GENERAL REQUIREMENTS FOR THE DESIGN APPROVAL OF A

FIRM BY CEMILAC

The firms who are designing and or manufacturing/repairing/refurbishing with a limited

military aircraft or airborne stores can seek Design approval of their firm from

CEMILAC in order to supply/repair airborne equipment to be used by Air Force, Army

or Naval aviation. The tasks under taken by them will follow the general requirements

stipulated in Military Specifications, Defence Standards and DDPMAS-75 documents.

The broad guide lines on which the design approval of firms to be processed by

CEMILAC are the following:

1. The firm must have done design and development of aircraft/airborne stores.

2. The list of design team is to be identified with their clear-cut specialization and

responsibilities.

3. The BIO-DATA of each member of design team is to be provided with their

signatures.

4. The list of authorised signatories for signing the reports, the names, specific

areas of specialisation, reports to he signed etc are to be indicated by the firm.

5. The organisation chart of the firm is to be provided.

6. The design practice/standard followed by the firm along with the drawing office

practice to be indicated clearly.

7. The duly completed Proforma on design approval is to be forwarded to

CEMILAC.

DESIGN APPROVAL OF FIRMS

GENERAL

Normally, it would be the policy of the Ministry of Defence to place Defence contracts for Aircraft/Rotorcraft/Weapons/Systems only with those firms whose management, technical resources and quality assurance are demonstrably adequate to provide products and services, to the required standards of quality of design, economically and in time. Approval of firms by CEMILAC would assist the evaluation of the firms from the point of view of compliance to the design requirements.

1. INTRODUCTION

1.1 The scheme of Design Approval of firms is designed to assist procurement of airborne stores to the laid down standards. Design Approval of Firms is also required as called for in the DDPMAS-75, Section III, Chapter I, Para 2 & 3. Following paras indicate in detail the procedure to be followed in meeting the requirements called for in the DDPMAS-75. The approval could be for the Design and Development of following types of products and/or services:

a. Total integrated Aircraft and Rotorcraft Systems.b. Guided Weapon Systems.c. Aircraft, Rotorcraft and Associated Equipmentsd. Aircraft and Rotorcraft Engines, Accessories and Materials.e. Modifications to the Existing/Bought out Aircraft, Rotorcraft, Engines,

Systems and Accessories.f. Concessions for deviations, salvage schemes, lifing of components,

assembly, production permits, indigenisation of materials/components, both for Licence Built and Bought out Aircraft/Rotorcraft/Systems.

1.2 The award of the Design Approval to a firm signifies a recognition that, because of its ability and experience in the design and development of products within a specified range, CEMILAC accepts the Certificate of Design issued by the firm which would indicate that a particular performance or objective has been achieved for a product or service compared with what is required by the specifications. For such range of products and/or services, the firm can be approved as the Design Authority or Coordinating Design Authority as appropriate. This Approval, however, is limited to the extent that the prerogative for Final Acceptance of the product and/or services will still be with CEMILAC who would verify conformance to the specification and the requisite test requirements.

1.3 DESIGN AUTHORITY (DA): A Design Authority is the firm responsible for the detailed design/modification to an existing design/indigenous substitution, etc., of a system, to approved standards and authorised to sign Certificates of Design in accordance with the procedures laid down in DDPMAS-75.

1.4 COORDINATING DESIGN AUTHORITY (CDA): A Coordinating Design Authority is responsible for the overall design of the system, including integrating the sub-systems/airborne stores designed by the other DAs into the main system. The Coordinating Design Authority may also be a DA for some of such sub-systems/airborne stores.

1.5 The procedures and associated conditions for grant of approval to the firms are discussed in the following paragraphs.

2. SCOPE

2.1 There will be two types of approval within this scheme.

2.1.1 GENERAL APPROVAL: This type of approval would be applicable for all types of design and development work in a specified category of work defined in the scope of the approval. This approval will be valid till it is revoked by CEMILAC.

2.1.2 PARTICULAR APPROVAL: This would be applicable for a specified equipment and/or project with a specified validity.

3. GENERAL REQUIREMENTS FOR APPROVAL OF A FIRMS DESIGN ORGANISATION

The general requirements for approval are indicated in Appendix ‘A’.

4. APPLICATIONS FOR APPROVAL OF FIRMS

A firm seeking approval as Design Authority or Coordinating Design Authorityunder the General category of Particular category will apply to CEMILAC in the proforma placed at Appendix ‘B’.

5. ASSESSMENT FOR DESIGN APPROVAL

On receipt of the application for approval from the firm, if it is considered that there is a case for according design approval to the firm, CEMILAC will appoint a team to complete a thorough appraisal. The appraisal would aim at establishing long term confidence in the firm’s design, development and test personnel, organisation and facilities relevant to the class of product/services/technologies concerned. The appraisal would be based in terms of:

5.1 Current and projected technical activities.

5.2 Design and related supporting organisation and facilities.

5.3 Qualification and experience of the relevant personnel.

6. CERTIFICATE OF DESIGN APPROVAL FOR FIRMS

Based on the evidence presented by the firm, if the appraisal shows that the firm meets the requirements of CEMILAC, a Certificate of Approval will be issued listing:

6.1 The Scope of Approval (a generalized description and/or list of classes of products and services.

6.2 The names of the approved signatories for the Certificate of Design.

6.3 The Board members (or their authorised equivalents in cases where there is no Board) who in the firm or organisation have the overall responsibility for the availability of resources for, and the security/scrutiny of the design.

6.4 The designer who has participated in the design function and who is responsible for the technical adequacy and integrity, of the design. Alternate signatories will be listed separately under terms notified to the firm by Chief Executive, CEMILAC.

6.5 The names of the other senior key design personnel and their specified responsibility.

6.6 Chief Executive or visiting Technical Officer, CEMILAC responsible for supervision.

7. DESIGN AUTHORITY FOR PRODUCTS MANUFACTURED UNDER LICENCE

Design organizations of firms engaged in the manufacture of aircraft / rotorcraft/airborne equipments under licence could also seek approval on design matters for specified stores. The design organisation of such firms, in cases like this, should possess the requisite design data either by transfer of technology from the licensor or developed within the organisation to the satisfaction of the Chief Executive, CEMILAC.

8. ACCEPTANCE OF DESIGNS COMPLETED BY NON-APPROVED DESIGN FIRMS

If contracts for some design activities are sub-contracted by a Design Approved firm to a firm which is not approved by the Chief Executive, CEMILAC, the veracity and integrity of design would have to be verified by the Design Approved firm before its acceptance by the Chief Executive, CEMILAC from airworthiness point of view. In case, the design contract with a non-approved design organisation is placed directly by the Ministry of Defence, the procedure for check points would be laid down by Chief Executive, CEMILAC, in each individual case, defining the extent and scope of control to be maintained either by a design approved firm designated for this purpose or one of the Chief Resident Engineers.

9. CEMILAC shall include from time to time firms with defined scope of activity in their list of approved firms.

10. Supervision shall be exercised by the CEMILAC by placing Resident Engineers or periodical visits by Visiting Technical officers.

APPENDIX ‘A’

REQUIREMENTS FOR APPROVAL OF AFIRM’S DESIGN ORGANISATION

CEMILAC requires that the design organisation of the firm seeking approval satisfied all the requirements stipulated by them for such approval. The essential requirements are given below:

1. ORGANISATION OF THE FIRM

The organisation of the firm shall, in the opinion of CEMILAC, be such as to ensure that in all matters affect airworthiness, full and efficient coordination exists within the design office and related technical departments and between the design office and other production departments of the firm.

2. DESIGN OFFICE STAFF

The Chief Designer or Head of design organisation qualified in design specialization will be the one approved by CEMILAC by name. The Chief Designer/head of design organisation will have an adequate number of key designers individually approved by CEMILAC, the categories and requirements of which are to be mutually agreed upon. The Chief Designer/head of design organisation will be responsible for the competency of his staff and the efficiency of his design organisation to the satisfaction of representative of CEMILAC who is responsible for the firm’s supervision.

3. SPECIALIST STAFF FOR DESIGN ORGANISATION

In addition, the design organisation shall include:

3.1 For Design & Development of Aircraft

Specialists in all branches of aeronautics, metallurgy, systems, engines and related fields, as necessary, for progressing the design activity.

3.2 For Design & Development of Aero-Engine and its Components.

Specialists in all branches of Powerplant design, analysis and testing. These specialists shall also be approved individually by CEMILAC.

4. ACCOMMODATION AND EQUIPMENT

4.1 The design department shall have adequate accommodation and requisite equipment including necessary system and storage facility for drawings, design calculations, stress and performance analysis, reproduction, printing and publishing of drawings/technical, information relating to the safe operation, maintenance, overhaul and repair of items for which the firm requires approval.

4.2 The approved firm will also required to provide at the works/design office, adequate, fully furnished office accommodation and other essential services to CEMILAC for their Resident Engineers.

5. RECORDS

Design records shall be such that proper correlation of design and amendments with the design records is ensured. The design department shall also have proper facilities and system for storage and retrieval of the records for extended periods.

6. TESTING

The firm shall have facilities or access to suitable approved facilities for making such tests as are necessary to establish compliance with airworthiness requirements including facilities for structural and metallurgical testing, flight testing, system rig tests, weighing and determining the position of the centre of gravity of the product depending on the terms of approval and type of work. Test results are to be relevantly recorded.

7. ACCEPTANCE OF DESIGN

Approved firm shall submit type records comprising drawings, component test results, flight test results, production specifications etc., to CEMILAC in accordance with provisions made in Section III of DDPMAS-75 at the conclusion of development for type certification. All the relevant drawings, specifications, test sheets, process, records etc., shall be sealed by Resident Engineer or by Visiting Technical officer deputed for the purpose. Such document shall not be amended, obliterated or destroyed without the approval of CEMILAC or its representatives.

8. MAINTENANCE OF APPROVAL

8.1 The design organisation shall be maintained at the standard originally approved by the CEMILAC. The Resident Engineer or visiting Technical Officer shall at all reasonable times, be given access necessary to establish this fact. If any significant change is contemplated in the constitution of the design staff, the same shall be notified to CEMILAC in writing prior to implementation.

8.2 The firm shall consult CEMILAC if there is any difficulty in the interpretation of the requirements or on any airworthiness matter, which in its experience, requires clarifications. If, subsequent to the approval of an aircraft or aero-engine or any airborne item, irrespective of whether the aircraft concerned is indigenously designed or produced under licence, as and when the firm becomes aware of defects, the firm shall advise the CEMILAC, in order that an appropriate joint action is taken.

8.3 If no changes occurred after a period of three years from the date of issue of Design Approval Certificate, the firm shall advise CEMILAC the relevant information in accordance with this document.

9. WITHDRAWAL, SUSPENSION OR MODIFICATION OF APPROVAL

9.1 CEMILAC may withdraw, suspend or modify the terms of approval, if the conditions under which it was granted are not met. The terms of approval may also be changed as a result of changes in the firm’s undertaking.

9.2 Sub-contractor firms are also governed by the above requirements.

APPLICATION FOR DESIGN APPROVAL

PART – I

(This has to be completed by the organisation seeking the Design Approval)

1. Name & Address of the Organisation ;

2. Type of Approval sought :

3. Class of Products/Services/Design :Activity/Technologies for whichApproval is sought

4. Evidence of experience for class of :

Products/Services/Activity

Technologies in terms of -

(a) Preparation of Specification :

(b) Design, Development & Testing :

(c) Engineering for manufacture :

(d) In-service support :

5. Details of Design and Build-standard :Control System, Method of controllingDesign Changes

6. Evidence of familiarity with Established :Airworthiness Practices & ProceduresOrganisation, if any, particularly to LookAfter the Airworthiness Aspects

7. Details of testing facilities available :in-house or otherwise which could beuseful for the appropriate class ofwork/activity, including environmental,ground & flight testing, wherever necessary.

8. Particulars of Quality Assurance :

GD (A/C)/QF/04

organisation and if it has approved ofDGAQA.

9. Names, Qualification, Experience and :other relevant details of the BoardMembers and senior key Design staffProposed as signatories for Certificateof Design.

10. Particulars of the Organisation :Structure showing the names, particularsand positions of Senior Staff Memberswho will be responsible for Design andDevelopment.

11. A statement showing members of :other technical and design staff

12. Details of earlier projects completed :

13. Details of projects not completed :

14. Cases, if any where short falls in :meeting Airworthiness Requirementswere found.

15. Details of test facilities analytical :and computational facility

(Signature of Applicant)

Designation:

Date: Organisation

PART – II

(To be completed by the Management Organisation)

This part is applicable to the organisation’s management who contractually undertakes the work from a Design Approved Firm/or from any other project management teams/Government. If a project management team locates such firms for completing the work package, it may comment on firm’s design/management organisation in Part IIA given below:

1. Whether above named Design :organisation part of ProjectManagement

2. If not, has the above named design :organisation been approached for specific package of work. Give details of package of work and reasons foridentifying the Design organisation

3. Comment on functional independence :of the organisation and how Designshort comings are dealt.

4. If any memoranda of understanding :on liability, cease of work, firmsdissolution, mode of making gooddesign shortcomings is proposed to besigned, give details.

Date : Signature of Head of Management of Firm

PART – IIA

Comments on the contents brought out by Applicant and also points Brought out in Part II.

Date : Signature of head Project Management/Design Approved Firm

PART – III

This part is applicable if the application is being submitted by a firm, which is a sub-contractor to a Design Approved Organisation.

1. Name & Address of the Design :Approved organisation

2. Details of the own approval :

3. Reasons for sub-contracting the design :work

4. Work package sub-contracted and :comments on how sub-contractor isassessed as suitable for undertakingthe work package and its design capacity

5. Comments on details proved by the :applicant, specially on OrganisationStructure, Independence in technicalFunctions, making good shortcomings,Design & Test Facilities, Liability etc.

6. Comment on sub-contractor’s under :standing of Airworthiness requirementsin respect of work package

7. Methodology visualized on periodic :surveillance to ensure sustainedsatisfactory Design Authority

8. If memoranda of understanding is :signed/proposed to be signed, copy ofthe same may be enclosed. Itsacceptability check points, integrationetc., be commented upon.

9. Proposal on how the function of :coordinated Design Authority would bedischarged on sub-contractors work.

Date: Head of Design Approved Organisation

PART – IV

This part is applicable where a Design Approved Organisation may not directly sub-contract, by Airworthiness Authority may require assistance of already Design Approved Organisation to sponsor the firm seeking Approval and also for undertaking periodic assessment.

1. Name & Address of the Design :Approved Organisation

2. Details of its own approval :

3. Comment on Statement of the appli- :-cant with regard to Design Capability,Organisation Structure, Independencein Technical Functions.

4. Comment on Firm’s Standing and on :its knowledge of Airworthiness Requi-rements, Attitudes towards Design shortcomings.

5. Proposal on periodic assessment on :the work package undertaken

6. Desirability or otherwise of a memoranda:of understanding on liability, Firmsclosure, Cease of Activity on Work Pack--age between the project Managementand the Firm.

7. Recommendation on special survei- :lance checks by specialist teams

Date: Signature of Head of the DesignApproved Organisation

PART – III

Recommendation of concerned Local Head of Airworthiness Authority under whose jurisdiction activity takes place or any other officer so nominated by Chief Executive, CEMILAC.

1. Salient points of the visiting team’s :Assessment

2. Material evidences supportive of or :otherwise for approval.

Date: Signature of Recommending Authority

PART – IV

(Decision of CEMILAC)

1. Approved/Not Approved :

2. If approved, number and date of :Approval which could be quotedon the work package

3. If approved with special conditions : (a)details of the same

(b)

(c)

4. If withheld for pending actions, details : (a)of the same

(b)

(c)

Date: Signature of Chief Executive (A)

Note

1. If the space provided in the columns are not sufficient, details may be provided in additional sheets.

2. Part – I to be completed by Chief of Design of the Design Organisation.

3. Part – II to be completed by the Head of the Management such as the Managing Director (Design Bureau), Programme Director, Director of Establishment.

4. In some cases, Design Bureau/Establishment/Project Management Group might locate an organisation for a specified package work. In such cases, Part – II shall be filled by that Organisation’s management and Part – IIA shall be completed by the Design Bureau/Establishment/Project Management giving such work package.

APPLICATION FOR APPROVAL OF TEST HOUSE

PART – I

(This has to be completed by the organisation seeking the approval)

1. Name & Address of the Organisation :

2. (a) Type of Approval sought : Testing

(b) Class of Services for which approvalis sought

(i) Metallic

(ii) Non-Metallic

(iii) Composites

(iv) Environmental Testing

3, Evidence of experience for class of Services/ :Activity in terms of

4. Details of Testing facilities available in-house :or otherwise which could be useful for the appropriate class of work/ activity, including environmental and ground testing, wherever necessary. Full particulars of all the machinery/equipments should be given. It should coveryear of make, range of application, accuracy, calibration, nature of tests that can be conductedetc.

5. Names, Qualification, Experience and other :relevant details of the Board Member and senior key staff proposed as signatories forCertificates of Test Results.

6. Particulars of the Organisation Structure :showing the names, particulars & positions ofSenior Staff Members who will be responsiblefor Testing.

7. A statement showing members of other :technical and Testing staff

8. Has any other Govt. Organisation approved :the Test House? If so the details of the samelike class of test, range please be given.

9. Details of calibration policy and periodicity :adopted for all testing machines.

10. Cases, if any where short falls in meeting :calibration Requirements were found.

11. Details of test facilities analytical and compu- :tational facility.

12. Test charges details if any :

(Signature of Applicant)Date: Designation:

Organisation:

PART II

Recommendation of concerned Local Head of Airworthiness Authority (RCMA) under whose jurisdiction activity takes place or any other officer so nominated by Chief Executive, CEMILAC.

1. Salient points of the visiting team’s :Assessment

2. Material evidences supportive of or :otherwise for approval

Date: Signature of Recommending Authority

PART - III

(Decision of CEMILAC)

1. Approved/Not Approved :

2. If Approved, number & date of approval :which could be quoted on the workpackage.

3. If approved with special conditions : (a)details of the same (b)

(c)

4. If withheld for pending actions, details : (a)of the same (b)

(c)

Date: Signature of Chief Executive

Note:

1. If the space provided in the columns are not sufficient, details may be provided in additional sheets.

2. Part – I to be completed by Chief of Test House Organisation.