Havacılıkta kalite ve JAR 145 onaylı bakım organizasyonu /
Yazar: A.ONUR YILMAZ
Danışman: DOÇ. DR. SEMRA DURMUŞOĞLU
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / İşletme Mühendisliği Ana Bilim Dalı
Derece: Yüksek Lisans, 1998
Konu: Mühendislik Bilimleri = Engineering Sciences ; İşletme = Business Administration
Dizin: Havacılık = Aviation ; ISO 9000 = ISO 9000 ; JAR 145 = JAR 145 ; Kalite güvence sistemi = Quality assurance system ; Onarım = Repair ; Standartlar = Standards

Özet:
2000'li yılların eşiğinde olduğumuz şu günlerde, her alanda artan rekabet koşulları, değişen müşteri talepleri ve hızlı bir şekilde gelişen bilim ve teknoloji, şirketleri yeniden yapılanmaya zorlamaktadır. Bu yeniden yapılanmada esas alınan öğe ise, 1980'li yılların başından itibaren toplumları dalgalar halinde saran kalite hareketidir. Kalite kavramının önem kazanması ile birlikte yeni sistemlerin kurulmasında referans olarak kullanılabilecek birçok kalite standardı yayınlanmıştır. Uluslararası Standardizasyon Teşkilatı tarafından yayınlanan ve en yaygın olarak kullanılan kalite standartları, ISO 9000 standartlarıdır. Bunlardan ISO 9001, tasarım/geliştirme, imalat, tesis ve hizmette kalite güvence olarak tanımlanan ve kapsamı en geniş olan standarttır. ISO 9002, tasarım/geliştirme dışında ISO 9001 'in tüm gerekliliklerini içerir. ISO 9003 ise son muayene ve testlerde kalite güvence sistemi olarak- tanımlanır. Yukarıda da belirtildiği üzere, kalite kavramının önem kazanmasının ve yeniden yapılanma ihtiyacının ortaya çıkmasının nedenlerinden birisi de teknolojik gelişmelerdir. Hava araçları da bu teknolojik ürünlerden birisidir. Bir hava aracının kendisinden beklenen güvenilirlik, hız, dayanıklılık, estetik gibi özelliklere sahip olabilmesi için kaliteyi temin edecek kurallara uygun şekilde tasarlanması, imal edilmesi, bakımının yapılması ve işletilmesi gerekir. Havacılık faaliyetlerinin başlamasından itibaren gerek ulusal gerekse uluslararası kuruluşlar tarafından bu amaçlara yönelik kurallar ve düzenlemeler yayınlanmıştır. Bugün ISO 9000 standartları havacılık sektöründe de geçerli ve kullanılmakta olan bir standart olmasına karşın, havacılık sektörü için özel olarak hazırlanmış standartlar tercih edilmektedir. Havacılık sektöründe söz sahibi olan ve çeşitli standartlar ve kurallar yayınlayan kuruluşlardan en önemlileri şunlardır: Uluslararası Sivil Havacılık Teşkilatı (ICAO), ABD Sivil Havacılık Teşkilatı (FAA) ve 1990 yılında Avrupa Sivil Havacılık Teşkilatları tarafından kurulan Birleşik Havacılık Otoriteleri (JAA). Bir hava aracının bakımının belirli kurallar çerçevesinde uygun tesislerde yapılması, güvenilirlik, zamanında uçuş ve maliyetlerin enaza indirilmesi bakımından son derece önemlidir. JAA tarafından sivil havacılık sektörüne hizmet veren bakım organizasyonları için yayınlanan JAR 145, JAA onaylı bir bakım organizasyonu olabilmek için gerekli şartlan içermektedir. Bir bakım organizasyonunun JAR 145 onayı alabilmesi için JAA üyesi bir ülke sınırları içinde bulunması veya bu sınırlar dışında ise JAA'nın sözkonusu organizasyona JAA üyelerince ihtiyaç duyulduğu konusunda ikna olması gerekmektedir. Organizasyon onay için genel olarak, uygun ve yeterli tesis, yeterli ve vasıflı personel, iş ve personel kayıt sistemi, sertifikalandırılmış bakım, bağımsız kalite sistemi, uygun dokümantasyon, prosedürlere uygun çalışma şartlarını sağlamalıdır. ISO 9001 standardı ile karşılaştırıldığında daha dar kapsamlı olan JAR 145 bugün Avrupa'da üst seviyede geçerliliğe sahiptir. Türkiye'nin en büyük havayolu işletmesi olan THY'ye ait Bakım Merkezi yaptığı çalışmalar sonucunda JAR 145 onayı almıştır. Türkiye de faaliyet gösteren özel bakım organizasyonları da onay alabilmek için gerekli çalışmaları sürdürmektedirler. vıı

Abstract:
This thesis defines the concepts related with quality, summarizes the quality improvements in aviation and explains the "JAR 145 Approved Maintenance Organisation" standard. It is hoped that this study shall be a reference document for aircraft maintenance organisations at the stage of choosing a quality assurance system and planning to get a JAR 145 approval. From the beginning of 20th century, rules and principles of scientific management have dominated in the business world and this situation has acted an important role- in increasing the production amount. Howewer some applications such as insufficiencies in adopting to varying market conditions and giving importance only to production amount by ignoring the quality, have caused unsuccesfulness in the business area. As a result, the quality which caused the quality increase in production and improvement of a management concept based on total quality strategy in all sectors, has been characterized as equivalent to the scientific management. This quality revolution that has surrounded all the societies has come out from the result of not only the life style and the new needs of the societies, but also the quick improvements in science and technology. While entering the 2000's, the reorganisation of present companies working under increasing competition conditions, has become a necessity in order to ensure customer satisfaction with a more widespread and continuous quality assurance, to get much more share in the market and at the same time to maximize the profit and minimize the costs. Various quality system standards have been defined for rating the companies in the stage of reorganisaton. Most commonly used standard published by International Standardization Organisation is ISO 9000 standards. These standards can be used in various areas from production to service. Some definitions of quality related concepts and ISO 9000 standards are given below: Quality: The totality of features and characteristic of a product or service that bear on its ability to satisfy stated or implied needs. Total Quality: is a set of principles and methods organized as a compherensive strategy with the goal of mobilizing the entire company in order to achieve the greatest client satisfaction at the lowest cost. Quality assurance: All planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality. ISO 9001: Quality systems - Model for quality assurance in design/development, production, installation and servicing. VUlISO 9002: Quality systems - Model for quality assurance in production and installation. ISO 9003: Quality systems - Model for quality assurance in final inspection and test. As mentioned above, one of the reasons that made the quality concept important was the complexity of products and the necessity of increasing the reliability and safety levels of them. Aircraft is one of these technological products. An aircraft must be designed, manufactured, maintained and operated properly to ensure safety. With the start of aviation activities, some rules and regulations defined and issued by national and international organisations in order to arrange aviation activities. In general, special standards and regulations has been prefferred. The first conference to establish some type of air law was held in Paris 1889. During the World War II, it was realised that certain standards were needed for airworthiness of aircraft, qualifications of flying personnel and specifications for navigation and air traffic control. After the war, a lot of Nations founded their National Civil Aviation Authorities to regulate the aviation activities in their lands. Federal Aviation Administration (FAA), which was founded in 1958 for the purpose of ensuring safety in aviation activities throughout the United States, is one of the most important national civil aviation authorities in the world. FAA issues Federal Aviation Regulations (FAR) for aircraft certification, aircraft operation and other aviation activities. These FARs are effective for all the aircraft flying in the US boundaries, all the aircraft which have the US registration mark and all the organisations which give maintenance services to the US registered aircraft or repair/manufacture components/parts for the US registered aircraft. A large number of airlines were organised and International air transportation was developed on a large scale, as a result of this, aviation became an international phenomena and some international aviation organisations have been founded to establish international rules and laws. At the invitations of United States, representatives of 54 nations met at Chicago on Nov, 1,1 944 for the purpose of reaching some agreement that would provide for the control of air transportation and aviation activities. International Civil Aviation Agreement was signed at Chicago which superseded the Paris Agreement. The principles developed under this agreement are administered by the International Civil Aviation Organisation (ICAO), which was founded by the agreement of Chicago Convention and which came into being on April 4, 1 947. ICAO, which works under the United Nations, establishes and periodically reviews general standards for air transportation on a worldwide basis. These standards cover licensing of personnel, airworthiness of aircraft, aeronautical charts, meteorological codes, registration of aircraft and identification markings on aircraft, rules of the air, accident investigation, airports, communications, facilitation and air traffic control and navigation. Some European Civil Aviation Authorities started in 1970 to co-operate with a view to producing common aviation standards so as to facilitate certification of products built jointly in Europe and the import and export within Europe. In 1979, 13 European Civil Aviation Authorities signed an arrangement concerning to the development and the acceptance of joint airworthiness requirements. The European National Civil Aviation Authorities signed an Arrangements Document IXreferenced Cyprus on 11 September 1990 which commits the said Authorities to cooperate in all aspects related to the safety of aircraft, in particular its design, manufacture, continued airworthiness, maintenance and operation to ensure that a consistent level of safety is achieved throughout the Member States, to avoid duplication of work between the Authorities and to facilitate exchange of products, services and persons. The Joint Aviation Authorities (JAA) was developed by this arrangement in 1990. The Arrangement Document has been signed by 27 National Civil Aviation Authorities so far. The members of JAA represent: Austria, Belgium, Denmark, Finland, France, Holland, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweeden, Switzerland and United Kingdom; candidate members: Cyprus, Turkey, Slovenia, Poland, Malta, Monaco, Czech Republic, Hungary, Slovakia. The JAA is responsible for the production and publication of Joint Aviation Requirements (JARs) and the associated guidance and administrative documents for the following purposes: 1. To ensure, through co-operation, common high levels of safety within the Member States. 2. Through the application of uniform safety standards, to contribute to fair and equal competition within the Member States. 3. To aim for cost-effective safety and minimum regulatory burden so as to contribute to Europen industries international competitiveness. Some of the JARs issued by the JAA are below: JAR 1 : Definition and Abbreviations JAR 21 : Certification Procedures for Aircraft, Products and Related Parts JAR 23 : Normal, Utility, Aerobatic and Commuter Category Aeroplanes JAR 25 : Large Aeroplanes JAR 27 : Small Rotorcraft JAR 29 : Large Rotorcraft JAR 36 : Aircraft Noise JAR 39 : Airworthiness Directives JAR APU : Auxiliary Power Unit JAR E : Engines JAR P : Propellers JAR OPS Part 1 : Commercial Air Transportation (Aeroplanes) JAR OPS Part 3 : Commercial Air Transportation (Helicopters) JAR TSO : Joint Technical Standard Orders JAR AWO : All Weather Operations JAR VLA : Very Light Aeroplanes JAR 66: Certifying Staff JAR 145 : Approved Maintenance Organisations JAR 147 : Training Center JAR MMEL/MEL-1 : Master Minimum Equipment List JAR FCL : Flight Crew Licance This study is focused on JAR 145 Approved Maintenance Organisations. For that reason, it will be helpful to know JAA Maintenance Policy for understanding the subject:1. For commercial air transport aircraft maintenance itself must, however, be carried out by an organisation holding an appropriate JAR 145 Approved Maintenance Organisation approval. Aircraft Maintenance also includes aircraft components which means any component up to and including the engine. 2. The JAR 145 Approved Maintenance Organisation must use Certifying Staff that meet the requirement of JAR 66. Certifying Staff being those persons authorised to release aircraft or components to service. 3. Certifying Staff must be trained at a JAR 147 Approved Training Center. An aircraft maintenance organisation gives maintenance service (overhaul, repair, inspection, replacement, modification or defect rectification of an aircraft/aircraft component) to the aircraft. Airlines can have their own organisations or they can have their aircrafts maintained at other maintenance organisations. In order to ensure safety, on time flight and cost reduction, it is very important to maintain an aircraft at a maintenance organisation which works in compliance with certain standards and rules. JAR 145 prescribes the requirements for issuing approvals to organisations for the maintenance of aircraft and aircraft components and prescribes the general operating rules for approved maintenance organisations. Maintenance organisation which carries out maintenance and release to service of aircraft/aircraft component, must work in compliance with JAR 145 requirements in order to be accepted by the JAA members. JAR 145 was first issued on 30 July 1991 and became effective on January 1992. JAR 145 requirements are given below: JAR 145.1 General JAR 145.3 Effectivity JAR 145.5 Definitions JAR 145.10 Applicability JAR 145.15 Application and Issue JAR 145.20 Extent of Approval JAR 145.25 Facility Requirements JAR 145.30 Personnel Requirements JAR 145.35 Record of Certifying Staff JAR 145.40 Equipment, Tools and Material JAR 145.45 Airworthiness JAR 145.50 Certification of Maintenance JAR 145.55 Maintenance Records JAR 145.60 Reporting of Unairworthy Conditions JAR 145.65 Maintenance Procedures and Quality System JAR 145.70 Maintenance Organisation Exposition (MOE) JAR 145.75 Priveleges of the Approved Maintenance Organisation JAR 145.80 Limitations on the Approved Maintenance Organisations JAR 145.85 Changes to the Approved Maintenance Organisation JAR 145.90 Continued Validity of Approval JAR 145.95 Equivalent Safety Case Maintenance organisations which are planning to be granted an JAR 145 approval, must provide a maintenance organisation exposition document for use by maintenance personnel, containing procedures about all the JAR 145 requirements and works in compliance with this MOE procedures. In addition they must establish an independent quality system to monitor compliance with and adequacy of the XIprocedures to ensure good maintenance practices and airworthy aircraft and aircraft components. Compliance monitoring must include a feedback system to the related persons to ensure necessary corrective actions. Organisations located within the territories of the countries that have joined the JAA may be granted approval when in compliance with JAR 145. They may apply directly to their National Civil Aviation Authorities for approval. Organisations located outside the territories of JAA members may only be granted approval if the JAA is satisfied that there is a need for such approval to maintain aircraft/aircraft components and when in compliance with JAR 145. These organisations must apply to the JAA for approval. After officai audits, applicants who meet the requirements, are entitled to a maintenance organisation approval. Comparing JAR 145 with ISO 9001 will make easier to understand the JAR 145 standard: 1. Both of them are internationally accepted standards and organisations gain prestige when they are granted JAR 145 or ISO 9001 approval. 2. Although JAR 145 is effective only for aircraft maintenance organisations, ISO 9001 may be used for much wider areas. 3. Quality policy, training, sufficient and qualified personnel, sufficient and proper tools-equipment, proper facility, independent quality system, procedures, record system are common requirements for both standards. 4. ISO 9001 is more comprehensive than JAR 145. It will be useful to explain the implementation process of JAR 145 in a maintenance organisation. THY Maintenance Center is a JAR 145 approved organisation. Its JAR 145 approval implementation process stages are the following: 1. Management decision for JAR 145 approval and nomination of responsible persons. 2. Preliminary works 2. 1. Choosing the consultant firm. 2.2. Personnel training. 2.3 Monitoring the system and implementation of corrective actions. 2.4. Documentation (MOE and Technical Procedures Manual) and application. 2.5. Getting approval from the consultant firm. 3. Getting the official approval. Today, most of the maintenance organisations in Europe have JAR 145 approval and aircraft operators prefer JAR 145 approved maintenance organisations to have their aircraft/components repaired. Beyond prestige, JAR 145 approval has become a necessity for organisations. However, JAR 145 maintenance organisation approval will be more efficient together with ISO 9001/9002 application. Xll