval is sought from the ZCAA and the substantiation data prepared for
the modification. The modification may be accomplished after approval has been issued by the Director
General.
3.
If the modification has been classified as major, an application for a local STC will be required. Only a
design organisation may apply for an STC approval.
The conditions for the implementation and proof testing of the STC will be stated by the ZCAA on the
temporary approval.
Once the permanent approval has been issued, the STC may be installed on other qualifying aircraft if
authorised by the STC holder.
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2.9.9
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Specialised Functions.
Only ZCAA approved Organisations shall be subcontracted for specialised functions (such as NDT,
welding, and plating) that this AMO is not rated to perform.
2.9.10 Specific Maintenance Requirements.
Specific maintenance requirements, that this AMO is not certified to perform, are as follows:
1.
Maintenance for IFR operations.
2.
Airspeed indicator and altimeter system tests and inspections.
3.
ATC transponder tests and inspections.
4.
Emergency locator beacon tests and inspections.
5.
Aircraft compass requirements.
2.9.11 Maintenance Away from Base.
Should the need arise to carry out maintenance away from base at another AMO, Bush Pilots Aviation Ltd
shall make timely advice to the Director General of its intention to carry out the maintenance prior to
commencement and shall supply the following information:
1.
Aircraft registration.
2.
Location where the intended maintenance shall be done.
3.
Type of maintenance to be carried out.
4.
Name and certification number(s) of the AME concerned.
5.
For scheduled inspections, the tools, spares, and documentation that must be taken with, to satisfactorily
carry out the work on each aircraft.
6.
Name of company operating the base if not the aircraft’s usual AMO.
2.10 Control of Airworthiness Data.
2.10.1 Airworthiness Data includes all the data that may be required to perform the scope of approval of
the organisation. This includes manufacturer’s data such as maintenance manuals, structural
repair, overhaul, and parts manuals as well as service bulletins and any other instructions issued
by the manufacturer. In addition, Airworthiness Data includes all applicable Airworthiness
Directives or other instructions issued or classified as mandatory by the Zambia Civil Aviation
Authority or the Aviation Authority that has approved the type certificate of the product.
2.10.2 The organisation shall keep all the current airworthiness data required to maintain the products it
is rated for and shall ensure that all personnel have free access to this literature and that all the
necessary and current data is provided at the place of work. The Accountable Manager is
responsible to ensure that subscriptions are maintained to support all the products on the scope
of approval of the organisation.
2.10.3 A List of Publications available shall be maintained with the following information:
-
Publication Description,
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Publication Number.
Publication Revision Date.
2.10.4 Any document that is no longer maintained up to date shall be withdrawn from use and marked
as “obsolete”. Obsolete manuals may not be used to perform maintenance.
2.10.5 Documents subject to revision, shall be checked on an annual basis to ensure that the revision
status is in agreement with the published revision status of the manufacturer.
-
Airworthiness directives are available free on the internet and will be referred to during every check.
-
A Document Provider Service is subscribed to by the AMO, the SBs will be checked at every Check as will
the status of the maintenance manuals (if this has not been done within the last three months).
-
In the case of vintage aircraft where no update service is available, there is no need to make a periodic
check.
2.10.6 Any copy of a document that is not subject to revision control, shall be marked ‘copy’ and shall be
destroyed after use. Copies that are made for use during a maintenance check are valid for a
period of 30 days.
2.11 Aircraft Maintenance Program, AD Procedures, Modification Procedures and Technical
Record Control.
2.11.1 Aircraft Maintenance Program.
Each aircraft shall be maintained in accordance with its appropriate Approved Maintenance Schedule.
In the case of an aircraft used on an AOC, the maintenance requirements are defined in the Approved
Maintenance Schedules. This also applies to aircraft utilized in flight training. The Accountable Manager
must therefore request the MCM for any such aircraft to be maintained.
All aircraft shall be maintained in accordance with its approved maintenance schedule.
Aircraft under 5700 kg may have a uniquely approved AMS. If such a document does not exist, the aircraft
shall be maintained in accordance with the maintenance schedule as defined by the manufacturer.
The Assigned AME shall select the appropriate maintenance schedule(s) for the inspection to be performed
and prepare the work pack based on the correct schedule.
2.11.2 AD/SB Procedures.
To ensure that all Airworthiness Directives applicable to an aircraft, as well as any other mandatory
instructions or bulletins are complied with, the assigned AME shall perform a search of such ADs and SBs
and shall establish a compliance checklist.
The ADs will be sourced from the FAA website.
The AD compliance checklist shall be completed and shall indicate the status with respect to each AD
applicable to the aircraft type. The results of previous aircraft records may be used in the completion of this
checklist. In this case, the reference to the previous records must be stated. All ADs complied with shall be
entered in the logbook. The same applies to SBs classified as mandatory by the aircraft manufacturer.
The AMO cannot ignore OEM documentation that is not classified as mandatory as such documents could
contain updates to mandatory documents or other significant safety information.
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Under certain conditions Part 6 has authorised the non-compliance with certain “Mandatory” SBs. In these
circumstances such SB must be recorded in the logbook as “not complied with”.
2.11.3 Aircraft Modifications
The requirements as prescribed in section 14.9.8 of this Maintenance Procedures Manual shall be adhered
to.
2.11.4 Aircraft Record Control
The following records shall be kept on behalf of the owner/operator:
1.
The total time in service (hours, cycles, and calendar time, as appropriate) of the aircraft and all life-limited
components.
2.
The current status of compliance with all mandatory continuing airworthiness information.
3.
Appropriate details of modifications and repairs to the aircraft and its major components.
4.
The time in service (hours, calendar time and cycles, as appropriate) since last overhaul of the aircraft or its
components that are subject to a mandatory overhaul life.
5.
The current status of compliance with the maintenance program; and
6.
The detailed maintenance records to show that all requirements for signing of a Certificate of Release to Service
of an aircraft have been met.
These records shall be kept for a minimum period of five years after the signing of the maintenance release.
These records shall be kept for a minimum period of 90 days after the unit to which they refer has been
permanently withdrawn from service.
In the event of a temporary change of operator, the records shall be made available to the new operator.
In the event of any permanent change of owner or operator, the records shall be transferred to the new
owner or operator.
2.12 Maintenance Documentation and Completion of Records.
2.12.1 The following documents shall be included in each scheduled maintenance work pack:
-
Job Card
-
Labels
-
Certificate of Release to Service
-
Inspection Reminder
-
Logbook – entries are made in the logbooks as required
2.12.2 Completion of Records
1. The assigned AME is responsible for compiling a work pack that contains all the documents
necessary to adequately record the maintenance work to be performed.
2. The Authorised Maintenance Engineer who performs the maintenance, or under whose supervision
the maintenance is performed, shall record the maintenance work performed in the work pack as
follows:
a. Any person who carries out maintenance on an aircraft or aircraft component shall record, on
completion of the maintenance –
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Details of the maintenance including, where applicable, the type of inspection and any approved
data used;
-
For a progressive or scheduled inspection, whether a detailed inspection or routine inspection
of the particular components or areas of the aircraft was carried out;
-
The serial numbers, if any, of components removed or fitted;
-
Details of measurements or test results obtained, including the results of any ground or air tests;
-
For an air speed indicator or altimeter system pitot static test and inspection, the date on which
the test was conducted, and the maximum altitude to which the altimeter has been tested;
-
The date of completion of such maintenance;
-
The references to the documents used to carry out the maintenance and their revision status;
-
The name of the person completing such maintenance, if other than the person certifying the
release to service;
-
The location and, if applicable, the name of the facility where such maintenance was carried out;
and
-
Where such maintenance has been carried out as a consequence of the failure of any
equipment, or damage caused by forced landing or accident, the reasons for carrying out the
maintenance.
b. The person who carries out the maintenance shall –
- Record the details referred to in sub-regulation (1) in the appropriate logbook or in a
maintenance record approved by the Director General.
- Where worksheets or other associated maintenance records are used to document the details
of the maintenance, make a reference to those records in the logbook, flight folio or in the
maintenance record approved by the Director General.
c.
Maintenance records in the work pack shall be entered legibly and in black ink.
- The maintenance records shall indicate the name (and stamp, if issued) of each person who
performed the maintenance as well as the name and stamp of each person who inspected the
maintenance performed.
d.
Should a correction be required, the erroneous entry shall be neatly ruled out (such that it can still be
read) and the new entry be made. The signature of the person who made the change shall be appended
to the change.
e.
Certificates of Release to Service may be typewritten or completed legibly and in black ink.
f.
A CRS (Certificate of Release to Service) and direct entry into the logbook is certified by means of a
signature and stamp.
g.
Logbook entries
- After successful completion of a non-scheduled maintenance task, the Certifying AME certifies
the work performed in the appropriate logbook. The following release statement shall be used:
- ‘The work recorded above has been carried out in accordance with the Zambia Civil Aviation
Requirements Aug 2015, as amended, and in respect of that work the aircraft is fit for release to
service’.
h.
Major repairs and modifications are recorded in the logbook. Copies of all certificates relating to the
maintenance of an aircraft shall be forwarded to the responsible Airworthiness Inspector once Class I
products or major components are installed to an aircraft after overhaul or repair.
i.
Having certified the work, the Certifying AME files copies of all the maintenance documents mentioned
above in the aircraft’s file as maintenance records. These records shall be retained for a period of five
years after release to service.
j.
Submission of documentation to the ZCAA
- After the successful completion of a Check II, a ZCAA inspection report is submitted to the
Director General. For an aircraft on a progressive inspection schedule, this form is submitted
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annually.
k.
Discrepancies
- When discrepancies that cannot be rectified or deferred have been identified during an
inspection, the certification statement prescribed in ZCAR’s Part 6 will be used:
- ‘I certify that aircraft 9J-___ has been inspected in accordance with (description) inspection and
is not released to service. A list of discrepancies and non-airworthy items dated (date) has been
submitted to the aircraft owner (or operator).
2.13 Rectification of Defects.
2.13.1 All defects reported by the owner or operator are recorded on a Job Card.
2.13.2 The Accountable Manager or authorised inspector shall transfer the defects recorded in the
Aircraft Technical Log onto the Job Card.
2.13.3 The responsible Maintenance Engineer adds any defects identified during the inspection to the
Job Card. During the inspection visit, all defects that may affect the safety of the aircraft must be
cleared.
2.14 Release to Service Procedure.
2.14.1 A Certificate of Release to Service may only be issued if the aircraft or component to be released
meets the applicable requirements.
2.14.2 In the case of a scheduled maintenance visit, an aircraft is released to service by completing and
certifying the logbook, the Certificate of Release to Service, and the Inspection Reminder once
the service check is completed.
2.14.3 In the case of defect rectification not associated with a scheduled maintenance check, an aircraft
is released to service by completing the appropriate flight folio or logbook entry.
2.15 Records for The Operator.
2.15.1 The Aircraft Maintenance Organisation shall provide a copy of each Certificate of Release to
Service, or Certificate Relating to Maintenance of an Aircraft to the operator of the aircraft,
together with a copy of any unique airworthiness data used for repairs or modifications carried
out.
2.15.2 The release certificates of components shall be pasted into the appropriate logbook.
2.15.3 Although logbooks belong to the operator, the Aircraft Maintenance Organisation may keep these
on behalf of the operator if requested to do so.
2.15.4 Records will be held on behalf of the operator as defined in section 14.12.2.
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2.16 Defective Aircraft Components
2.16.1 Any component or equipment which is found to be unserviceable shall have a Repairable Label
attached after the component or equipment is cleaned and correctly categorised by a certifying
Inspector. The component shall be blanked, and then handed to the competent store person for
the required action. The Repairable Label shall be correctly completed and certified by the
Certifying Inspector.
2.16.2 The item shall be routed to the Repairable Stores area or directly forwarded to an approved
repair facility after the completion of the required stores documentation.
2.16.3 Components or equipment received from outside contractors after repairs or overhauls were
carried out, shall be submitted to the stores, and handled in terms of section 14.4.
2.16.4 Unserviceable components beyond economic repair will be permanently marked as scrap and
defaced, before being disposed of. Note that life expired discard items must be mutilated in a way
to prevent unscrupulous persons from re-introducing such items as “serviceable”.
2.17 Special Aircraft Maintenance Procedures
2.17.1 Engine Running Procedure.
1.
This Aircraft Maintenance Organisation will carry out ground running of aircraft engines (in aircraft) in
accordance with the Manufacturer’s Maintenance Manuals and/or procedures.
2.
Engine parameters will be recorded as required during the engine ground running.
3.
Engine ground running will only be carried out at the airfield run-up area within the airfield by a person
authorised to perform engine ground running. The aircraft wheels shall be chocked.
4.
The person(s) carrying out the engine ground runs will ensure that the areas in front and behind the
engines are clear prior to engine start and remain clear during the run.
2.17.2 Aircraft Pressurisation Tests
1.
This Aircraft Maintenance Organisation will carry out aircraft pressurization tests in accordance with the
Manufacturer’s Maintenance Manuals and / or procedures.
2.
All pitot-static systems must be correctly connected and blanked before the tests starts.
3.
All doors, windows, exits etc. must be checked before the test to be sure they operate correctly. This
must be repeated after the test is complete.
4.
No attempt to open doors, windows, hatches, etc. is to be made after testing, until cabin pressure has
been reduced to match the ambient pressure.
2.17.3 Aircraft Towing Procedures
1.
Aircraft towing will be performed under the control of a maintenance engineer or a pilot.
2.
He/she will ensure that the tow vehicle and tow bars are serviceable.
3.
The pilot or engineer will be in the pilot seat before towing is commenced.
4.
When the aircraft is parked, this person will only leave his position once the aircraft’s park brake is
activated and the aircraft wheels properly chocked.
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2.17.4 Aircraft Taxiing Procedures
1.
Aircraft shall not be taxied in or out of the hangar.
2.
Only taxi on designated taxiways.
3.
No run ups are to be conducted on the apron. Run ups should only be conducted on the designated run
up are.
2.17.5 Duplicate Inspections of Controls.
1.
2.
No Certifying Inspector will certify an aircraft, component or equipment for release logbook(s), or other
maintenance record approved by the ZCAA.
An authorised duplicate safety inspection will consist of:
a. An inspection carried out by an authorised AME to certify the Release to Service of the control
system after maintenance and;
b. A second inspection carried out by another authorised certifying AME or inspector who may be
qualified as follows-:
-
The holder of a valid company authorization on type or on a similar type within the same
group, or
A type rated AME or an AME holding a valid license for the category, but not type rated,
or
The holder of a valid ATPL or CPL rated on the type concerned, if none of the persons
mentioned above are available.
A person authorised by any approved AMO to perform duplicate inspections.
2.17.6 Flight Testing.
As part of a Check-II, an acceptance flight test may be performed by any appropriately rated pilot
approved by the ZCAA. A release for the purpose of the flight test must first be recorded in the
logbook.
Flight testing of aircraft for the purpose of the issue of a Certificate of Airworthiness or after major
modifications or repairs, will be performed in terms of the requirements.
2.17.7 Specialised Activities.
Only ZCAA approved organisations shall be used for specialised activities such as Welding, NDT,
and plating.
2.18 Refueling of Aircraft.
2.18.1 No refueling of aircraft will take place within a hangar.
2.18.2 Mobile Telephones or any other portable electronic devices must be switched off within a range
of 10 metres of refuelling activities.
2.19 Prohibition of Smoking.
2.19.1 Smoking is PROHIBITED within a hangar, within 50 meters of the fuel installation, and on all
aircraft aprons and taxiways.
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Part L2 Line Maintenance
L2.1 Not applicable to this facility
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3 Part 3 Quality Assurance System.
3.1 Objectives of the Quality Assurance System.
The objectives of the Quality Assurance System are as follows:
1.
To monitor, and report to the Accountable Manager, the level of compliance with the Organisation’s
Maintenance Procedures Manual, Part 6 of the ZCAR’s and general ZCAA airworthiness requirements.
2.
To ensure that corrective actions are taken for non-conformities identified and to ensure the implementation
of preventive actions, where necessary, to prevent the recurrence of such non-conformities; and
3. To present to the Accountable Manager for analysis and review, quality indicators such as audit reports,
accidents, incidents, occurrences, and customer complaints.
Note:
The Accountable Manager shall ensure that the system is understood, implemented, and
complied with at all levels.
3.2 Quality Audit of the Organisation.
An annual audit program shall be compiled and submitted to the Accountable Manager for approval.
All elements of the AMO shall be audited at least once per year. Those elements that need to be audited
more frequently shall be audited at a frequency determined by the need of the organisation. The Quality
Assurance Manager shall ensure that the audit program is followed.
3.3 Quality Audit of Aircraft.
A physical audit of work in progress will be performed as part of the quality audit. Quality audits of aircraft
maintenance may address:
-
Composition and completeness of the work pack.
-
Use of the correct specified forms.
-
Correct execution of the customer order.
-
Compliance with Airworthiness Directives and Service Bulletins.
-
Control of life limited items and other time-controlled events.
-
Use of correct Job Cards.
-
Use of up-to-date airworthiness data.
-
Use of the correct specified special equipment where applicable.
-
Correct implementation of special processes where applicable.
-
Authorisation of staff involved in maintenance.
-
Completion of inspection sheets.
-
Completion of release documentation.
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3.4 Quality Audit Remedial Action.
3.4.1
Non-conformities identified during sampling audits carried out shall be recorded on the Audit
Report. The Quality Assurance Manager shall ensure that appropriate corrective action is taken
within 30 days, and that preventive action is implemented within an agreed time frame.
3.4.2
The Quality Assurance Manager will check on the implementation of corrective action and
preventive action and close out the finding if satisfactory.
3.5 Occurrence Report.
3.5.1
Workshop related accidents, incidents, unusual occurrences, service difficulties, bogus aircraft
parts, recurring defective aircraft components, equipment, etc., which may affect the safe
operation of the aircraft, engine, propeller, component and/or equipment shall be reported to the
Accountable Manager by raising an Occurrence Report.
3.5.2
The Accountable Manager shall investigate the problem/defect and recommend the action to be
taken. The corrective and preventive actions shall be assigned to an appropriate person for
completion.
3.5.3
The Occurrence Report shall then be forwarded to the person responsible for the implementation,
recording and certification of the corrective and preventive actions to be taken.
3.5.4
The corrective and preventive actions taken shall be reviewed and closed out by the Accountable
Manager.
3.5.5
An Occurrence or Major Defect Report shall be forwarded to the ZCAA within 72 hours, in cases
where the safe operation of an aircraft is affected.
3.6 Client Complaints.
3.6.1
Client complaints must be reported to the Accountable Manager on the report form located in
Part Two of this manual.
3.6.2
The accountable manager shall investigate:
-
The validity of the complaint.
-
The potential safety hazard associated with the service rendered.
-
The cause that led to the complaint.
-
The corrective and preventative action(s) required to prevent the recurrence of the same or similar complaint.
3.6.3
The Occurrence/Complaint Report shall be then forwarded to the person responsible for the
implementation, recording and certification of the corrective and preventative actions to be taken.
3.6.4
The corrective and preventative actions taken shall be reviewed and closed out by the
Accountable Manager.
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3.7 Management Analysis and Overview.
3.7.1
Quality indicators such as audit reports, progress on corrective action, accidents, incidents,
occurrences, customer complaints and personnel reports shall be reviewed by the Accountable
Manager. This is done by means of the normal operation of the system of internal audits and
recording of accidents, incidents, and customer complaints. The Accountable Manager has close
contact with the personnel and is able to identify any personnel issues.
The Accountable Manager shall attend to these quality issues by means of the normal operation of the quality
system in order to improve the safety and effectiveness of the AMO.
The appropriate action decided upon shall be documented and implemented to maintain an adequate level
of conformance to airworthiness requirements.
3.8 Certifying Personnel Competence and Training.
Refer to section 1.7.1 in Part 1.
3.9 Certifying Personnel records.
Refer to section 1.7.1 in Part 1.
These records shall be reviewed annually by the Accountable Manager to ensure that they are kept up to
date.
3.10 Quality Audit Personnel.
These personnel shall be:
-
Sufficiently experienced in the organisation’s systems and procedures and technically
knowledgeable of the aircraft being maintained to enable them to perform their duties satisfactorily.
-
Experienced in the techniques of Quality Assurance/Control or receive suitable training before taking
up their duties; and
-
Given clearly defined terms of reference and responsibility within the Organisation and reporting lines
to the Accountable Manager.
3.11 Deviation/Concession control.
-
Deviations and Concessions do not apply.
3.12 Exemption control
Any request for exemption from the Zambia Civil Aviation Requirements Part 6 shall be submitted by the
Accountable Manager to the Director General in terms of Part 6 of the Zambia Civil Aviation Requirements
Aug 2015.
3.13 Specialised activities.
-
Specialised activities are contracted to organisations with appropriate approvals.
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4 Part 4 – Documentation (Air Operators)
4.1 Not applicable to this facility
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5 Part 5 – Appendices
- Floor Plan
Toilet
Administration
Office
Quarantine
and Rubber
Goods Store
Flammables
Store
Nitrogen
Storage
5.1 Appendix A
Walkway
Ground
Equipment
Storage
Workshop
Bonded Store
Hangar Doors
Security
Main Apron
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5.2 Appendix B
Maintenance Procedures Manual
- List of Certifying Inspectors
Name
1
2
3
4
5
NB
Derek West-Mace
Robinson Chanda
Pascal Mutale
Macdonald Chirwa
Mathius Lusambo
AME License Number
AMO Stamp No.
1012
798
672
2854
675
Four
One
Five
Three
Two
Signature
Any lost company stamp must be reported to the Accountable Manager and the lost stamp is
declared obsolete and never to be used again and the matter reported in writing to the ZCAA.
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5.3 Appendix C
Maintenance Procedures Manual
- Work Pack – Single Engine
See Insert
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5.4 Appendix D
Maintenance Procedures Manual
- Work Pack – Twin Engine
See Insert
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5.5 Appendix E
Maintenance Procedures Manual
- Log Book Entry
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5.6 Appendix F
Maintenance Procedures Manual
- Job Card
JOB CARD
J/C No.
Aircraft Reg
Date
Date completed and invoiced
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5.7 Appendix G
Maintenance Procedures Manual
- Defect Sheet
Z/AMO/99/2017
DEFECT SHEET
Jobcard No:
A/C Reg:
Tacho/Hobbs Hrs:
No
Date:
Engineer:
Defect
Spares Used
No
Rectification
Description
Special Tool Used
Serial No
Calibration Expiry Date
Time
Signature
Part No
Qty
AME Signature
I hereby certify that in carrying out the foregoing specified maintenance, all the requirements prescribed in
the ZCARS, as amended, which are applicable hereto, have been complied with.
Certified By:
________________________________
Date
Signature:
________________________________
Stamp
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5.8 Appendix H
- Labels
Bush Pilots Aviation
Bush Pilots Aviation
AMO
Scrap Item
Description: _______________________
Part No: __________________________
Serial No: _________________________
AMO
Serviceable Item
Description: ____________________________
Part No: _______________________________
Serial No: ______________________________
Shelf Life Exp on: ________________________
Hrs since New: __________________________
Hrs since O/H: __________________________
Repair/Modification
Status: _________________________________
Defect Report
Yes:
No:
Reason why item is classified as scrap
Release Cert. No.
____________________
Stamp: _________________________
Stamp___________
Signed: _______________
Date: __________
Date___________
Signed____________________________
Bush Pilots Aviation
AMO
Repairable Item
Description: ________________________
Part No: ___________________________
Serial No: __________________________
Defect Report
Yes :
No:
Action to be taken
Signed: ___________________ Date: ___________
Stamp: ____________________________
Licence No: ________________________
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5.9 Appendix I
Maintenance Procedures Manual
- Certificate of Release to Service
AMO
BUSH PILOTS AVIATION
CERTIFICATE OF
RELEASE TO SERVICE
No: ______________
Z/AMO/99/2017
Nationality and registration marks: ……………………………………………………………………………………………….
Aircraft type: ……………………………………………….
Serial number: ………………………………………………
I hereby certify that I am satisfied that the above-mentioned aircraft and all its equipment are in every way
serviceable for flight and that all maintenance has been carried out in accordance with ZCAA CARs as
amended, and its approved maintenance schedule.
This certificate lapses at a total of …………...…… (Airframe TT) …………………….…. (Tacho) hours of flight time or
on ……………….……, whichever occurs first, unless the aircraft is involved in an accident or becomes
unserviceable, in which case the certificate becomes invalid for the duration of the period.
Signed: ………...……………………….
License/Stamp Number: ……………………………..
Date: ……………………………………..
Time: ……………………………..
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5.10 Appendix J
Maintenance Procedures Manual
- Arrival Inspection Form
Z/AMO/99/2017
ARRIVAL INSPECTION SHEET
Date
Owners Name:
Address:
Cell:
Email:
Item
Yes/No/Qty
Airframe Logbook
Engine Logbook
Propellor Logbook
Flight Folio
Weight & Balance
Insurance
C of A
C of R
Radio Licence
Microphone
First Aid Kit
Keys
Headset
Any Noticeable Damage on Aircraft:
A/C Reg:
Make:
Model:
Serial No:
Assigned Job Card No:
Notes
Item
Fire Extinguisher
Chocks
Fire Axe
Signal Strip
Spare Oil
Fuel
Tow Bar
Sunshades
A/C Cover
Fuel Dipstick
Fuel Strainer
Flashlight
Other
Yes/No/Qty
Notes
Description of work to be carried out:
*PLEASE NOTE THAT NO AIRCRAFT WILL BE RELEASED UNTIL ACCOUNT HAS BEEN SETTLED IN FULL*
I/We confirm that I/We have read, accept and have the authority to accept the above conditions
Name: ______________________
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5.11 Appendix K
Maintenance Procedures Manual
- Certificate of Fitness for Flight
Z/AMO/99/2017
CERTIFICATE OF FITNESS FOR FLIGHT
Aircraft Registration ____________________ Serial Number _____________________
I/We hereby certify that I/We have this day inspected the above aircraft, the engine(s) and it’s
installation(s), and the instrument(s) system, and I/We are satisfied that it is safe in every way for flight
provided the loading conditions specified in the flight manual or Certificate of Airworthiness or the
owner’s manual have been complied with.
Signed__________________________ AME Licence No._________________________
Category(s)______________________
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5.12 Appendix L
Maintenance Procedures Manual
- Inspection Reminder
INSPECTION REMINDER
Next Inspection:
Bush Pilots Aviation Check Due:
Sub H Farm 1892,
Chisamba
AMO
Z/AMO/99/2017
____________________
At _____________ Hrs ___________
C of A Expiry Date:
Aircraft Registration:
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5.13 Appendix M
Maintenance Procedures Manual
- Post Inspection Check Sheet
Z/AMO/99/2017
POST INSPECTION SHEET
Date
Job No.
A/C Reg:
Have the following issues been tended to in the log books….....
Have the flight hours been filled in?
Have the CRMA's been entered?
Have the log book entries been entered?
Has the engineer signed and stamped all the log books?
Are the following documents in the flight folio….......
Current Certificate of Airworthiness
Certificate of Registration
Current Certificate of Release to Service
Current weight and balance
Current Insurance
Current Radio Licence
Have the following items been checked and returned to the aircraft?
Flight folio
Fire Extinguisher
First aid kit
Tech Log
Have the tech log copies been filed?
Has the check/ defect been entered into the tech log?
Are the items that were checked off on the arrival inspection sheet accounted for?
Is the CO detector still valid?
Is the compass swing up to date and the card in place?
Has the aircraft been cleaned?
Has a thorough physical inspection been done?
Is the work pack complete and signed off by the engineer?
Have copies of the CRMA's and 81-30's been attached to the workpack?
Have the following items been filed to the aircraft folder?
Completed workpack
Copies of the CRMA's
Expired Certificate of Release to Service
Expired Certificate of Airworthiness
Expired weight and Balance report
Expired insurance
Expired radio licence
Are there soft copies of all the documents in the aircraft folder on the computer?
Is the compliance checklist up to date?
Is the fuel level the same as it was when the aircraft arrived?
Has the inspection reminder been completed and placed in the aircraft?
Post inspection completed by:
Name: ______________________ Signature:______________________
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5.14 Appendix N
Maintenance Procedures Manual
- CAA Operations Specifications for Aircraft Maintenance Organisations
See Insert
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5.15 Appendix O
Maintenance Procedures Manual
- Occurrence Report/ Client Complaint Report
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5.16 Appendix P
Maintenance Procedures Manual
- List of Approved Suppliers
Dart Aircraft Electrical
Aeronautical House
Site 86, Rand Airport
Germiston, 1419
South Africa
Niner Juliet Logistics
P.O.Box AP4
Kenneth Kaunda International Airport
Lusaka
Zambia
Joc-Air
Hangar 36, Airport Rd
Lanseria International Airport
Lanseria
South Africa
Aircraft General Spares PTY LTD
Rand Airport
Germiston, 1419
South Africa
Vasloscene
Unit One, Alton Park
149 New Rd
Midrand
Johannesburg
South Africa
Afrox Zambia
Chisokone Avenue
Ndola
Zambia
Aircraft Spruce
452 Dividend Drive
Peachtree City
GA, 30269
U.S.A
Aviation Rebuilders
The Showroom
Rand Airport
Germiston
1419
Airpower Inc
4900 South Collins
Arlington Municipal Airport
Arlington
TX, 76018
U.S.A
Aero Engineering and Powerplant
Hangar No. 4
Wonderboom Airport
Pretoria
South Africa
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5.17 Appendix Q
- Rules for the Issue of a Competency to Perform Special Aircraft
Maintenance Procedures
1.
Conditions for issuing of a competency
Competency for controlling the following special maintenance procedures may be granted if the applicant
meets the following requirements:
a. Engine Running
Hold a valid pilot’s license or an AME license with category A and C authorisation for the aircraft
type or have passed the AMO’s training on engine running.
b. Aircraft Towing
The person who drives the towing vehicle is in charge of the towing process and must hold a valid
driver’s license and an airside induction training certificate if applicable.
c.
Aircraft Taxiing
Meet the requirements, that is:
-
Hold a valid pilot’s license, or
-
has received instruction in the taxiing of an aircraft from, and has been declared competent to
taxi an aircraft by, the holder of a flight instructor rating or, in the case of a foreign aircraft, a
person authorised by an appropriate authority; and
-
if the person uses a radio apparatus, such person is authorised to use the radio apparatus; and
-
is conversant with the aerodrome layout, routes, signs, markings, lighting, air traffic service
signals and instructions, phraseology and procedures, if required, and is able to conform to the
standards required for safe aircraft movements at such aerodrome.
2. Issuing of a Competency
The Accountable Manager may issue a company competency with authority from ZCAA certificate to
authorize the performance of any of the special maintenance tasks mentioned above. The evidence of
compliance with the rules must be recorded on the applicant’s personal file.
For the sake of independence the Quality Assurance Manager must approve the competency of the
Accountable Manager.
The competency certificate will be issued on the organisation’s letterhead and must indicate:
-
The AMO name and number
-
The initials and name of the successful candidate
-
The functions authorised
-
The date of issue
-
The validity period or expiry date.
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5.18 Appendix R
Maintenance Procedures Manual
- Audit Schedule
See Insert
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5.19 Appendix S
Maintenance Procedures Manual
- Audit Findings
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