CIVIL AVIATION REQUIREMENTS
SECTION 6- DESIGN STANDARDS & TYPE CERTIFICATION
SERIES 'B', PART I
ISSUE I, DATED 20th AUGUST, 1999 EFFECTIVE: FORTHWITH
Subject: APPROVAL OF DESIGN ORGANISATIONS
1.
INTRODUCTION
Rule 133B of the Aircraft Rules, 1937 stipulates that organisations engaged in design
and manufacture of aircraft, aircraft components and items of equipment including
materials, forgings, castings and standard parts shall be approved by the Director
General of Civil Aviation. DGCA may, on request and being satisfied, approve an
organisation to operate under the system of approval. For operating under an
approved system, the organisation or person shall comply with such requirements as
may be specified by the DGCA. An approved organisation shall provide, for the use
and guidance of its personnel, manuals which shall contain details of information
concerning policies, procedures, practices and quality control methods relating to
activities of that organisation and as may be specified by the DGCA.
This CAR lays down the requirements for approval of design organisation and is
issued under the provisions of Rule 133A of the Aircraft Rules, 1937.
2.
APPLICATION FOR APPROVAL
An organisation seeking approval for design activities should apply to DGCA on the
form CA 182E (Appendix 'A') along with the applicable fees as laid down in Rule
133C of Aircraft Rules, 1937. The application along with the enclosures, should be
submitted in duplicate to: DGCA (Attn.: Director, Research and Development),
Technical Centre, Opposite Safdarjung Airport, New Delhi -110003.
CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
3.
REQUIREMENTS FOR GRANT OF APPROVAL
An organisation seeking approval for the design and development of product or part
shall comply with the following requirements:
3.1
The design organisation shall have sufficient staff as may reasonably be expected to
undertake the airworthiness investigation of the volume of work in the class for which
approval is sought. The staff shall include (as applicable) specialists qualified in all
branches of aeronautics. It shall be demonstrated that satisfactory formal
arrangements exist by which adequate access to such necessary expertise is available
for the purpose of conducting work under the authority of the organisation' s design
office.
3.2
The applicant for approval shall nominate the following persons:
a) The person in direct charge of the design organisation: Chief of Design
b) The technical director or senior executive to whom the person directly in charge
of the design organisation is responsible.
c) Other senior members of the design organisation and of related departments.
d) Authorised persons to approve design and test reports, certificates and other
documents.
3.3
The applicant shall provide a "Design and Engineering Organisation Manual" (refer
Appendix B for guidelines) of the design organisation, including the following
information:
a)
The terms of reference of senior personnel, as applicable to activities under
DGCA approval.
b)
The associated chains of responsibility.
c)
The scope of the design office facility, together with information on essential
procedures, test equipment and records.
d)
The procedures adopted for conducting inspections, tests, examinations, and
reporting thereon.
e)
Any further matters that the DGCA decides as necessary arising from initial
assessment or subsequent supervisory visits.
f)
The arrangements by which work may be undertaken on behalf of the
organisation.
CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
3.4
Two copies of the Design and Engineering Organisation Manual and all subsequent
amendments shall be supplied to the R & D Directorate of DGCA and one copy each
to the Regional office of R & D Directorate and Airworthiness Directorate wherever
applicable.
3.5
The design office shall be so organised that, unless otherwise agreed by the DGCA,
all assumptions, calculations, drawings and reports on which airworthiness depends
are subject to verification. Such verification shall involve checking by a person other
than the one who did the original work and may take the form of suitable tests
ensuring the basic accuracy of the calculations and drawings.
3.6
Design records shall be such as to provide substantiation of, and proper correlation
between, all the data comprising the design. The method used shall be such as to
make possible the provision of the necessary design information of any product on
which the airworthiness of an aircraft may depend as long as the product may be in
service, and until such time after as may be agreed by the DGCA.
3.7
The qualifications and experience of the design office staff shall, to the satisfaction of
the DGCA, be adequate to conduct the work and in establishing compliance with the
requirements, and shall be such as to ensure that good judgment is exercised with a
full appreciation of current aeronautical practices in design matters, whether or not
specifically covered by requirements. The management of the organisation shall take
into account the needs of airworthiness requirements as appropriate to the class of
work to be undertaken under the Terms of Approval.
3.8
The organisation shall, to the satisfaction of the DGCA, be such as to ensure that, in
all matters affecting airworthiness, full and efficient co-ordination exists within the
design office and related technical departments, and between the design office and
other departments of the organisation.
3.9
The organisation shall have facilities, or access to suitable approved facilities, for
making such tests as are necessary to establish compliance with the requirements. The
calibration of test equipment shall be checked as frequently as is necessary to
maintain confidence in the accuracy of the equipment.
3.10
The applicant shall have facilities, or access to suitable approved facilities, for
producing and publishing the appropriate technical information required for the safe
operation, maintenance, overhaul and repair of the items for which the organisation is
approved and, where applicable, the arrangements shall include notification, by
documents such as Service Bulletins, of mandatory modification and inspections duly
approved by DGCA. The manufacturer and owner of the aircraft shall be provided
with such information.
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
3.11
An organisation approved as a design organisation placing orders on suppliers and
unapproved organisations shall satisfy itself that the origin of each item supplied is
identified and satisfied that the item is acceptable and suitable for the intended
purpose. DGCA representative shall have access to such organisations.
3.12
The design organisation and the manufacturing organisation shall submit to the
DGCA a detailed description of the means by which they will meet the DGCA' s
requirements for continued airworthiness, for the project and will provide suitable
undertakings to ensure that such requirements are met throughout the life of the
product.
3.13
The organisation, seeking approval, shall provide suitable office space and facilities
within the premises of design organisation for DGCA representatives.
4.
4.1
GRANT OF APPROVAL
Granting of the approval for design and development of product or part will be
dependent upon the request of the applicant and his capability/ capacity to perform the
design work as adjudged by DGCA. The scope of work will be specified in the
approval while granting initial approval or extending the approval of the organisation.
Part approval or provisional approval shall not be granted.
4.2
On receipt of completed application form and its scrutiny by DGCA, a preliminary
meeting will be convened with the applicant to get familiarised with the organisation.
The organisation will be apprised of the various requirements of DGCA and the
documents required to be submitted, including compliance against various paragraphs
of this CAR.
4.3
On scrutiny of the documents if the applicant is found to meet the requirements, a
team of experts from DGCA will visit and inspect the organisation to confirm that the
applicant has established the required capability.
4.4
The DGCA team during its course of visit shall satisfy that the organisation can
satisfactorily accomplish the work relevant to the proposed scope of work.
4.5
Subject to the satisfactory report made by the DGCA team, the organisation may be
authorised to undertake the work and issue 'design/analysis/test report' in respect of
the product. The organisation shall be approved and the scope of work will be
defined.
4.6
The validity of approval shall not exceed one year.
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
4.7
In the event of organisation wishing to increase the scope of its existing approval, it
must make a fresh application to the DGCA [Attn.: Director (Research &
Development)]. On being satisfied that the proposed additional work can be carried
out and the applicant has developed sufficient capability to carry out the additional
work in accordance with this CAR, DGCA may enlarge the scope of work.
5.
5.1
RESPONSIBILITIES OF DESIGN ORGANISATION
The organisation shall be responsible for ensuring:
a) That the Type Record associated with the Type Certification standard of the
aircraft, including the Type Certificate Data Sheet and other associated
documents, and all approved variants and modifications introduced with their
agreement since the original Type Certification, is held, maintained and updated
as necessary.
b) That inspection records of all aircraft/components released by them for
Airworthiness Certification under the Type Certificate are properly maintained.
c) That where possible, service experience is monitored to provide them with
information on problems and defects affecting aircraft in service.
d) That all problems and defects affecting airworthiness, of which they become
aware, are investigated and, where appropriate, corrective action made available
to operator. This may be by introducing modifications and/or by promulgating
instructions/advice to users by Service Bulletins or by other suitable means.
e) That the investigation carried out under sub-para (d) identifies those significant
problems and defects affecting the intended airworthiness certification standard of
the aircraft and that Regional Airworthiness and R & D Offices of DGCA are
notified accordingly.
f) Co-operation with the DGCA to determine and publish those actions essential for
airworthiness reasons, based on the result of service or other experience.
g) That master copies of all Flight and Technical Manuals are maintained and
updated as necessary to reflect changes for which they are responsible.
Amendments to manuals shall be published and distributed.
5.2
The organisation shall retain these responsibilities until there are, to their knowledge,
no aircraft of the type registered and eligible for airworthiness certification in India
and elsewhere under the Type Certificate.
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
6.
RENEWAL OF APPROVAL
The organisation shall apply at least 30 days before the expiry of the validity of
approval and specifically confirm that the capability of the organisation has not
degraded in any manner.
7.
GENERAL REQUIREMENTS
The organisation shall meet the following requirements at all times during the validity
of approval:
7.1.
The organisation shall be maintained at the standard necessary to undertake the work
for which it is approved and the DGCA shall, at all reasonable times, have access to
the organisation for the purpose of assessing the standard in use.
7.2.
Any change of the Chief Executive shall be notified to the DGCA in writing. The
DGCA may require the organisation to supply further information in order to satisfy
itself of the suitability of the official concerned insofar as it may affect the DGCA
approval of the organisation.
7.3.
Changes in the persons nominated in accordance with paragraph 3.2 shall be notified
to the DGCA in writing. Such changes require prior approval of DGCA.
7.4.
The "Design and Engineering Organisation Manual" required under para 3.3 shall be
reviewed periodically by the Organisation and necessary amendments should be
promulgated after due approval from DGCA.
7.5.
An approved organisation shall provide, for the use and guidance of its personnel,
manuals which shall contain details of information concerning policies, procedures,
practices and quality control methods relating to activities of that organisation and as
may be specified by the DGCA.
7.6.
The organisation shall consult the DGCA if in any difficulty about the interpretation
of the Civil Aviation Requirements, associated procedures or on any airworthiness
matter which in their opinion involves new problems or techniques.
7.7.
At all reasonable times DGCA representatives shall have access to all drawings,
calculations, reports and records relating directly to the airworthiness of an aircraft,
engine, or any part thereof. Before conducting any test, the organisation shall inform
DGCA about the test program and furnish test schedules at least one week in advance.
7.8.
The organisation shall keep the DGCA representatives fully informed of all defects
and problems that may arise during design, development and inspection and which
could have a bearing on airworthiness.
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
7.9.
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
To review the deviations, limits and tolerances beyond those given in drawings,
manufacturing defects, material substitution, etc., a Material Review Board (MRB)
should be constituted by the organisation. The MRB should comprise designers,
production & quality control personnel and DGCA representatives.
7.10. In order to provide information on problems and defects of aircraft, engine or part in
service, the organisation shall maintain a suitable monitoring system. If, subsequent to
approval of an aircraft, engine or part, the organisation becomes aware of defects
which affect the continuing airworthiness of the product, the organisation shall take
necessary corrective action. Organisation shall also maintain the record of such
defects/ deficiencies. DGCA shall be informed of all such corrective actions.
7.11. The DGCA may withdraw, suspend or vary the terms of approval if, in the opinion of
the DGCA, the conditions required for approval are not complied with. The terms of
approval may also be varied as a result of changes in the company.
Sd/(B.K. JOSHI)
Dy. DIRECTOR GENERAL OF CIVIL AVIATION
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
APPENDIX 'A'
APPLICATION FOR APPROVAL OF DESIGN ORGANISATION
FORM CA-182E
1.
Name & Address of the Firm/Organisation
2.
Brief Details of the nature of work for which
approval is sought
3.
Location of the firm/organisation
4.
Number of employees
(a) Design office
(b) Production and inspection staff
5.
Names, qualifications and experience of
(a) Chief of Design
(b) Dy. Chief of Design
(c) Chief Quality Control Manager
6.
List of facilities/infrastructure
(a) Design/Drawing offices
(b) Manufacturing facilities/infrastructure
(c) Inspection equipment including special
equipment
7.
Existing DGCA authority, if any
8.
Whether a general layout of the firm/
organisation is attached (write Yes or No)
9.
Details of Fees remitted
Date : _______________
(Signature of the applicant)
Note : Extra sheets may be attached to furnish additional information, if any.
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
APPENDIX 'B'
GUIDELINES FOR PREPARATION OF DESIGN AND ENGINEERING
ORGANISATION MANUAL
1. The Design and Engineering Organisation Manual will form the basis of DGCA approval
of the Organisation.
Requirements for preparation of Manual
2. Identification. The Manual should contain the following:
a) Name of the organisation, document title and reference number.
b) Amendment standard by issue number/date/amendment record.
c) Approval by Chief of Design.
d) Distribution list.
e) Official title of person responsible for administration of the Manual.
f) Contents List or Index.
3. Introduction. The introduction should explain the purpose of the document for the
guidance of the Organisation' s own personnel, and should give general information and
profile of the organisation, in order to provide background information to the DGCA.
Where appropriate, relationships with other Organisations, forming part of the same
group, should be mentioned.
4. Organisation's Premises and Undertakings. Brief details of premises should be
included quoting addresses, approximate floor space, and types of buildings. The scope of
the Organisation' s aerospace undertakings, at the addresses of the various premises,
should be defined.
5. Terms of Approval. The Manual will form the basis of DGCAs approval. A concise
definition of the work authorised will be prescribed in the DGCA terms of approval. It is
recommended that the DGCA approval are reproduced and included in the Manual. The
schedule of approval may, in some cases, be supplemented by Capability Lists. A
Capability List must bear an issue number and date and may not be amended without the
agreement of the DGCA. A note to this effect should be included at the bottom of the
page.
6. Personnel. This Section of the Manual should nominate the persons required under
paragraph 3.2 of this CAR, giving their terms of reference within the Organisation, and,
in particular, outlining responsibilities for liaison with DGCA.
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
a) A diagram, or diagrams, showing chains of responsibility of nominated departmental
heads, and senior technical personnel up to the Chief Executive, should be included.
These diagrams should also indicate, by suitable means, and/or written description,
how technical co-ordination through out the organisation is effected.
b) The "Personnel" Section should also contain a list of Approved Persons as
design/analysis/test reports signatories giving their names, positions in the company,
and three sample signatures. Details of certification responsibilities should be
included.
c) In some cases, the Organisation may wish to include more information, concerning
personnel and their responsibilities, than is required by the DGCA, but amendments to
the Manual which affect nominated staff, as required by CAR, must not be made
without DGCA concurrence.
7. Facilities. This Section should provide information concerning the organisation' s
technical facilities and associated essential equipment, which will vary according to the
type of activity involved and the specific terms of approval sought.
7.1 Under the Section devoted to facilities, information under the headings given below
should be included, where applicable. If there is a good deal of detailed information
the use of Appendices is recommended.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
Research.
Design/Drawing Office.
Development.
Type Testing.
Planning.
Manufacture and/or Process.
Overhaul and Repair.
Routine Testing.
Storage.
Quality assurance and /or Inspection.
Metrology and Standards.
Specialised Facilities e.g. NDT, Spectrography.
Publications and Library.
Technical Records.
Product Support.
Training.
7.2 The headings should be varied to suit the size of the Organisation and its activities.
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CIVIL AVIATION REQUIREMENTS
SERIES 'B' PART I
SECTION 6- DESIGN STANDARDS &
TYPE CERTIFICATION
20TH AUGUST, 1999
8. Procedures. A concise description is required of the Organisation' s technical procedures
covering all aspects of work conducted within the DGCA Terms of Approval; this should
show how matters affecting airworthiness are controlled, by references, where
appropriate, to existing internal instructions. In order to meet the Requirements,
Organisations may elect to establish a Quality control system. The system adopted will,
obviously, depend on the size and complexity of the Organisation and the nature of the
work undertaken.
8.1 The headings below are examples of the procedures which may need to be covered in
this Manual:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
Quality program, policy and administration, including the Quality Audit system.
Product design and development control.
Modification procedures.
Concession procedure.
Product evaluation, including product approval, field responsibility and defect
investigation.
Reliability programs.
Control of bought-out items, including Quality Control Surveillance of subcontractors.
Manufacture and process control.
Control of stock, including procedures for handling non-conforming parts.
Tool, metrology and test equipment control.
Process Control.
Technical records.
Technical publications control, including Service Bulletin procedures.
Equipment overhaul, modification and repair procedures, including certification.
Test flight procedures.
Training.
Appendices, giving examples of (i) standard forms, cross referenced to the written
procedures section; (ii) tags indicating the purpose and use of each (III) inspection
stamps, and other identification symbols used top indicate status of parts;(IV)
approved certificate and/or Test Certificate.
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