Module No. 1 Aircraft Production II.

Procedures for certification and

continuing airworthiness of aircraft.
Aircraft production considerations/ factors in terms of III. Technical requirements for the
design: certificating of new large airplanes
1. Purpose designs
2. Environment IV. Deals with helicopters.
3. Regulation 2. Article 33 – state of registry to recognize and
4. Financial render valid airworthiness certificate issued by
5. Safety another contracting state.
3. Doc 9760 – breakdown of annex 8, airworthiness
• Aircraft production is done per station to be efficient.
manual and guidance on airworthiness related
• Airbus is in Europe - Toulouse, France
regulations.
• Boeing is in U.S. (Arlington, virginia) 4. Circular 95 - guidelines from state of design to
• A320 – worlds advanced passenger aircraft state of registry.
(currently)
FAR 21/EASA PART 21 – certification procedure for
Production of A320 products and parts
1. Assembly line (pre-fal) Product – engine, aircraft, or propeller
a. Problem: size
b. Bigger parts are manufactured from Product approval – document issued by the FAA to allow
different places/countries. the production of a product.
i. Wing, leading and trailing edge.
ii. Fuselage (forward aft center) State of design – country or jurisdiction having regulatory
iii. Vertical and horizontal tail plane authority over organization responsible for the design
iv. Pylon/nacelle
State of Manufacture - country or jurisdiction having
c. Transfer to headquarters using beluga
regulatory authority over organization responsible for the
aircraft
production.
2. Final assembly
a. Station 59 ETSO – European Technical Standard Order
i. Cabin monument installation
• Cabin crew rest EPA – European part approval
lavatory
ELA 1 – European Light Aircraft
ii. Outfitting process
• Electrics and hydraulics Sub part J – design organization
b. Station 50
i. Structural Fuselage join up Sub part G – production organization
• 3 biggest parts
23 – normal utility aerobatic
• Manually riveted
• CIGAR 25 – large airplanes
c. Station 40
i. Cabin-wing fuselage join up 27 – small rotorcraft
ii. First power on 29 – large rotorcraft
iii. H and V tail cone installed
iv. Pylon 31 – Gas Balloons
v. Main landing gear
d. Station 30 33 – engines
i. Cabin customization
35 – Propellers
ii. Indoor ground test
e. Station 20 34 – aircraft engine emission and fuel venting
i. Engine installation
ii. Cockpit furnishing 36 – aircraft Noise
f. Station 18
i. Outdoor ground test Certificates:
ii. Final testing Type Certificate (TC) – issued when the design complies
g. Painting with the standard, from SOD to manufactures
Regulations: Restricted Type Certificate / Provisional – issued for new
International Civil Aviation Organization (ICAO) invention w/o current rules and standards

1. Annex 8 – airworthiness, march 1 1949, Supplemental TC – issued as additional certificate with

standards, minimum basis modification/alterations done
I. Definitions
Product Certificate – given by SOD Aloha airlines flight 243 1988
Airworthiness Certificate – C of A, given by SOR 1 casualty
Aircraft Registration Requirements for TC: 89+ flight cycle
1. Technical Overview and Certification process 35+ flight hours
a. Primary certificating Authority
b. Submit papers to easa or faa 19/20 life span
c. 5 yrs for aircraft and 3 years for engine CPCP corrosion prevention and control program, 1988
2. Certification program – check guidelines.
3. Compliance Demonstration ⁃provided by the manufacturer.
a. Ground test/flight test
4. Technical closure and issuance of TC – PCA ⁃Prevent and control corrosion
closes investigation.
A. Level 1 - within acceptable/allowable limit, corrosion
Module No. 2 basic maintenance program would be blended out.

Base - involves the removal of an aircraft from service,
for a longer period usually more than one day and could
be up to thirty (30) days. This occurs in a hangar, where
the aircraft is separated from its operating environment;
specialized tools and equipment are required.
B. Level 2 - outside the acceptable limit, blended out
modified or replace.
C. Level 3- potential airworthiness concerns require
urgent action.

Line - is carried out on the apron, during turnarounds, SSIP, SUPPLEMENTAL STRUCTURAL inspection
while the aircraft remains in its operating environment. program

Component - Avionics units, various mechanical and - half service life

electrical aircraft and engine components, and even the - High flight hrs/cycle
entire engines are among some of the components that - Structural concern
are inspected in detail in a specialist shop, after being - Proactive/preventive approach
removed. SSID, SUPPLEMENTAL STRUCTURAL INSPECTION
Maintenance Program – a document which describes the DOCUMENT
specific maintenance task and their frequency - reactive/corrective approach
completion. - contains the recommendation for the inspection
Air Navigation Order article 2567 procedures and replacement or modification of
parts
Maintenance Planning Document – document which
contains all the MRB requirements plus the mandatory PSE principal structural element
scheduled requirements. Are provided by the - load carrying items
manufacturers to describe repetitive task that are
required to maintain their aircraft. FCS flight control system
MSI: Maintenance Significant Items, has cause and LOV Limit of validity
effect. E.g., pump
TCH type certificate holder
SSI: Structurally Significant Items,
AOC Air operator certificate
AWL: Airworthiness Limitations, life limited parts
ALS airworthiness limitation section
-flights hours
ICA Instruction for continued airworthiness
-flight cycles
CMR: Certification Maintenance Requirements, no limits
Questions
MRBR: Maintenance Review Board Report
1.Faulty design about 737 (Activity)
⁃outlines the initial minimum requirements
- MCAS MANOEUVRING CHARACTERISTIC
⁃Provided by the manufacturer Augmentation System is the faulty design

MSG-3 Analysis: Maintenance Steering Group 2. Steps of assembly line (stations).

Formula= MRBR + CMR + AWL= MPD 1. Assembly line - biggest parts are
manufactured from different places.
 2. Final assembly line
Station 59, cabin monument installation electrics and
hydraulics
Station. 50, 3 biggest parts structural fuselage join up
cigar manually riveted
Station 40, CWFJ first power on h, v tail and tail cone
installed pylon and main landing gear
Station 30, cabin customization indoor ground test
Station 18, outdoor test
Painting
Station 20, engine installation cockpit furnishing
3. Differentiate MRBR to MSG.
MRBR outlines the initial minimum scheduled
maintenance/inspection requirements to be used in the
development of an approved continuous airworthiness
maintenance program.
MSG It provides a process which is used for developing
scheduled maintenance tasks and intervals, which will be
acceptable to the regulatory authorities, the operators
and the manufacturers.
4. Explain MCAS and sensor
MANOEUVRING CHARATERISTIC AUGMENTATION
SYSTEM, is connected to the angle of attack sensor. The
MCAS design parameters originally envisioned
automated corrective actions to be taken in cases of high
AoA and g-forces beyond normal flight conditions.
5. Differentiate line base and component
maintenance.
This Aspect of maintenance is carried out on the apron,
during turnarounds, while the aircraft remains in its
operating environment. Part 145 regulations define line
maintenance as any maintenance tasks that can be
performed outside of a hangar, under open skies. Tasks
related to line maintenance are relatively straightforward,
and often involve routine in-service inspections, daily
check actions, troubleshooting and rectifications.
Components designated as Line Replaceable Units
(LRUs) can be replaced during this time. Line
maintenance is usually limited by the availability of
ground support equipment.
Avionics units, various mechanical and electrical aircraft
and engine components, and even the entire engines are
among some of the components that are inspected in
detail in a specialist shop, after being removed. LRUs
also face the same fate. In this type of maintenance, you
will be working on specific detached parts, rather than on
the aircraft itself. A Component Maintenance Manual
(CMM) is used to identify the tasks that should be carried
out on a particular component. It includes the procedures
for restoring the component to a serviceable state.
6. Corporate Culture ng Boeing.
Robison points out that Boeing’s culture of listening to it’s
engineers and making a habit of considering their input
was key to their success. Well the culture began to
change in the late 1990’s and that coincided with the
1997 merger with McDonnell Douglas Corp. Many within
Boeing felt this was the beginning of a long descent into
a focus on profit over safety.The very culture at Boeing
appears to be broken, with some senior employees
having little regard for regulators, customers and even
co-workers. Perhaps most tellingly, the documents show
Boeing employees repeatedly questioning the
competence of their own colleagues, and the quality of
the company's engineering.
7. Aircraft Process Certification.
8. How can Lack of training be a cause of crash?
Without adequate knowledge, employees will not be able
to follow basic safety precautions and this may cause an
accident.
9. CAMO VS CAMP.
Continuing Airworthiness Management Organization
(CAMO) approval: supporting documentation.
Information for military aviation duty holders regarding
their continuing airworthiness of their military air systems
responsibilities
A CAMP is a certificate holder/program manager-
developed maintenance program and is authorized for
use by FAA-issued Operations Specification
(OpSpec)/Management Specification (MSpec) D072,
Aircraft Maintenance – Continuous Airworthiness
Maintenance Program (CAMP)
10. Explain the FAA provision license/certificate.
A provisional category special airworthiness certificate is
issued to conduct special purpose operations of aircraft
with provisional type certificates. The duration of this
airworthiness certificate is limited to the duration of the
provisional type certificate. Two classes of provisional
type certificates may be issued. Class I certificates may
be issued for all categories and have a duration of 24
months. Class II certificates are issued for transport
category aircraft only and have a duration of 12 months
12. Differentiate flight hours and flight cycles.
Flight hours (FH) refer to the actual number of
hours flown by the aircraft over a specific period from the
time it lifts the wheels from the ground during take-off to
the time the wheels touch the ground during landing.
While Flight Cycles (FC) includes take-off and landing
runs
13. What are the Aircraft Manufacturers.
Boeing, Airbus, textron, lockheed martin corp, safran,
bombardier, gulfstream aerospace
14. 4 type certificate process - explain each.
a. technical overview and certification process. The
product designer presents the project to the primary
certificating authority (PCA). 5 yrs for ac and 3 yrs for
engine. Submit docs.
b. Certification programme. Checks the guidelines
c. Compliance demonstration, ground test and flight test
d. Technical closure and type certificate,pca close
invesetigation issues TC. validation is carried out under
a Bilateral Aviation Safety Agreement (BASA)
15. 4 regulatory bodies in the country (ICAO, FAA,
EASA, CAAP). No abbreviation.
ICAO - international civil aviation organization
FAA - Federal Aviation Administration
EASA - European Union Aviation Safety Agency
CAAP - Civil Aviation Authority of the Philippines
16. The design process identifies 4 things. SSI, etc.)
Airworthiness Limitations AWL
Certification maintenance requirements CMR
Maintenance Significant Items MSI
Structurally Significant Items SSI
17. Difference between Type certificate and
Airworthiness Certificate.
TC - issued by the state of design
C of A - issued by stet registry, per aircraft
A Type Certificate is a certificate that the FAA gives the
manufacturer of an aircraft, certifying the design of the
aircraft
if you make a major modification to a certified aircraft, it
requires an STC-- a "Supplemental Type Certificate," to
confirm that with the new equipment, the aircraft design
is still airworthy and the limitations are accurate
On the other hand, an Airworthiness Certificate is issued
for each aircraft individually and certifies that this here
particular airplane is airworthy.
18. Difference between Type certificate and
supplemental certificate.
A supplemental type certificate ( STC ) is a type
certificate ( TC ) issued when an applicant has received
FAA approval to modify an aeronautical product from its
original design.
type certificate (TC) is a document by which the authority
states that an applicant has demonstrated the
compliance of a type design to all applicable
requirements.
19. Fill in the blanks: Airworthiness PCAR PART _ .
(5)
Part 5
20. EASA Part 21 and FAR 21
Certification procedures for ac and related products
parts and appliances and of design and production
organization
21. Explain Aloha airlines and its connections to
cpcp.
Fatal accident cause due to detached front fuselage
caused by corrosion
22. Airbus Assembly Line together with Final
assembly line.
23. Factors considered before aircraft production.
- purpose
- Environment carbon emission
- Regulation patent laws
- Financial costs
- Safety