DESIGNATED MANUFACTURING INSPECTION REPRESENTATIVE

Designated Manufacturing Inspection Representative (DMIR) basically: 1. Conduct conformity inspections to determine that prototype products and related articles conform to the design specifications. 2. Conduct any inspections to determine that production products and related articles conform to the approved type design and are in a condition for safe operation. 3. Assist FAA to determine the suitable means of compliance in term of manufacturing process of the product. 4. Issue original standard or special airworthiness certificate for eligible aircraft and airworthiness approvals for products and articles at Boeing's facility, only when it has been determined that the products to the approved design requirements and are in a condition for safe operation. In this case, original standard airworthiness certificate is issued to B737-800 with added electrical taxiing system.

With the supplemental type certificate, as stated by FAR 21 section 123, the Boeing need to: 1. Make each product available for inspection by DMIR. 2. Maintain at the place of manufacture the technical data and drawings necessary for the DMIR to determine whether the product and its parts conform to the type design.

Under FAR 21 section 125, Boeing is then required to establish a production inspection system as stated in section 13 (c). Boeing shall: 1. Establish a Materials Review Board (this include the representative from the inspection and engineering departments) and materials review procedures. 2. Maintain complete records of Materials Review Board action for at least two years.

The production inspection system must then provide means for determining at least the following: 1. Incoming materials, and bought or subcontracted parts, used in the finished product must be as specified in the type design data, or must be suitable equivalents. 2. Incoming materials, and bought or subcontracted parts, must be properly identified if their physical or chemical properties cannot be readily and accurately determined. 3. Materials subject to damage and deterioration must be suitably stored and adequately protected. 4. Processes affecting the quality and safety of the finished product must be accomplished in accordance with acceptable industry or United States specifications. 5. Parts and components in process must be inspected for conformity with the type design data at points in production where accurate determinations can be made. 6. Current design drawings must be readily available to manufacturing and inspection personnel, and used when necessary. 7. Design changes, including material substitutions, must be controlled and approved before being incorporated in the finished product.

8. Rejected materials and parts must be segregated and identified in a manner that precludes installation in the finished product. 9. Materials and parts that are withheld because of departures from design data or specifications, and that are to be considered for installation in the finished product, must be processed through the Materials Review Board. Those materials and parts determined by the Board to be serviceable must be properly identified and re-inspected if rework or repair is necessary. Materials and parts rejected by the Board must be marked and disposed of to ensure that they are not incorporated in the final product. 10. Inspection records must be maintained, identified with the completed product where practicable, and retained by the manufacturer for at least two years.

Under FAR 21 section 130,

Boeing is required to submit to FAA a statement of

conformity (FAA Form 317) which is signed by an authorized person who holds a responsible position in the manufacturing organization and must include a statement that the product conforms to its type certificate and is in condition for safe operation. FAR 21.139 requires Boeing to establish and maintain a quality control system for the product. DMIR will inspect the quality control system of Boeing manufacturing facility to ensure that the facility has the ability to maintain the quality in its production line.

Under FAR 21.143, Boeing must submit, for approval, data describing the inspection and test procedures necessary to ensure that each article produced conforms to the type design and is in a condition for safe operation, including: 1. A statement describing assigned responsibilities and delegated authority of the quality control organization, together with a chart indicating the functional relationship of the quality control organization to management and to other organizational components, and indicating the chain of authority and responsibility within the quality control organization; 2. A description of inspection procedures for raw materials, purchased items, and parts and assemblies produced by Boeing's suppliers including methods used to ensure acceptable quality of parts and assemblies that cannot be completely inspected for conformity and quality when delivered to the Boeing's plant; 3. A description of the methods used for production inspection of individual parts and complete assemblies, including the identification of any special manufacturing processes involved, the means used to control the processes, the final test procedure for the complete product; 4. An outline of the materials review system, including the procedure for recording review board decisions and disposing of rejected parts; 5. An outline of a system for informing company inspectors of current changes in engineering drawings, specifications, and quality control procedures; and 6. A list or chart showing the location and type of inspection stations.

7. Boeing shall make available to the FAA, information regarding all delegation of authority to suppliers to make major inspections of parts or assemblies for which the prime manufacturer is responsible.

Boeing is then entitled to a production certificate, once it has complied with FAR 21.139 and FAR 21.143 after the examination of supporting data and after inspection of the

organisation and production facilities. After obtaining supplemental type certificate and production certificate, Boeing is then entitled to an airworthiness certificate for the addition of electrical taxiing system on the new B737-800 fleets.

FLIGHT TEST AND GROUND TEST Following the award of the airworthiness certificate, Boeing need to do ground and flight test to prove that addition of electrical taxiing system is not affecting the overall system of the B737800 and to prove that B737-800 is safe to fly. Ground test includes demonstration of the whole taxiing process of B737-800 from the airport gate to the runway. The taxiing system should not affect the current system on the aircraft especially the landing gear system where the motor is installed. At the runway, the aircraft is required to take off and then land safely. This process will prove that the installation of the motor does not affect the operational behaviour of the landing

gear. Extra weight due to the motor should not cause extra stress on the landing gear. Stress analysis is done on the landing gear during and after landing of the aircraft. Test procedure 1. Boeing will provide Letter of Definition to FAA. Letter of definition defines the programme that is being done and need to be tested. 2. Engineering division that handle the project will submit Engineering Work Authorisation to Boeing. 3. Flight test details is issued by Boeing. The details include: a. Test schedule b. Analysis from the test result c. Instrumentations that involved during the test 4. Flight test specification is provided by Boeing and the approved by FAA. It contains the general description of the test. 5. Test item planning sheet (TIP sheet) that contains detailed test description is also provided by Boeing and then reviewed by FAA test crew. 6. Boeing need to fill up Type Inspection Authorisation (TIA) form that contains the description of alteration done, that is installation of electrical taxiing system. Under section 18(a), Boeing need to show that the aircraft with the installed taxiing system that will be used in the testing is as described in the Letter of Definition. Section 18(b) defines the tests that is necessary to prove the safe operation of the aircraft. TIA is needed before the testing. 7. Testing is done.

8. After the test, certification report is written by the flight test crew, coordinated with project engineer and approved by FAA/DER. 9. Type Inspection Report is then written by flight test crew and approved by FAA/DER. After these procedures, and if the test is able to prove that the aircraft is safe to fly with the installation of electrical taxiing system, Boeing is now ready to prepare the maintenancerelated documents for the electrical taxiing system.

Figure 1 Test procedure