# Presentation: 676319

## ENHANCED REPAIR STATION AND AIR CARRIER OUTSOURCING OVERSIGHT SYSTEM

- Dan Bachelder

- June 8, 2006

## Briefing Points

- Background
- System Safety Concepts
- Program Goals
- Risk Based Oversight System for Repair Stations
- Air Carrier Outsourcing Tools
- Proposed Additional Enhancements
- Development Plan
- Conclusion

## The OIG/ACURS Workgroup was tasked by Flight Standards to develop a standardized system safety based oversight system for outsourcing and repair station oversight.  
The workgroup has developed a risk based oversight system that allows for continuous assessment of each repair station to re- target Flight Standards’ resources for use in the areas of highest risk. 
This system is for use by Flight Standards personnel involved in the certificate management including air carrier maintenance outsourcing and repair station oversight.  

**The workgroup has developed a risk based oversight system that allows for continuous assessment of each repair station to re- target Flight Standards’ resources for use in the areas of highest risk. **
**This system is for use by Flight Standards personnel involved in the certificate management including air carrier maintenance outsourcing and repair station oversight.  **

**Background**

## System Safety Concepts

**Safety should be built into the system, not added on to a completed design.**
**Safety is a property of the system, not a component.**
**Accidents are not always caused by failures and all failures do not cause accidents.**
**Analysis to prevent the accident is emphasized instead of reacting to the accident.**
**Emphasis is on identifying hazards as early as possible and then designing to eliminate or control those.**
**Recognize tradeoffs and compromises in system design.**** **

## Program Goals

**A comprehensive standardized approach to maintenance surveillance**
**Both**** air carrier maintenance outsourcing and repair stations are considered.**
**Allows for continuous assessment of air carrier outsourcing and repair stations**
**Target Flight Standards’ limited resources for use in the areas of highest risk.  **

**Program Goals**

## Risk Based Oversight System for Repair Stations

**Risk Based Oversight System for Repair Stations**

**A System Safety based approach**
**Applicable for oversight of any size certificate holder**
**Identifies specific procedures to enhance the oversight of repair stations.  **
**Comprised of a baseline surveillance program, a repair station data package, a repair station assessment tool, and a risk management tool**** **

## Risk Based Oversight System for Repair Stations

**1. ****Baseline Repair Station Surveillance Program **

**3. Repair Station Assessment Tool**

**6. Risk Management Process to be initiated for issues of concern**

**7. New Surveillance Program Data, RMP & Other Information**

**4. Modified Surveillance Program**

**5. Overall Assessment of Repair Station**

**2. Repair Station Data Package**

**Risk Based Oversight System for Repair Stations**

## 1.  Baseline Surveillance

**Divides the current PTRS activity codes 3650/5650 into 14 elements, which constitutes a complete facility inspection**
**Ensures that all aspects of 14 CFR 145 Repair Station operations are considered.**
**This partition better defines the intent of the FAA guidance and provides a more comprehensive surveillance structure.  **
**All applicable, triggered activity codes must be completed and closed before the 3650/5650 records are closed.  **
**	****Certificate Requirements****	****Personnel  **
**	****Records System ****	****	****Training **
**	****Manuals ****	****	****	****Conduct a Detailed In-Process/Task Inspection**
**	****Housing and Facilities ****	****	****Work Away From Station***
**	****Technical Data ****	**** ****	****Quality Control ****	**
**	****Tools and Equipment****	****	****Contract Maintenance***
**	****Parts and Material ****	****	****Air Carrier & Air Carriers Requirements***

## Used for both assessment and surveillance planning.   
Assists the PIs, other assigned inspectors, Supervisors, and Managers in identifying areas of concern or criticality about a specific repair station.  
As a result the PI may modify the Baseline Surveillance Program, begin a Risk Management Process for issues of concern or both.
Provides overall assessment of the repair station which will be utilized to populate the planning module.
Assists in targeting FAA resources for use in the areas of highest risk.

**Assists the PIs, other assigned inspectors, Supervisors, and Managers in identifying areas of concern or criticality about a specific repair station.  **
**As a result the PI may modify the Baseline Surveillance Program, begin a Risk Management Process for issues of concern or both.**
**Provides overall assessment of the repair station which will be utilized to populate the planning module.**
**Assists in targeting FAA resources for use in the areas of highest risk.**

**3.  Repair Station Assessment Tool**

## Air Carrier Outsourcing Oversight Enhancements

**Air Carrier Outsourcing Oversight Enhancements**

**A System Safety based approach**
**Applicable for oversight of any size certificate holder**
**Identifies specific procedures to enhance the oversight of outsourcing.  **
**Comprised of the current tools available to the air carrier certificate management offices and a new Outsource Oversight Prioritization Tool.  **

## Air Carrier Outsourcing Oversight Enhancements

**Air Carrier Outsourcing Oversight Enhancements**

**1. Repair Station Data Package**

**2. Outsource Oversight Prioritization Tool**

**4. New Surveillance Program Data & Other Information**** **

**3. Prioritized Outsource Oversight**** **

## 2.  Outsourcing Oversight Prioritization Tool

**To be used for surveillance planning.   **
**Will assist the 14 CFR Part 121, 121/135 and 135 (10 or more ) Principal Inspectors in prioritizing maintenance provider oversight.  **
**Will allow for prioritization of outsource surveillance for the coming year.  **
**Will target resources for use in the areas of highest risk****.**

## Additional Outsourcing Enhancements

- 14 CFR Part 121 Certificate Management Teams will conduct a detailed in-process / task inspection. Participation of team members will be by regional invitation. (Reference:  FAA Order 8300.10, Chapter 134.)
- Utilization of ATOS Elements 1.3.7 (Outsourcing) and 1.3.11 (CASS) be utilized for all 14 CFR Part 121 CMTs and interface with multiple chapter of FAA Order 8300.10, including Chapters 64/69.
- Quarterly utilization report created for air carriers include information regarding outsource maintenance.  This includes the type of work performed, number of visits to the top 12 leading outsource maintenance providers, and outsource maintenance as a percent of the total maintenance.  (Reference:  FAA Order 8300.10, Volume 3, Chapter 158.)
- Enhanced repair station oversight training for 14 CFR Part 145, Part 135 and Part 121 inspectors.

## Proposed Additional Enhancements

**Enhancements to the current PTRS system to improve data reliability.  These modifications involve the inclusion of the following information in the PTRS system.  **
**Only available for 3650/5650**
**This is not limited to 14 activity codes.  Other codes can be added as required.**
**Enhanced repair station oversight training for 14 CFR Part 145, Part 135 and Part 121 inspectors.**
**The overall assessment of all 14 elements will be shown.**
**The date the element PTRS was closed will be shown.**

## Potential Format – Only available for PTRS codes 3650 and 5650

PTRS Code 		Description 					
3604/5604		Certificate Requirements
3605/5605		Records Systems
3660/5660		Manuals
3657/5657		Housing and Facilities
3656/5656		Technical data
3658/5658		Tools and equipment
3601/5601		Parts and Materials
3659/5659		Personnel record
3661/5661		Training
3654/5654		Conduct a detailed
			in-process/task inspection
3606/5606		Work away from station*
3608/5608		Quality control 
3663/5663		Contract Maintenance*
3618/5618		Air Carrier requirements* 

***PTRS Code ******	******	******Description**** **	**	**	**	**	*
**3604/5604****	****	****Certificate Requirements**
**3605/5605****	****	****Records Systems**
**3660/5660****	****	****Manuals**
**3657/5657****	****	****Housing and Facilities**
**3656/5656****	****	****Technical data**
**3658/5658****	****	****Tools and equipment**
**3601/5601****	****	****Parts and Materials**
**3659/5659****	****	****Personnel record**
**3661/5661****	****	****Training**
**3654/5654****	****	****Conduct a detailed**
**	****	****	****in-process/task inspection**
**3606/5606****	****	****Work away from station***
**3608/5608****	****	****Quality control **
**3663/5663****	****	****Contract Maintenance***
**3618/5618****	****	****Air Carrier requirements***** **

** ****Additional Enhancements**

## Available for all 14 element PTRS codes and will possess the following three pull down menus:
Inspectors will utilize a pull down menu to describe sub-elements of concern.  The system allows for more than one to be selected.
Inspectors will utilize a pull down menu to describe the particular issue of concern for each of the sub-elements selected.
Inspectors will utilize a pull down menu with word pictures to assess the particular inspection.  Note:  overall assessment of the inspection will also be available for 3650/5650.

**Inspectors will utilize a pull down menu to describe sub-elements of concern.  The system allows for more than one to be selected.**
**Inspectors will utilize a pull down menu to describe the particular issue of concern for each of the sub-elements selected.**
**Inspectors will utilize a pull down menu with word pictures to assess the particular inspection.  Note:  overall assessment of the inspection will also be available for 3650/5650.**

**Additional Enhancements**

## It is recommended that element PTRS activities posses three pull down menus as shown below:
 e
				Example: Sub-element menu for Certificate Requirements Element: 
					Air Agency certificate
					Operation Specifications
					Capabilities List
					Geographic Authorization
					Line Maintenance Authorization
					Exemptions

				Issues of Concern for Certificate Requirements will be:
					Content/information
					Currency
					Revisions systems
					Distribution
					Availability
					Other

** *****e***
**	****	****	****	****Example: Sub-element menu for Certificate Requirements Element: **
**	****	****	****	****	****Air Agency certificate**
**	****	****	****	****	****Operation Specifications**
**	****	****	****	****	****Capabilities List**
**	****	****	****	****	****Geographic Authorization**
**	****	****	****	****	****Line Maintenance Authorization**
**	****	****	****	****	****Exemptions**
** **
**	****	****	****	****Issues of Concern for Certificate Requirements will be:**
**	****	****	****	****	****Content/information**
**	****	****	****	****	****Currency**
**	****	****	****	****	****Revisions systems**
**	****	****	****	****	****Distribution**
**	****	****	****	****	****Availability**
**	****	****	****	****	****Other**
**	****	****	****	**

***Sub-element***

***Issue of Concern***

**Proposed Additional Enhancements**

## 				Word Pictures to provide an overall assessment of the inspection

***Inspection Assessment***

**Proposed Additional Enhancements**

## Development Plan

- Phase 1:
- System Safety Based Oversight System for Repair Stations and Outsourcing including paper version of RSAT, RMP and OPT
- Policies and guidance including the new 3650/5650 and the corresponding 14 elements PTRS codes
- Process documentation – Work Instructions
- Process validation – table top testing of the process
- System Requirements to include automation and training for phase 2
- Phase 2:
- Enhanced PTRS System
- Comprehensive SPAS Repair Station Data Package
- Automated version of RSAT, RMP and OPT
- Testing and training of the new processes and tools

## This oversight system provides:
An enhanced risk based oversight system 
A comprehensive standardized approach to maintenance surveillance
Both air carrier maintenance outsourcing and repair stations are considered.
Allows for continuous assessment of air carrier outsourcing and repair stations
Target Flight Standards’ limited resources for use in the areas of highest risk.  

**An enhanced risk based oversight system **
**A comprehensive standardized approach to maintenance surveillance**
**Both**** air carrier maintenance outsourcing and repair stations are considered.**
**Allows for continuous assessment of air carrier outsourcing and repair stations**
**Target Flight Standards’ limited resources for use in the areas of highest risk.  **

**Conclusion**** **