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FAA PMA QUALITY MANUALTable of Contents - click here for PDF demo - opens in new tab/page 1.0 Scope Changes to the Quality System are approved by the FAA Manufacturing Inspection District Office (MIDO) prior to implementation. The Company immediately notifies the FAA MIDO, in writing, of changes that affect inspection, conformity or airworthiness of approved articles. This quality assurance manual is submitted to the Federal Aviation Administration (FAA) for information and conformance according to Regulatory Compliance requirements. This manual includes verification policies and procedures and instructions for the design, development and manufacture of Parts Manufacturer Approval (PMA) articles for various model aircraft under the authority of Title 14 Code of Federal Regulations (14 CFR). This manual establishes and maintains a quality assurance system to ensure compliance and conformance with FAA-PMA Articles manufactured for use on certified aircraft or as detail components of an aircraft assembly. Changes that impact inspection, conformity and airworthiness are only implemented into this manual with prior FAA approval. The Company notifies the FAA in writing, in advance, when the manufacturing facility is relocated or expanded to other locations. Prior to shipping FAA-PMA parts from a new location, the new facility is evaluated and approved by the FAA. The Company is committed to the ongoing maintenance and improvement of the quality management system; to ensure this, management focuses on deploying practical steps that positively support quality and environmental policies.
1.1 Overview of Responsibility and Authority The organizational chart in Appendix 1 is an overview of the management structure of the Company. See personnel roster for the name of the Responsible Authority (RA) in each branch of management that includes multiple assignments. In all cases, the appropriate person has ... The Accountable Manager of the Company has been assigned the role of Quality System Management Representative. The Accountable Manager is responsible for ... The Accountable Manager is responsible for ... In addition, the Accountable Manager ... To ensure proper communication between and throughout all levels of employees within the Company, internal communication is ... requires management to ... Management Review meetings are conducted according to procedure Management Process Procedure. This procedure defines ... Section A: Design Data Control A1 Copies of all drawings for FAA Approved articles are ... A2 Design data is filed by Drawing Number and the latest revision is ... A3 Minor design changes to the PMA Articles are ... A4 Major design changes are ... These design changes may require amendments or additions to:
A5 Material Review Board (MRB) is ... Documents are controlled to ensure information is ... The controls for documents are defined in procedure Control of Documented Information Procedure. Paper records are controlled to provide evidence of conformity to requirements. The Company has established a documented procedure for control of electronic records. Electronic records are ... Section B1: Configuration Management The configuration of products is controlled through advanced configuration management techniques that have been built upon the requirements of ... Configuration management is conducted according to procedure Configuration Management Procedure. C1 Materials received are required to ... Supplied items that support manufacturing and or assembly of FAA-PMA articles are inspected for ... a. Reports of unsatisfactory conditions are ... b. Review of documented unsatisfactory conditions increases ... An on-site visit may be required that verifies: C2 Material is labeled to ... C3 Materials are stored ... C4 Vendors supply ... Note: As part of the receiving inspection process, a comparison is made between the Supplier's packing sheet and the purchase order then each shipment is inspected for:
After acceptance of incoming shipments, the Responsible Authority ... C5 When discrepancies are ... C6 Rejected articles are ... C7 Requirements Purchasing is treated as a process within the Company's quality system. ... The Company does not ... The process is fully defined in the Purchasing Procedure. C71 Purchasing Process The purchasing process ... C7.2 Purchasing Information Purchase orders are used to transmit the Company's requirements to Suppliers. C7.3 Verification of Purchased Product Incoming materials are ... The process is defined in the Receiving Procedure. C8 Identification and Traceability All products are identified throughout product life cycle. This is fully defined in Production Procedure. Other identification and traceability requirements are ... C9 Preservation of Product The Accountable Manager ... The instructions are detailed in the applicable job documentation and general rules are defined in Shipping Procedure. Section D: Manufacturing Control The Design and Development process ensures that design activities are conducted in a controlled manner, which is defined in Design and Development Procedure. Instructions for Continued Airworthiness (ICA) are kept current with design changes. D1 Materials received are required to ... D2 A Shop Routing Sheet is used to document the number of pieces at each step of the manufacturing process and is used to annotate any losses. A shop routing sheet is used for ... D3 The Company uses a folder for ... D4 Parts are inspected to ... D5 Small parts (sub-assemblies) are marked according to FAR 45.15(b) with a tag attached to the part or the packaging for the part. D6 Parts are permanently marked or tagged with:
D7 Requirements: The Company plans and carries out processes for product realization. In general, this includes assurances that:
The Quality inspector completes the required inspection form and by signing off is attesting that they have verified the requirements as documented in the drawing, work instruction or other reference. These activities are fully defined in Production Procedure. All products are identified throughout product life cycle. Other identification and traceability requirements are ... D7.1 Production Documentation Production operations are performed according to ... In addition, the Company may utilize ... These activities are fully defined in the Production Procedure and Design and Development Procedure. D7.2 Control of Production Process Changes Only the Configuration Control Board may approve changes to production processes. The Company identifies and obtains Customer and/or regulatory authority approval for changes when ... These activities are fully defined in the Production Procedure and Design and Development Procedure. D7.3 Control of Production Equipment & Tools Production equipment, tools and programs are ... D7.4 Control of Work Transferred on a Temporary Basis Outside the Organization's Facilities When the Company provides supplies for outside processing, such as acceptance testing, it is done under the following controls:
D7.5 Control of Service Operations The Company services supplies returned to it for warranty work or repair - field servicing is(is not) performed. For such product work, ... D8 Customer Property Where Customer property is provided to the Company for processing or use, it is ... Damaged or missing Customer property is ... Government and Customer property is controlled according to Production Procedure, specified contractual requirements and ... D9 Preservation of Product The Accountable Manager specifies, where required and according to contractual directives, instructions for ... The instructions are detailed in the applicable job documentation and general rules are defined in Shipping Procedure. D10 Identification and Traceability All products are identified throughout product life cycle. This is fully defined in Production Procedure. Other identification and traceability requirements are ... D11 Monitoring and Measurement of Product To ensure the conformance of product to requirements, monitoring and measurement is conducted ... The Quality Group is responsible for ... Inspection methods may include but are not limited to: ... The inspection includes verification of compliance to:... Inspection by statistical sampling is applied, as appropriate and when specified, in ... Authorized sampling plans for product acceptance are based on SAE ARP9013, Statistical Product Acceptance Requirements and documented in work instructions. The specified sampling plan for a designated application is ... In the event supplies are needed prior to receipt of Certified Test Data, Certificate of Compliance or Analysis, approved Request for Deviation or Waiver or other limited risk condition, at least two applicable MRB members may ... D11.1 Inspection Documentation The engineering drawing, FAA-approved design data and/or other technical documentation provide the requirements for all deliverable supplies. In all cases, this includes ... D11.2 First Article Inspection (FAI) When required by purchase order or Customer specification, a First Article Inspection (FAI) is performed. The FAI is ... D12 Competence, Training and Awareness All Company personnel are hired on the basis of their ability to ... The Company has implemented a training program that:
Management conducts periodic reviews of employee performance. Appropriate records of education, training, skills and experience are ... The training program is defined in Training Procedure. Section E: Inspecting & Testing E1 Request For Service Inspectors (RFS) determine that each completed part conforms to the design data and is ... Inspectors perform the following:
E2 RFS Inspectors have access to FAA approved data and specifications when inspecting FAA-PMA articles. When witnessing acceptance tests, the Inspectors ... E3 All inspection records described above and the record of disposition are ... E4 Requirements Inspection methods may include but are not limited to: ... E4.1 In-Process Inspection In-process inspections are conducted during production to ... E4.2 Final Inspection Once all operations are complete, the lot is submitted to Quality for a final inspection. This is performed according to an accepted sampling plan, The sampling plan is ... Section F: Inspection, Measuring and Test Equipment Control F1 Tools, gauges and test equipment are ... F2 Tools, gauges and test equipment that become inaccurate are ... F3 Special tools, shop aids, master gauges or molds manufactured by RFS that are contracted with or purchased from a vendor are ... F4 Inaccuracy of tools, gauges, test equipment and molds identified during periodic inspections are ... a) The Company notifies MIDO of any quality escape. b) The Company processes actions according to Section N herein. F5 Scales, shop aids and measuring devices used for inspection are ...
F6 Requirements All measuring and test equipment instruments and devices used to determine an article's conformance to specified requirements are ... Section G: Inspection and Test Status G1 The inspector affixes an initial on the Inspection Record indicating ... G2 Rejected components are ... Section H: Nonconforming Product and Article Control H1 Nonconforming and rejected materials are ... H2 Nonconforming parts may ... H3 Major Change incorporation to FAA-PMA articles are first approved by FAA ACO and MIDO with PMA addition. H4 Requirements All supplies found to be nonconforming against specified requirements are ... Procedures are available for receiving and processing feedback for in-service failures, malfunctions and defects. The procedures include ... Procedures are available that establish a system for receiving, processing and tracking in-service failures. The procedures include provisions to ... Service problems, unairworthy conditions, unsafe features and unsafe characteristics are reported to the FAA according to FAR §21.3 (§21.9) and are ... See Control of Nonconformities Procedure. Section I: Corrective and Preventive Action I1 Corrective actions review non-conformities of manufactured articles to:
I2 Action is taken to:
I3 Preventive Action is taken to:
I4 Requirements I4.1 Corrective Action The Company has implemented and maintains a robust system for identifying and reporting nonconformities requiring corrective action. These nonconformities can ... This process is defined in Corrective Action Procedure. I4.2 Preventive Action In addition to the preventive measures taken for corrective action requests (used to prevent recurrence of an existing problem) the Corrective and Preventive Action process is used to ... This process is defined in Corrective Action Procedure. J1 All materials are ... J2 Acceptable finished products are ... J3 Parts are ... J4 Parts are ... J5 Parts are ... J6 Requirements: Preservation of Product The Responsible Authority specifies, where required and according to contractual directives, instructions for ... general rules are defined in Shipping Procedure. Section K: Control of Quality Records K1 The Company controls and distributes ... approved changes are made available to:
And manage records as:
K2 The Company retains files for ... Note: The Company ensures that only FAA approved data is used for manufacturing, instruction and support. K3 Requirements: Control of Records Paper records are ... defined in procedure Control of Documented Information Procedure. L1 Request For Service Inspectors conduct Internal Audits according to ... See Internal Audit control log:
L2 Requirements: Internal Audit Internal quality audits are conducted to ensure ongoing compliance with requirements of the Company's policies and procedures. This is accomplished by ... The internal audit process is fully defined in Internal Auditing Procedure. Section M: In-Service Feedback Service Difficulty Reports (SDRs) M1 When in service difficulties are discovered, they are reported to the FAA ACO and MIDO. Note: The Company reports 14 CFR 21.3 conditions to the FAA ACO and MIDO within 24 hours, with the exceptions of weekends and recognized holidays. Self Disclosure Reporting M2 When in-service difficulties are found for an article, they are reported to the FAA's geographic MIDO. Airworthiness Directives (ADs) M3 In the event that an Airworthiness Directive is issued by the FAA, the Company immediately implements applicable changes, if any, to articles affected by the AD. - When appropriate, changes related to an AD are ... A quality escape is defined as any article that has been released from the quality system that does not conform to the applicable design data or quality system requirements. N1 The Company notifies the FAA of any apparent quality escape by contacting the FAA MIDO office. Initial notice of a voluntary disclosure may be submitted orally, by electronic means or by written hardcopy. N2 Notification is made in a timely manner, normally within 24 hours of the discovery of the apparent quality escape, with the exception of weekends and recognized holidays. N3 Quality escape notifications include the following information:
Section O: Issuing Authorized Release Documents The Company provides for ... O1 The Company ensures that only qualified personnel issue authorized release documents. Evaluation of persons responsible for authorizing release documents includes ... O2 FAA Form 8130-3. O3 Conditional Requirement. Section P: PMA Article Part Marking P1 PMA articles: Responsible Authorities permanently and legibly mark all FAA PMA articles with the following:
P2 Sample of marking used on all PMA articles:
P3 ... Section Q: Shipping / Export of Completed Articles Q1 All required documents are ... Q2 Before exporting products to other Countries, FAA AC 21-2 and Bilateral Agreements are reviewed for applicable requirements. Q3 All shipping documents are followed and completed according to ... Section R: Supplemental Requirements Supplemental FAA policies are defined in Supplemental Policies. INSERT ORG CHART INSERT FACILITY MAP REVISION HISTORY AND APPROVAL RECORD Quality System Policy Copyright © JnF Specialties, LLC. All rights reserved worldwide. PROPRIETARY INFORMATION - UNCONTROLLED IF PRINTED UNLESS OTHERWISE MARKED |