Says Agency Has "Tough" Standards
Below is the FAA's updated
Fact Sheet on use of outsourced repair stations, released Thursday
in connection with the House Transportation and Infrastructure
Committee, Subcommittee on Aviation, hearing on FAA oversight of
outsourced air carrier maintenance.
Repair stations are closely regulated and monitored by the FAA.
The agency requires air carriers to ensure that their contract
maintenance and training programs, and the contractors themselves,
fully comply with federal regulations. There are approximately
4,227 domestic and 694 foreign FAA-certified repair stations.
Tough FAA Standards for "Outsourced" Maintenance
Some air carriers contract out ("outsource") aircraft
maintenance. For example, it may be more efficient to have an
original manufacturer perform engine overhauls, repair of
components or warranty work. Airlines must meet stringent FAA
requirements if they rely on contract maintenance.
- Air carriers have to ensure that all contractors follow the
procedures specified in the air carrier’s maintenance
program.
- Air carriers must list all contractors on a vendor list; only
substantial maintenance providers have to be approved in the air
carrier’s operation specifications.
- FAA must approve use of any non certificated contractor. The
airline must show that the provider has the capability,
organization, facilities and equipment to perform the work.
Eyes on Repair Stations
Both the air carrier and the FAA inspect work done at repair
stations. The air carrier conducts oversight through its Continuing
Analysis and Surveillance System, which requires audits of the
facilities working on the carrier’s aircraft.
The FAA does at least one comprehensive, in-depth inspection
every year at each repair station inside the United States. The
inspection requirement comes from the National Work Program
Guidelines (NPG) order issued annually, and is based on risk
analysis of results from the previous year’s surveillance.
The NPG establishes a base level of surveillance data that should
be evaluated, including areas such as facilities, maintenance
processes, technical data and training programs.
FAA inspectors perform on-site visits and review air carrier
audits. An FAA inspector is not required to give notice prior to an
inspection. But as a practical matter, the repair station may be
notified to ensure the right people are available and any necessary
coordination between the repair station and remote facilities or
contractors is accomplished.
FAA inspectors have comprehensive guidance for checking each of
15 safety areas. As each area is inspected, an assessment is
recorded in a national database. The FAA uses the assessments to
retarget resources and develop the following year’s
inspection program.
The inspector presents any issues found to the repair station
informally during a briefing prior to leaving the facility. A
formal letter of findings follows, and the FAA may start
enforcement actions for violations of regulations.
Oversight of Foreign Repair Stations
Many
US air carriers rely on foreign repair stations outside the United
States for at least some of their maintenance. These facilities are
certified annually by the FAA, and a repair station may lose its
certificate if it does not comply with FAA requirements.
The agency only certifies the number of foreign repair stations
it can effectively monitor. Oversight is conducted by FAA
inspectors assigned to International Field Offices in London,
Frankfurt, Singapore, New York, Miami, Dallas and San
Francisco.
FAA standards for foreign and domestic repair stations are the
same. Just as for domestic repair stations, the FAA conducts at
least one comprehensive, in-depth inspection annually for renewal
of the repair station’s certificate. The FAA notifies a
repair station prior to an inspection to meet the repair
station’s security requirements, make sure the appropriate
personnel are available, and allow the facility to do any needed
coordination with remote work sites or contractors. The agency also
notifies the appropriate U.S. embassy and the country’s
national aviation authority.
Using risk analysis tools, FAA inspectors identify potential
safety hazards and target inspection efforts on areas of greatest
risk. During the inspection, the FAA verifies that the facility and
personnel are qualified to perform the maintenance functions
requested by the air carrier or listed in their operations
specifications. The entire inspection is done during a single
visit; the size and complexity of the repair station may require
several days and several inspectors to complete the work.
The United States has country-to-country Bilateral Aviation
Safety Agreements with France, Germany and Ireland. These
agreements eliminate duplicate efforts by the FAA and the national
aviation authorities, and specify that each authority perform
certification and surveillance activities on behalf of the other.
The FAA audits these national aviation authorities, reviews their
inspector guidance materials, inspector staffing levels and
training programs, and performs joint repair station audits with
the authorities’ inspectors. Under these agreements, the FAA
conducts sample inspections of repair stations located in these
countries. In FY 2006 the FAA performed sampling inspections at 21
percent (35) of the 165 affected repair stations.