Source: https://www.ntsb.gov/investigations/AccidentReports/_layouts/ntsb.recsearch/Recommendation.aspx?Rec=A-04-008
Timestamp: 2018-09-21 11:28:45
Document Index: 96072608

Matched Legal Cases: ['art 121', 'art 121', 'art 121', 'art 121', 'art 121', 'art 121']

Safety Recommendation A-04-008
Recommendation: TO THE FEDERAL AVIATION ADMINISTRATION: Require 14 Code of Federal Regulations Part 121 air carriers to modify their existing maintenance manuals, if necessary, so that they contain procedures at the end of maintenance for a complete functional check of each critical flight system.
Response: The FAA’s last letter concerning Safety Recommendation A-04-8, dated May 25, 2010, stated that you had revised operations specification D091 to replace the term “substantial maintenance” with “essential maintenance,” defined as maintenance that would result in a failure effect that would endanger the continued safe flight and landing of the airplane if it were performed improperly or if improper parts or materials were used. You stated that this new term and definition would help ensure that air carriers and FAA offices consistently apply appropriate maintenance guidance or procedures. Our November 23, 2010, reply stated that, to complete the action recommended in A 04-8, the FAA would need to ensure that all Part 121 carriers had incorporated original equipment manufacturers’ post-maintenance functional checks/tests in their maintenance manuals. Pending completion of that effort, Safety Recommendation A-04-8 remained classified “Open—Acceptable Response.” Although Safety Recommendation A-04-8 is now 12 years old, we are not aware of any requirement you have issued for operators to include the recommended procedures in their existing maintenance manuals. Accordingly, we request an update on any actions that you have taken or planned to address this recommendation. In the meantime, Safety Recommendation A 04-8 is classified OPEN—UNACCEPTABLE RESPONSE.
Response: To fully evaluate the FAA's response to this recommendation, we also considered the FAA's August 13,2009, letter to the NTSB concerning related Safety Recommendation A-04-7, which asked the FAA to require manufacturers of aircraft operated under 14 CFR Part 121 to identify procedures for a complete functional check of each critical flight system; determine which maintenance procedures should be followed by such functional checks; and, if necessary, modify existing maintenance manuals so that they contain procedures for a complete postmaintenance functional check. In its August 13, 2009, letter, the FAA indicated that, for critical aircraft systems, it would define an appropriate set of post-maintenance functional checks/tests (PFCT) that will be required to (1) verify that the maintenance met the intended purpose and (2) ensure that completion of the maintenance did not result in an unsafe system condition. The FAA planned to sample original equipment manufacturers' (OEM) current practices for selecting PFCTs and examine how these are incorporated into their maintenance documentation. On April 6, 2010, the NTSB wrote to the FAA that the plan to define PFCTs for all critical aircraft systems, verify that the PFCTs meet the criteria they have devised, and then ensure that PFCTs are included in all appropriate maintenance procedures was responsive to the recommendation. Pending the FAA's completing those actions, Safety Recommendation A-04-7 remained classified "Open-Acceptable Response." To complete the recommended action, the FAA will need to ensure that carriers incorporate all maintenance manual revisions that result from FAA actions in response to Safety Recommendation A-04-7. Pending completion of that effort, Safety Recommendation A-04-8 remains classified OPEN – ACCEPTABLE RESPONSE.
Response: Letter Mail Controlled 6/16/2010 MC# 2100201 - From J. Randolph Babbitt, Administrator: The Federal Aviation Administration published new guidance in the form of a FAA Notice 8900.1 03 (enclosed). This change revises operations specification (OpSpec) D091 to address a change in terminology and meaning from the previously used term "substantial maintenance" to the new term "essential maintenance." A standard term and definition will help ensure that air carriers and FAA offices consistently apply appropriate maintenance guidance or procedures. The following definition of essential maintenance is maintenance that would result in a failure effect that would endanger the continued safe flight and landing of the airplane if it was performed improperly or if improper parts or materials were used. Essential maintenance includes the accomplishment of the Required Inspection Item. Part 121 air carriers must accomplish their maintenance with the highest possible level of safety. This part requires that each aircraft released to service is airworthy and has been properly maintained for operation. They are required to have a manual that contains adequate instructions to ensure that aircraft are released to service in an airworthy condition. This includes instructions to perform any required checks to verify the effectiveness of any corrective actions taken prior to further flight. If any instructions are found to be ineffective, the air carrier must modify their existing manual to correct any deficiencies noted. Part 121 air carriers are also required to ensure that any person who accomplishes maintenance on his or her aircraft is adequately trained to complete the maintenance instructions provided in the maintenance manual. Again, if deficiencies are noted, corrective actions must be taken at whatever level necessary (air carrier or original equipment manufacturer (OEM)) to correct the issue. This may include additional training or in some cases correcting the instructions to ensure the desired outcome. The FAA believes that the new standardized definition of essential maintenance, along with part 121 air carriers' incumbent responsibility to ensure that their aircraft are released in an airworthy condition, the effectiveness of their manual system and training, including the completion of any work or task cards, and the air carriers' normal interface with the OEMs, effectively address the intent of the Board's recommendations. We consider our actions complete.
Response: Letter Mail Controlled 6/28/2004 3:14:12 PM MC# 2040357 - From Marion C. Blakey, Administrator: The FAA will issue a flight standards information bulletin to inspectors to notify their assigned air carriers of the need to review and, if necessary, modify the carriers' maintenance manual procedures to ensure that a functional check of each critical flight system is performed after maintenance. It is anticipated that the bulletin will be issued by October 2004.