EQCP-Issue 2-Revision 9 Dated July 2014

Kuwait Airways Corporation

EQCP

Engineering Quality Control Procedures

Document Number

KAC/ED/5

Engineering And Quality Control Procedures

Issue 2 Revision 9 Chapter 0

KAC/ED/5 Page 1 of 1 Date : July 2014

RECORD OF REVISIONS

Issue No Revision No. Embodied By [ Name ] Date

2 0 A. Adwani April 2007

2 1 A. Adwani July 2007

2 2 A. Adwani October 2007

2 3 A. Adwani January 2008

2 4 A. Adwani September 2008

2 5 A. Adwani August 2009

2 6 A. Adwani September 2012

2 7 L.Sadasivam June 2013

2 8 L.Sadasivam April 2014

L.Sadasivam July 201492

Engineering And Quality Control Procedures Issue 2

Revision 7 Chapter 0.1

KAC/ED/5 Page 1 of 5 Date : June 2013

LIST OF EFFECTIVE PAGES Chapter Page Date Status Chapter Page Date Status

6 1 Jul 07 2 Jul 07 3 Jul 07 4 Jul 07 5 Jul 07 6 Jul 07 7 Jul 07

Revisions 1 Sep 12 7 1 Apr 07

8 1 Apr 07 LEP 1 Sep 12 2 Apr 07

2 Sep 12 3 Sep 12 9 1 Apr 07 4 Sep 12 5 Sep 12 10 1 Apr 07

LEP 1 Sep 12 11 1 Apr 07 2 Apr 07

Contents 1 Sep 12 3 Apr 07 2 Sep 12 4 Apr 07 3 Sep 12 5 Apr 07 4 Sep 12 6 Apr 07 5 Sep 12

12 1 Sep 12 2 Sep 12 3 Sep 12

1 1 Sep 12 4 Sep 12 5 Sep 12

2 1 Apr 07 6 Sep 12 7 Sep 12

3 1 Nov 07 8 Sep 12 2 Nov 07 9 Sep 12 3 Nov 07 10 Sep 12 4 Nov 07 11 Sep 12 5 Nov 07 12 Sep 12 6 Nov 07 13 Jun 13 R 14 Sep 12

4 1 Nov 07 15 Sep 12 2 Nov 07 16 Sep 12 3 Nov 07 17 Sep 12 18 Sep 12 5 1 Apr 07 19 Sep 12

2 Apr 07 20 Sep 12 21 Sep 12

22 Sep 12 Abbreviation: R = Revised with Revision number, A = Added, D = Deleted, ILB = Intentionally Left Blank



KAC/ED/5 Page 2 of 5 Date : J u l y 2014


12 22 Sep 12 R 14 Apr 07 2 23 Sep 12 R Apr 07 3 24 Sep 12 R Apr 07 4 25 Sep 12 R Apr 07 5 26 Sep 12 R Apr 07 6 27 Sep 12 R Apr 07 7 28 Sep 12 R 29 Sep 12 R 15 1 Jul 14

30 Sep 12 R 2 Jul 14 31 Sep 12 R 3 Apr 07

32 Sep 12 R 4 Apr 07 33 Sep 12 R 5 Apr 0707

35 Sep 12 R 6 Apr 07 36 Sep 12 R 7 Apr 07 37 Sep 12 R 38 Sep 12 R 16 1 Apr 07 39 Sep 12 R 2 Apr 07

App. A 40 Sep 12 R 3 Apr 07 App. B 41 Sep 12 R 4 Apr 07

42 Sep 12 R 5 Apr 07 43 Sep 12 R 6 Apr 07 44 Sep 12 R 7 Apr 07

App. C 45 Sep 12 R 8 Apr 07 46 Sep 12 R 9 Apr 07

App. D 47 Sep 12 R 48 Sep 12 R 17 1 Aug09 49 Sep 12 R 2 Aug09

50 Sep 12 R 3 Aug09 App. E 51 Sep 12 R 4 Aug09

5 Aug09 13 1 Sep 12 R 6 Aug09 2 Sep 12 R 7 Aug09 3 Sep 12 R 8 Aug09 4 Sep 12 R 9 Aug09 5 Sep 12 R 10 Aug09 6 Sep 12 R 7 Sep 12 R 18 1 Sep 12 R 8 Sep 12 R 2 Sep 12 R 9 Sep 12 R 3 Sep 12 R 10 Sep 12 R 4 Sep 12 R 11 Sep 12 R 5 Sep 12 R 12 Sep 12 R 6 Sep 12 R 13 Sep 12 R 7 Sep 12 R 14 Sep 12 R 8 Sep 12 R 15 Sep 12 R 9 Sep 12 R

10 Sep 12 R 14 1 Apr 07 11 Sep 12 R

DDDDD



KAC/ED/5 Page 3 of 5 Date : September 2012


19 1 Apr 07 2 Apr 07 33 1 Sep 12 R

3 Apr 07 2 Sep 12 R 4 Apr 07 3 Sep 12 R

4 Sep 12 R 20 1 Apr 07 5 Sep 12 R 2 Apr 07 6 Sep 12 R 3 Apr 07 7 Sep 12 R 4 Apr 07 8 Sep 12 R 5 Apr 07

34 1 Apr 07 21 1 Apr 07 2 Apr 07

2 Apr 07 3 Apr 07 3 Apr 07 35 1 Sep 12 R

22 1 Apr 07 2 Sep 12 A 2 Apr 07 3 Apr 07 36 1 Apr 07

23 1 Apr 07 37 1 Apr 07 24 1 Apr 07 38 1 Apr 07

2 Apr 07 2 Apr 07

25 1 Apr 07 39 1 Apr 07 2 Apr 07

26 1 Apr 07 40 1 Apr 07

27 1 Apr 07 2 Apr 07 3 Apr 07

28 1 Apr 07 4 Apr 07 2 Apr 07 3 Apr 07 41 1 Apr 07 2 Apr 07 29 1 Apr 07 42 1 Apr 07

30 1 Apr 07 2 Apr 07 2 Apr 07 43 1 Apr 07 31 1 Apr 07 2 Apr 07

2 Apr 07 3 Apr 07 44 1 Apr 07 4 Apr 07 2 Apr 07 5 Apr 07 6 Apr 07 45 1 Apr 07

32 1 Apr 07 46 1 Jul 07



KAC/ED/5 Page 4 of 5 Date : April 2014


46 2 Jul 07 63 1 Jul 07 2 Jul 07

47 1 Sep 12 3 Jul 07 2 Sep 12 4 Jul 07 3 Sep 12 5 Jul 07

48 1 Apr 07 64 1 Apr 07 2 Apr 07 65 1 Jan08 49 1 Apr 07 2 Jan08

2 Apr 07 3 Jan08 3 Apr 07 4 Jan08 4 Apr 07 5 Apr 07 66 1 Apr 07

50 1 Oct 06 67 1 Apr 07 2 Oct 06 2 Apr 07 3 Oct 06 3 Apr 07

51 1 Apr 07 68 1 Apr 07 2 Apr 07 69 1 Apr 07

52 1 Apr 07 70 1 Apr 07 53 1 Apr 07 2 Apr 07 54 1 Jul 07 71 1 Apr 07

2 Jul 07 2 Apr 07 55 1 Sep 12 R 72 1 Apr 07

2 Apr 07 56 1 Apr 07 3 Apr 07

4 Apr 07 57 1 Apr 07

2 Apr 07 73 1 Apr 07 2 Apr 07

58 1 Apr 07 3 Apr 07 2 Apr 07 4 Apr 07 5 Apr 07

59 1 Apr 07 74 1 Apr 07

60 1 Apr 07 75 1 Apr 14

61 1 Apr 07 76 1 Apr 07

62 1 Apr 07 2 Apr 07 2 Apr 07 3 Apr 07 3 Apr 07





77 1 Apr 07 93 1 Apr 07 2 Apr 07 2 Apr 07 3 Apr 07 3 Apr 07 4 Apr 07 4 Apr 07

78 1 Apr 07 94 1 Aug09 2 Aug09 79 1 Apr 07 3 Aug09 4 Aug09

80 1 Apr 07 5 Aug09

81 1 Apr 07 95 1 Apr 07

82 1 Apr 07 96 1 Apr 07

83 1 Apr 07 97 1 Apr 07

84 1 Apr 07 98 1 Apr 07 85 1 Jan08 99 1 Apr 07

2 Jan08 3 Jan08 100 1 Apr 07

2 Apr 07 86 1 Apr 07 3 Apr 07

2 Apr 07 3 Apr 07 101 1 Apr 07

2 Apr 07 87 1 Apr 07 3 Apr 07

2 Apr 07 4 Apr 07 88 1 Apr 07 102 1 Jan08

89 1 Apr 07 103 1 Apr 07

2 Apr 07 90 1 Apr 07

2 Apr 07

91 1 Apr 07

92 1 Apr 07 2 Apr 07




CONTENTS LIST

CHAPTER TITLE

0 Record of Revisions 0.1 LEP 0.2 Contents List 1 Introduction 2 Objectives and Responsibilities of a Quality Control Organization 3 Kuwait Airways Quality Control Organization 4 Recurrent Training 5 Outstations, Technical Handling Approval and Stores Control 6 Stores Procedures: Quarantine, Bonded and Salvage Stores 7 Approved Certificates, Tag Numbers and Component Labels 8 Release of components and parts to outside operators 9 Stores Premises 10 Stores Restricted Entry to Premises 11 Serviceable, Unserviceable, Stagger, Trouble Shooting Labels and

Repair Procedures 12 Stamps, Authorization Certificate and Scope of Authority

13 Aircraft Maintenance Check Control and Recording 14 Duplicate Inspection of Controls 15 Maintenance, Inspection, Hydrostatic Test and Retirement Life of

Pressure Cylinders 16 Workshops Inspection Records and Procedures




CONTENTS LIST

CHAPTER TITLE

17 Technical Log Correct Usage and Relationship to Base Checks and Technical Record System

18 Special Inspections / Service Bulletins / Modifications 19 Concessions, Dispensation and Trail Extensions Procedure 20 Aircraft Towing 21 Technical Records Procedure 22 Component Control 23 Boroscope Inspection 24 Technical Library 25 Urgent Technical Information Base and Outstations 26 Engineering Bulletins 27 Unserviceable Components Responsibilities of Approved Staff 28 Automatic Test Station 29 Quality Control Investigation into Incidents / Accidents / Malpractice

/ Errors 30 Allowable Deficiency and Minimum Equipment List 31 Cannibalization Procedure in Nil Stock AOG Situation 32 Shift Handovers 33 Control of Aircraft Safety Equipment 34 Approved Maintenance Schedule Complication and Amendment

Procedure 35 Fuelling of Line Aircraft 36 Power Plant Post Installation Checks 37 Workshops Unauthorized Energy and Use of Equipment 38 Quality Control Scrap Action 39 Control Cable Assembly Manufacture and Test Procedures




CONTENTS LIST

CHAPTER TITLE

40 Control of Manufactured, Repaired or Salvaged Components / Parts Removed from Aircraft

41 Engine Ground Running Procedure 42 Test House Procedures and Quality Control Checks 43 Routine Checks to be carried out by Test House Laboratory (Chemical

Tests) 44 Routine Checks to be carried out by Test House Laboratory ( Physical

Tests) 45 Radiation Precaution 46 Procedure for the Periodic Checking of Controlled Equipment 47 Quality Control Surveillance of Planned Audits 48 Quality Control Surveillance of Hangar Inputs 49 Aircraft Weight and Balance 50 Control of Aircraft Water Supply 51 Tooling manufacture and serial/part number allocation 52 Intentionally Left Blank 53 Intentionally Left Blank 54 Acceptance of Aeronautical Parts 55 Electrostatic sensitive mats and straps 56 Certification of Other Operators Aircraft 57 Aircraft Parking Normal/Prolonged/High Wind 58 Pax/Crew entry doors and emergency exit operation 59 Intentionally Left Blank 60 System Warning Tags 61 Welding in the Hangar Fire Hazard 62 Fire during engine start 63 Quality Control of Fuel




CONTENTS LIST

CHAPTER TITLE

64 Components / Parts Found Defective After Issue from Stores 65 Reportable Occurrences and Defects 66 Intentionally Left Blank 67 Non Revenue Flight Tests 68 Storage Life of Emergency Rations 69 Intentionally Left Blank 70 Overhaul and Repair Component Capability Systems 71 Distress Flares / Signal Day and Night Storage, Shelf Life

Inspection, Ultimate Life and Disposal 72 Cartridges Used in Fire Extinguisher Bottles Storage, Shelf Life,

Inspection, Ultimate Life and Disposal 73 Schedule of Storage Life Items 74 Fleet Inspections 75 Aircraft Tyre Life and Retread Requirements 76 Aircraft Mandatory Documents 77 Issue of Parts and Materials from Stores and Return of Items Drawn

from Stores On loan or Issued to Flight Packs and Not Used 78 Testing of Components on Aircraft 79 Component Change Cards Supplied by Aircraft Manufacturer 80 Further Flight Report 81 Engine Overhaul Shop Documentation 82 Engine Overhaul Shop Inspection Records and Procedures 83 Intentionally Left Blank 84 Intentionally Left Blank 85 AIDS/ACMS: Cassette (Tape) and DFDR/SSFDR transcription

handling procedures




CONTENTS LIST

CHAPTER TITLE

86 Shot Peening Operators Approval Procedure 87 All Weather Operation 88 Intentionally Left Blank 89 Intentionally Left Blank 90 Use of Flexible Hydraulic Hoses in lieu of Rigid Metal Tubing 91 Shelf Life Extension of Wheel Assemblies Held at Outstations 92 Overhaul Agency Approval Procedures for Overhaul / Repair /

Modification of Components, Units or Parts Appendix A

93 Introduction of New Airplanes into Kuwait Airways Services 94 Maintenance Control Center (MCC) Responsibilities and Procedures 95 DFDR and AIDS Cassette Removal for Incidence Analysis 96 Engine Transport 97 Packaging of Fuel System Components 98 In House Third Party repairs 99 Repair Warranty 100 Waiver of test charges by Boeing/Airbus industry on Avionics Units 101 VVIP Flights 102 Ferry and Non-Revenue Flights 103 Tool Control Procedure


Revision 6 Chapter 1


INTRODUCTION

1. The Engineering and Quality Control Procedures (EQCP) is issued to define in detail the technical and procedural requirements to be adhered to by all concerned sections of the Engineering Department, particularly the holders of Quality Control Authorizations, and to maintain a Quality Control Surveillance and Planned Audit System within the Engineering Department of Kuwait Airways on the basis of KAC Approved Maintenance Organization Exposition Document (MOE).

This is to satisfy Kuwait DGCA requirements in accordance with Kuwait Civil Aviation Safety Regulations.

2. The EQCP is issued and amended under the authority of Manager, Quality Control, and approved by DGCA-Kuwait. Amendments to the procedure shall be highlighted by darkened bar on the left hand side.

3. The authorized holder of a copy of the EQCP is responsible to ensure that:

A. All revisions are correctly incorporated without delay.

B. EQCP is readily available to the holder's staff and that revisions are brought to their attention.

C. Written recommendations for change are forwarded to the Manager, Quality Control.

D. Manager, Quality Control is advised of any change in the holder's title or address.

E. Loss of EQCP is reported to the Manager, Quality Control, in writing.

F. When the holder's duties no longer require him to hold EQCP, it is returned to the Engineering Department, Technical Library.

Faisal Al-Azmi Manager, Quality Control




OBJECTIVES & RESPONSIBILITIES OF A QUALITY CONTROL ORGANIZATION

The primary objective of a QUALITY CONTROL ORGANIZATION is to maintain on behalf of the Airline, a continuous check on the effectiveness of the maintenance and overhaul of its aircrafts and equipments and to ensure that all requirements of the Airworthiness Authorities and those of the Airline are met.

This responsibility can only be fulfilled by adequate and methodical checking at all stages of maintenance, overhaul, rectification, repair and modification, controlled by properly maintained records at every stage.

The main responsibilities are to ensure that:-

1. All materials used in the maintenance, overhaul, repair, rectification or modification of an aircraft conform to the required specification.

2. All detail and component parts conform to the correct part number, and specification.

3. All manufacturing processes and prescribed inspection and/or test are correctly performed.

4. All work can be traced back to its origin at any stage in the life of the aircraft by means of an adequate and accurate system of records.

5. By means of an adequate and accurate system of recording, all operating times of the aircraft, lifed components and other items specified in the Maintenance Schedule, are strictly adhered to.

6. The necessary control is exercised in all the company facilities to ensure that all aircraft are maintained or overhauled to the highest safety standards.



KAC/ED/5 Page 1 of 7 Date : November 2007

QUALITY CONTROL ORGANIZATION

1. INTRODUCTION

The purpose of this procedure is to explain the organization and distribution of duties within the Quality Control Section.

2. CERTIFICATION RESPONSIBILITIES

All Quality Control authorization holders (KUK Stamp holders) are technically responsible to the Quality Control Manager for work related to their certification responsibilities on aircraft. They are administratively responsible to their individual section managers.

3. DIVISION OF RESPONSIBILITY AND LEAVE RELIEF

1. Quality Control Manager

The duties and responsibilities and leave relief of the Quality Control Manager are laid down in the MOE Chapter 1.4.

The Quality Control Manager has divided the duties and responsibilities of the Quality Section into one Chief Quality Controller, two Superintendents, and six supervisors:

Chief Quality Controller Superintendent Airworthiness

Standards and Procedures Supervisor Licensing and Examinations Supervisor

Superintendent Audits Audits Supervisor Aircraft Maintenance Supervisor Workshops Supervisor Investigations Supervisor





3. DIVISION OF RESPONSIBILITY AND LEAVE RELIEF (Cont'd)

2. Chief Quality Controller

Responsible to the Quality Control Manager for the following:

a. Supervising the revision and currency of the MOE, the EQCP, MELs, Capability List, Base Maintenance & Facilities Manual, and Engineering Bulletins in compliance with the published regulations of the DGCA-Kuwait, EASA 145, and IOSA as appropriate.

b. Monitoring all relevant mandatory requirements and instructions for continued airworthiness and issuing compliance instructions in the form of SPIs.

c. Supervising the review of Maintenance Schedule amendments for MPD and regulatory compliance.

d. Supervising the conduct of Technical examinations for the grant of Quality Control authorizations

e. Supervising the issue and recording of all staff Type and Workshop authorizations. f. Supervising the preparation for issue of authorizations to other suitably qualified

organizations.

g. Supervising audit activities to ensure that all work is performed in accordance with approved Maintenance Schedules, approved manuals, DGCA published regulations, and approved procedures.

h. Ensuring all maintenance records are continually secured and stored in accordance with DGCA published regulations.

i. Supervising the investigation of any non-compliance with airworthiness requirements, MOE, or EQCP procedures and taking appropriate action to prevent reoccurrences.

j. Supervising the investigation of all technical incidents, occurrences, and significant defects and ensuring appropriate preventative action is taken.

k. Supervising the preparation and submission of DGCA occurrence reports.

l. Reviewing all concession and dispensation applications and maintaining records of those applications.

m. Supervising the receiving inspections for aircraft parts and consumables. n. Supervising of workshop capabilities. o. The immediate leave relief of the Quality Control Manager Leave Relief: Superintendent Airworthiness






3. Superintendent Airworthiness


a. The revision and currency of the MOE, the EQCP, MELs, Capability List, Base Maintenance & Facilities Manual, and Engineering Bulletins in compliance with the published regulations of the DGCA-Kuwait, EASA 145, and IOSA as appropriate.


c. The review of Maintenance Schedule amendments for MPD and regulatory compliance. d. The conducting of Technical examinations for the grant of Quality Control authorizations e. The preparation for issue, monitoring, and recording of all staff Type and Workshop

authorizations.

f. The preparation for issue of authorizations to other suitably qualified organizations. g. The immediate leave relief of the Chief Quality Controller Leave Relief: Superintendent Audits

4. Superintendent Audits


a. Ensuring that all work is performed in accordance with approved Maintenance Schedules; approved manuals; DGCA, EASA 145, and IOSA published regulations; and approved procedures.

b. Ensuring all maintenance records are continually secured and stored in accordance with DGCA published regulations.

c. Monitoring the validity of all documents required for the maintenance of aircraft to ensure currency.

d. Monitoring of all technical instructions and procedures issued to engineering staff to ensure uniformity, standards, and policies are maintained.

e. Investigating any non-compliance with airworthiness requirements, MOE, or EQCP procedures and taking appropriate action to prevent reoccurrences.

f. Investigating all technical incidents, occurrences, and significant defects and ensuring appropriate preventative action is taken.






g. Preparing and submitting DGCA occurrence reports.

h. Reviewing all concession and dispensation applications and maintaining records of those applications.

i. The Preparation, administration, implementation, and recording of the planned audit system inline with published regulations.

j. Administration, implementation, and records of receiving inspections for aircraft parts and consumables.

k. Administration, implementation, and records of workshop capability. Leave Relief: Superintendent Airworthiness

5. Standards and Procedure Supervisor

Responsible to the Airworthiness Superintendent for the following:

a. The revision and currency of the MOE, the EQCP, MELs, Capability List, Base Maintenance & Facilities Manual, and Engineering Bulletins in compliance with the published regulations of the DGCA-Kuwait, EASA 145, and IOSA as appropriate.


c. The review of Maintenance Schedule amendments for MPD and regulatory compliance. Leave Relief: Licenses and Examinations Supervisor

6. Licences and Examinations Supervisor

Responsible to the Superintendent Airworthiness for the following:

a. Administrating and conducting technical examinations for the grant of Quality Control authorizations

b. The preparation for issue, monitoring, and record keeping of all staff Type and Workshop authorizations.

c. The preparation for issue, record keeping, and monitoring of authorizations to other suitably qualified organizations.

Leave Relief: Standards and Procedures Supervisor






7. Audits Supervisor

Responsible to the Superintendent Audits for the following:

a. To develop, plan, and administer an effective audit program of Kuwait Airways facilities, procedures, products, vendors, line stations, and contracted engineering organizations.

b. To develop, plan, and administer an effective fuel and water monitoring program of Kuwait Airways aircraft at base and outstations.

c. To prepare and maintain yearly audit schedules. d. To monitor audit findings and results for negative trends. e. To prepare a yearly audit report for the Accountable Manager. f. To monitor the implementation of corrective actions. g. To arrange for, receive, accompany, and assist external auditors of Kuwait Airways. Leave Relief: Investigations Supervisor

8. Aircraft Maintenance Supervisor


a. To carry out vetting of all hangar check packs, task cards, and defect cards. b. To carry out vetting of all line maintenance task cards, technical logs, and SDRFs. c. To review, monitor, coordinate, and record dispensations and concessions. d. To ensure maintenance records are secured and stored in accordance with DGCA

published regulations.

e. Assist and advise in the technical investigation of incidents and occurrences. f. To monitor all hangar inputs, line maintenance activities, and to carry out structural

sampling inspections to ensure standards and procedures are maintained.

g. To attend escape slide deployment operational checks. h. To perform scheduled and unscheduled audits of hangar and line maintenance in

accordance with the yearly audit plan.

i. Coordinate and follow up C of A inspections, Test Flights, and significant defects. Leave Relief: Workshops Supervisor






9. Workshops Supervisor


a. To carry out vetting of all workshop check packs, task cards, and defect cards. b. To review, monitor, coordinate, and record workshop capabilities, dispensations and

concessions.

c. To assist and advise in the technical investigation of incidents and occurrences. d. To monitor all workshop activities to ensure standards and procedures are maintained. e. To perform scheduled and unscheduled audits of workshops and stores in accordance with

the yearly audit plan.

f. To monitor all stores activities to ensure standards and procedures are maintained. g. To administer an efficient stores receiving inspection for components and consumables

Leave Relief: Aircraft Maintenance Supervisor

10. Investigations Supervisor


a. Coordinate, conduct, report, and record investigations into aircraft technical discrepancies and occurrences.

b. Prepare, issue, and record mandatory DGCA occurrence reports. c. Administer, prepare, issue, and record the 120 day Certificate of Maintenance Review on

all Kuwait Airways aircraft.

d. Prepare a quarterly investigation and occurrence review and analysis report for the Quality Control Manager.

Leave Relief: Audit Supervisor

3. COMMON RESPONSIBILITIES OF QUALITY CONTROL PERSONNEL

In the interests of safety and efficiency, all Quality Control staff are required to:

a. Maintain their knowledge of current DGCA, EASA 145, and IOSA regulations to high levels.

b. Maintain their knowledge of the MOE and the EQCP to high levels.






c. Maintain an awareness of current technical, procedural, and safety issues. d. Promote safe practices and encourage procedural compliance. e. Promote honest and non-punitive open reporting of errors, incidents, difficult and

inefficient procedures, and staff safety concerns.

f. Facilitate and coordinate with the Operational Safety Office on any issue of mutual concern.




RECURRENT TRAINING

1. COMPUTERISED SYSTEM

The recurrent training program is accessed through the Kuwait Airways intranet site on http://www2.ourkac.com/default.aspx . To access the recurrent training program users must:

1. Open their web browser. 2. Go to http://www2.ourkac.com/default.aspx if using the internal Kuwait Airways intranet.

If outside Kuwait Airways, go to http://emct.kuwaitairways.com/kacttweb/ui/login.aspx

3. Click on the upper "Departments" link button. 4. Click on the "TT" Department link. 5. Click on the Left Hand "EMCT" link. 6. Enter their Username and Password in the space provided and press Login.

2. USING THE RECURRENT TRAINING PROGRAM

1. Upon entering the recurrent training program, the following opening screen will appear:




RECURRENT TRAINING

2. USING THE RECURRENT TRAINING PROGRAM (cont)

2. Staff must click on the name of all unread articles (identified by their blue color) in the "Article Name" column.

3. After thoroughly reading the article, staff must click on the white "Pending" button in the "My Status" column. The screen below will open:

4. Staff must now fill a summary of the article contents as they have understood them in the box provided.

5. Click on the "Submit Summary" button. 6. Click on the "Close" button. The screen will close and the opening training screen will be

presented again.

Note: You will notice that the "Pending" button has now changed to a blue "Submitted". 7. Once a month, Instructors from the Training Center will review all "Submitted" summaries

and either approve or reject them. Rejected submissions will now appear as red "Rejected" buttons in the "My Status" column. Approved entries will appear as green "Approved" buttons.

8. If staff receive a "Rejected" notice, they must re-read the article and resubmit a new summarization by pressing the red "Rejected" button in the "My Status" column.




RECURRENT TRAINING

2. USING THE RECURRENT TRAINING PROGRAM (cont)

Any questions that staff may have during their review of an article may be submitted to the concerned training center Instructor by pressing on the "QA" button in the "Q&A" column. When staff receive an answer to their question, it will be indicated at the top of the opening screen in the "You have (X) answer to view." To view the answer, press the "QA" link of the respective article.

3. STAFF RESPONSIBILITIES

All authorised staff are responsible to access the recurrent training program once per month and read, summarize, and submit any required articles. Staff on leave are expected to access the recurrent training program on the first working day following their leave.

Note: The recurrent training program is a vital part of our responsibilities as an approved AMO. Staff that fail to access the recurrent training program for a period of one month or more without a valid reason will receive the following sanctions: 1. First Time : Written Caution 2. Second Time: Written Warning 3. Third Time: One month Approval suspension

3. QUALITY CONTROL RESPONSIBILITIES

1. Quality Control will use the programs "Audit" module to check staff status to ensure all required articles have been read, summarized, and accepted before renewing approval books.

2. Quality Control will send the Training Center a copy of any changes to staff approvals to ensure that the staff approval database is kept current in the program.

3. Quality Control will monitor status to ensure staff are fulfilling their responsibilities as per item 3 above.




OUTSTATIONS, TECHNICAL HANDLING APPROVAL AND STORES CONTROL

1. INTRODUCTION

Technical handling and Certification of KAC aircraft at outstations and procedures for storage of aircraft parts at these outstations shall be controlled as per Quality Control regulations described hereunder.

At all enroute stations, technical log certification shall be carried out by authorized KAC personnel or an approved organization who have been authorized by Manager, Quality Control.

Technical handling arrangements for KAC outstations are described in Technical Handling and Pooling Facilities Manual copies of which are located onboard each aircraft, in the ECC office at Kuwait, in the Materials Manager's office, and at certain outstations.

2. PROCEDURE FOR APPROVAL OF OUTSTATIONS

A. The Line Maintenance Manager or the Regional Maintenance Manager shall select suitable organizations as required taking into account current authority approvals, adequate facilities, equipment, personnel, and company procedures to satisfy KAC Quality Control and DGCA requirements for the handling and certification of KAC aircraft.

B. Line Maintenance Manager shall then forward his recommendations to the Quality Control Manager along with:

i) Copies of organization's approval (including its respective Schedule of Approval) from a regulatory authority of a contracting state to ICAO.

ii) Type of aircraft to be certified and the stations to be covered.

C. The Quality Control Airworthiness Superintendent shall scrutinize and ensure the copies of the documents provided by Line Maintenance Manager are in proper order. He shall open a folder for the organization and pass this to the Audit Supervisor.

D. The Audit Supervisor will assign a QC auditor to carry out an audit and provide the organizations staff with procedure training. During the audit, the QC auditor will obtain a controlled copy of the organizations MOE and pass this on to the Technical Library.

E. After a successful audit, the Airworthiness Superintendent shall review the folder to ensure all is in order and issue a Certificate of Approval to the organization. The certificate will be dispatched through the Line Maintenance Manager.





F. The Airworthiness Superintendent shall then revise the MOE to reflect the newly approved organization and inform the Technical Library to add the organization to the distribution list for:

1. MOE 2. EQCP 3. Engineering Bulletins 4. Technical Notices

G. After receiving the Certificate of Approval the Line Maintenance Manager shall proceed with the finalization of the contract with the concerned organization, clearly defining the following responsibilities:

i) Availability of required tools and equipment for the work contracted.

ii) Initial provision and continuation of relevant technical information.

iii) Compliance of DGCA regulations.

iv) Completion and retention of technical records; Basic Check sheets shall be retained for 3 months and SDRF for minimum 2 years.

v) Provision of adequately trained, qualified, and competent personnel responsible for handling and certification.

vi) Provision of spares and their storage and procedures.

vii) Filing and retention of technical log defect record sheets (Pink copy for station) at respective outstations.




LM or RMM requestsapproval for service

providerfrom MQMQ

Request

AirworthinessSupdt

Opens Folder

Supervisor Audit

Carry out Audit

Audit ResultFindings

Supervisor Audit

Assigned Auditor

Reject AirworthinessSupdt

Reject Letter

Rejection Letter

SatisSupervisor Audit

AirworthinessSupdt

Audit Copy

Issue certificate

y Copy to master filey Copy to Foldery Copy to MW

MQ For Approval

Original Certificate

ProcedureTraining

Updates Folderwith Procedure

Training

MW adds Provider toDistribution Lists

y MOEy EQCPy Engineering Bulletinsy Technical Notices

Update Folder

Folder Contentsy Request Lettery AMOy Audit Copyy Procedure Trainingy Certificate Copy

MOE to MW

Update MOE






3. Surveillance and Audits

Periodic surveys of outstation facilities shall be carried out at regular intervals not exceeding 1 year.

4. Duration of Approvals

Outstation approvals shall be time limited to a maximum period of 2 years after which they shall be reviewed and revalidated as required.




STORES PROCEDURES: QUARANTINE, BONDED AND SALVAGE STORES

1. INTRODUCTION

This instruction gives guidance on the procedure to be adopted for the Receipt, Inspection and documentation of items received in stores.

2. RECEIPTS

All items shall be received into "Receipt Section" of the Quarantine Stores.

3. QUARANTINE STORES

The Quarantine Store is provided for the storage of raw materials and parts until such time it can be ascertained that they conform to specification, drawing and other requirements, are free from transit defects and have the necessary "Release" information/documentation.

Materials officers shall carry out the following functions depending on approved and non-approved items.

A. Non Approved T/L 1&2 Parts

The inspection indicator will display "Yes". After verifying quantity and identification marks against the details on accompanying documents, update receipt using transaction "MSRU/MSRU X" (as applicable). The system will automatically prompt user to update MSIPK/MSIPC, to close the order. "MSIPK" and "MSIPC" can also be accessed independently. Tools and test equipments subjected to calibration and controlled by Quality Control shall always be T/L3. Receipt Section staff shall only update receipt using "MSRU" and route the part along with its documents including test and calibration certificates to Quality Control Stores Inspection for inspection and updating prior to despatching the same to Q.C. Test house.

B. For Non-Approved T/L-O Parts

Inspection indicator must always display "NO" and updating MSRU will close the purchase order.





C. Processing Approved Parts Ex PO, RO and SB Orders

All items shall have inspection indicator display "YES".

Material Officers (Receipts) shall be responsible to collect all parcels from the "Awaiting Checking" area as per allocated work; Unpack the parcel, check the contents and identify the same with invoice or packing slips. Ensure goods received are as per accompanying documents, and are complete and not damaged. Any discrepancy or deviation shall be noted on relevant documents. Utmost care shall be taken to locate release documents/approved certificates for all parts/ test equipments.

After Checking and verifying all documents, update receipt using MSRU. Ensure MPN and serial number for RO and SB orders matches with goods received. If MPN's and S/Nos received are different than ordered, it must be entered in column "other MPN/MSN".

Discrepancies are to be noted on all documents before passing the goods and documents to Inspection/Packing.

If the order is not available in the system, goods and documents shall be passed to quarantine stores.

After updating all aircraft parts and T/L 3 tools and test equipment, items shall be passed with documents and certificates to stores inspection. All non approved parts shall be passed to packing unit with tags, as applicable to their respective tracking levels.

D. The Stores Inspector shall establish through the incoming Release Document and MSIP transaction that the item received is as per the order, in case of a purchase order or that the item received has been repaired/modified/overhauled as specified on the repair order. He shall also inspect the item for correct packaging as per the manufacturers or ATA 300 specifications, transit damage, and any other defects.

Materials received without approval documentation or found defective must be failed or updated as unserviceable, as applicable. Both failed and unserviceable item must be quarantined till resolved or disposal decision is made.

E. All T/L 3 and 2 parts shall have manufacturers' serial number (MSN) and KAC serial number. As a policy matter, it has been decided to have MSN as company serial numbers upto 6 digits. If the MSN is more than 6 digits, then the last 6 digits shall form the company serial No. (CSN), Maxi-Merlin System allows only one T/L 3 or 2 parts to be





updated (MSIP) at a time, since each serial number shall be allocated a tracking tag number for providing traceability. T/L "1" and "0" parts can be updated as per quantity received and system does not provide traceability beyond receipt inspection.

F. The Stores Inspector shall conform that item received is correct as per the order and accompanies necessary release documentation. He shall then update the system by transaction MSIP/MSIPX as indicated below.

i) Pass the item as serviceable.

ii) Pass the item as unserviceable.

iii) Fail the item.

When the item is passed as serviceable or unserviceable, receipt status shall change to "RECVD" (Received) and serviceable items shall then be passed to packing section. Unserviceable item shall be routed to salvage stores for further processing, except damaged items, subject to insurance claim, are to be routed to Quarantine Stores. On Both occasions, system will allot a tag number and produce a "S" or "U/S" tag (KUK/MAXI/001) as applicable. Stores Inspector shall allot a Release Document Number (RDN) for each release certificate and shall update the same all "S" and "U/S" units by using transaction "CCUCS". These RDN shall be numbered in the following order.

Year/Inspection Stamp No./Consequential number starting from 100.

e.g.) RDN 94/10/101, 94/11/1123 etc.

These certificates shall be filed in the same sequence.

Release documents for T/L 1 and 0 must be filed in date/vendors name sequence, starting from A to Z.

e.g.) ABG, Boeing, Collins etc.

G. Stores Inspection shall then pass the "S" and "U/S" parts to packing section for binning preparation and U/S parts to Salvage Unit for further action.

Failed parts must be routed to quarantine stores for further follow up action. When resolved, these parts shall be routed to Stores Inspection, after updating MSRU. Stores Inspection shall re-inspect the parts and update/pass the same if the original query is resolved satisfactorily.





H. Shelf Life / Finite Life Management

i) Tracking Level 3 & 2 Parts

Material Planners are responsible, when creating a new part number in Maxi-Merlin system to indicate, in number of days the SLE applicability as recommended by manufacturer or laid down in EQCP PII 73 (Transaction "CCUPS"). System will automatically allocate the applicable SLE date whenever a part is declared "S" by MSIP/PTMP-F/CCSER.

These dates can be overridden by "CCUSL" transactions to change the SLE date if need arises.

ii) Tracking Level 1 & 0 Parts

Stores Inspectors shall make a text type entry for T/L 1 and 0 Part numbers, after passing the item using transaction MSSU.

iii) Maxi-Merlin System produces the following SLE forecast/call up work sheets: MS2651 SL, MS2652 SL and MS2653 SL. These reports are to be used to pull out S/L expired parts from locations indicated. Stores Supt. is responsible to remove these parts and route the same to Stores Inspectors for declaring these parts as U/S, for T/L 3 and 2 items.

Shelf life expired T/L 1 & 0 parts are to be issued out from stock. T/L parts are to be routed to stores inspection for including these into Maxi-Merlin system. T/L "0" parts are to be disposed off by Materials Section.

iv) Finite Life Limited Parts (T/L 3)

When creating a new part number, Material Planners are responsible to identify and update Maxi-Merlin system, using CCUPS transaction, the maximum number of life in calendar days as recommended by manufacturer or EQCP PII 71, 72 & 73. Maxi-Merlin will force the authorized personnel declaring a T/L-3 Part "S" (transaction MSIP, PTMP-F, CCSER) to enter the earliest date such parts are due for call up. Component Control Unit of material section is responsible for call up of these parts from their current locations including installed units. Stores Inspectors are responsible for declaring U/S, on all units recalled from stores, by component control.





4. EMERGENCY SALE/LOAN OF SPARES FOR KAC AIRCRAFT AT OUTSTATIONS

A. To meet AOG requirements of KAC aircraft at outstations, sometimes it becomes necessary to borrow spares from other airlines or arrange for spares to be delivered directly from the Manufacturer. Under these emergency situations, the spares borrowed or delivered at the outstation shall be inspected for general condition, transit damage and shelf/finite life limitation by the Station Engineer fitting the part. He shall than Fax/Telex details of the part received along with the supplier's approval certificate number and condition of the part to material section. He shall also forward the original approved certificate to Store Inspection through Materials Section.

B. Materials Section shall create shared business order (MSSB) for borrowed and loaned parts to enable receipt section to update MSRU and pass it to stores inspection.

C. Stores Inspector shall confirm that data updated is correct and update the system by MSIP and pass the document to component control for actioning MSSB transaction. Release documents shall be retained by Stores Inspection.

5. ISSUE OF PARTS TO MANUFACTURER/REPAIR AGENCY DIRECTLY BY KAC VENDOR/SUB VENDORS

The following procedure is to allow limited supply of parts/materials from vendor/sub vendor, who shall be requested to ship the parts/materials directly to the manufacturer/repair agency for installation on a component, assembly or aircraft.

Purchase order shall be raised for parts/materials required from vendor/sub vendor who shall be requested to ship the parts/materials directly to the manufacturer or repair agency, along with a set of invoices, packing sheets and authorized release certificate. Vendor/Sub-vendor shall also be advised to mail the original set of documents to Materials Section, Kuwait.

The manufacturer/repair agency shall be requested to carry out the receipt inspection of the parts/materials when received and endorse/stamp the release documents as necessary. The endorsed release documents shall then be transmitted by fax or a photocopy be forwarded to Materials Section, Kuwait. These shall be forwarded to Stores Inspection for verification and acceptance of the release documents and approval for updating MSRU by Receipt Section staff.





After MSRU update by Receipt Section, Stores Inspection shall close the purchase order by MSIP transaction, allocate RDN (Release Document Number) and file the release documents. In case of T/L 3 or 2 purchase order dispatched directly, copy of the invoice must be sent to component control for transferring/installing the units on appropriate aircraft/assembly. T/L 1 & 0 items must be issued out by materials section, so as to reduce the stock balance accordingly.

6. STORES CONCESSION NOTE

Materials awaiting approved documentation or verification of any information from the vendor, if urgently required may be released under a Stores Concession Note (KUK/GEN/1583) granted by Manager, Quality Control.

A. Procedure during working hours

Technical Stores Supvr. is responsible for approaching QC Supvr., Stores Inspn/ with details of the circumstances and evidence. If agreeable, a blank serialized form KUK/GEN/1583 (stores Concession Note) shall be given by QC Supvr. Stores Inspn and shall be filled and duly signed by Manager/Asst. Manager, Materials and forwarded to Manager, Quality Control for approval. QC Stores Inspn shall then release the part for use and shall follow up and acquit all pending Stores Concession Notes without undue delay.

B. Procedures during silent hours/holidays

The Duty Store Officer, in co-operation with the requisitioner, shall contact by telephone, the Manager, Quality Control and obtain approval to use the part in Quarantine Stores after giving the details of the circumstances and evidence.

If agreeable, the Duty Store Officer will release the component/part to the requisitioner.

Tech Stores Supvr. must ensure that Stores Inspn. is informed of this the next working day, a Stores Concession Note is filled and duly signed by Manager/Asst.Manager, Materials and forwarded to Manager, Quality Control.





7. BONDED STORES

Bonded Stores shall contain only materials and parts which have been proved to conform to specification and/or drawings. Materials and parts for other than aeronautical purposes shall not be included in this Store.

On no account shall unserviceable parts be handed into the Bonded Stores serving counters.

8. SALVAGE STORES

All items received into the Salvage Stores must be correctly labeled and actioned in Maxi-Merlin indicating in-transit to KWI-SLVG, before acceptance.

The procedure for distribution of items from Salvage Stores shall be found in EQCP PII-11.

9. GENERAL

Planned Audit Checks shall be regularly carried out by QC Engineers in accordance with EQCP PII-47 on all Stores and reports issued as specified.




APPROVED CERTIFICATES, TAG IDENTIFICATION NUMBERS AND MAXI-MERLIN SYSTEM GENERATED SERVICEABLE/ UNSERVICEABLE LABEL KUK/MAXI/001

The purpose of this procedure is to bring to the notice of all concerned staff that Approved Stores Serial Number (ASS No) has been replaced by Maxi-Merlin System generated Tag Identification Number with the introduction of Maxi-Merlin System.

When an item is received in stores and passed as serviceable or unserviceable, the Maxi-Merlin System produces a single identification tag (KUK/MAXI/001) for serviceable or unserviceable items as applicable. This tag has a system generated tag identification number which is used for various levels of tracking, depending on tracking levels.

Stores Inspection shall allot a Release Document Number (RDN) for each release certificate and this shall be entered in the system to enable the traceability of approved certificates.

Tag identification Number (TIN) is printed onto all serviceable labels and must be recorded on all inspection worksheets, procedure sheets, unit change sheets, SDRFs, and Technical Log Sheets when ever a part is fitted to an aircraft or sub assembly.

An ICT number shall be transcribed by stores personnel onto all issued requisitions. This number is not required to be recorded in to worksheets, procedures sheets, Tech Logs, etc...




RELEASE OF AERONAUTICAL COMPONENTS/PARTS/MATERIALS SYSTEMS TO OUTSIDE OPERATIONS

1. INTRODUCTION

Aeronautical supplies shall be defined as components, parts, materials intended for use on aircraft which have been manufactured and fabricated from materials and drawings, in accordance with design standards laid down by aircraft manufacturers, and approved by the relevant airworthiness authorities.

Kuwait Airways is an approved organization holding Aircraft Maintenance Organization Approval, as defined in Kuwait DGCA approval ref. DGCA/AMO/1.

2. AERONAUTICAL SUPPLIES HELD IN KAC STORES, PREVIOUSLY OBTAINED FROM OUTSIDE SOURCES AND UNUSED BY KAC

Such parts shall be released with thier original incoming documentation. A certified statement that the part has been stored in conformance to the manufacturers requirements can be issued by Quality Control if required by the buyer.

It is the responsibility of the buyer to define his release requirements in the purchase order.

3. RELEASE OF COMPONENTS OVERHAULED/REPAIRED OR MODIFIED BY KAC

Components or parts that have been overhauled, repaired or modified by KAC shall be released with a Form KUK 106 "Authorized Release Certificate" or an EASA Form 1 depending on the requirements of the buyer and the approved capability of the workshop.

4. KAC AUTHORIZED RELEASE CERTIFICATES (FORM KUK/106, Iss 4) EASA FORM 1

Authorized Release Certificates shall be serialized and issued consecutively. A copy of all KUK 106 certificates must be kept in the issuing section. For EASA form 1, one copy shall be kept in Technical Records and one copy shall be kept in Stores Inspection.

If an Authorized Release Certificate is issued and subsequently cancelled, the copies should be clearly marked to indicate the cancellation.




RELEASE OF AERONAUTICAL COMPONENTS/PARTS/MATERIALS SYSTEMS TO OUTSIDE OPERATIONS

5. AUTHORIZED RELEASE CERTIFICATES AUTHORIZED SIGNATORIES

Authorized Release Certificates may be signed on behalf of Kuwait Airways only by persons nominated in Part I, Chapter 1-6 of the Exposition Document.

6. RELEASE OF COMPONENTS/PARTS/MATERIALS/SYSTEMS THAT HAVE BEEN TESTED OR EXAMINED BY THE TEST HOUSE

These items shall be released with an Approved Test Certificate issued by the Test House.

Approved Test Certificates shall be serialized and issued consecutively.

If an Approved Test Certificate is issued and subsequently cancelled, the copies should be clearly marked to indicate the cancellation.

Form No. KUK/GEN/1509, Issue 6 shall be issued to report and certify the physical testing of materials.

Form No. KUK/660, Issue 7 shall be issued to report and certify tests or examination, other than physical tests, carried out by Test House.

Distribution of KUK/GEN/1509, Issue 6, and KUK/660, Issue 7, approved certificates shall be as follows:-

KUK/GEN/1509 KUK/660

Customer (White) Customer (White)

Manager, Quality Control (Yellow) Manager, Quality Control (Green)

Chief Quality Controller (Green) Test House (Yellow)

Test House (Blue) Chief Quality Controller (Blue)

7. APPROVED TEST CERTIFICATE AUTHORIZED SIGNATORIES

Approved Certificates may be signed on behalf of Kuwait Airways only by persons nominated in Part I, Chapter 1-6 of the Exposition Document.




STORES PREMISES

1. DUST EXCLUSION

The Stores area is air-conditioned, dust-proof and designated areas are controlled for storage of specific materials and parts. No smoking is allowed in all bonded store areas.

To ensure that such conditions are maintained and to minimize the ingress of dust, Stores Personnel must ensure that all doors are properly closed when not in use.

Entry into the Stores area shall be only through personnel entry doors.

Main bay doors shall be opened only in the event of large material entry and if practical, should be restricted during adverse conditions such as dust storms. At all times unloading shall be accomplished as rapidly as possible and the door kept open for the minimum time possible.

2. SECURITY AND PROPER SEGREGATION OF STORAGE SECTIONS

The sliding door between quarantine and bonded store and the door between the unloading bay and offices must be closed and locked during silent hours and kept closed at other times.

The bonded store to hangar and workshop areas must always be locked except when issue of large items is being made. This may be done only under the supervision of an issuing Stores Officer.

When not staffed, all servicing hatches must be locked close.

The salvage store must be locked close when the Salvage Store Officer is not in the Salvage Store premises.

The inflammable goods store must be locked at all times, except when the receipts or issue are being made.

Entry into the Stores areas is restricted to authorized personnel listed in Quality Control Procedure PII-10.




STORES RESTRICTED ENTRY TO PREMISES

A condition implicit in terms of approval of an Approved Organization is that the strictest control of materials, both serviceable and unserviceable must be applied. This is achieved by organization and procedures which comply with KCASR.

A correspondingly strict control of access to the Stores area is also applied to personnel to ensure that the procedure laid down for acceptance and issue of aeronautical parts is controlled. This is achieved by restricting entry into the stores areas to only certain authorized persons.

Authorized Persons Engineering Director and Dy. Engineering Directors All Stores personnel Stores Inspectors Quality Manager Quality Control Engineers in performance of their duties DGCA Surveyors in performance of official duties Persons authorized by Stores Manager or Quality Manager in writing. Restricted Premises Receipt Section Quarantine and Bonded Stores Inflammable Stores Unauthorized Persons

In normal working hours a person may enter the Stores with the express permission of the Stores Inspector and Stores Superintendent provided that he is accompanied at all times by a Storekeeper.

Outside normal working hours an Engineer may, with the permission of the Senior Stores Officer on duty, be allowed entrance to any part of the Stores, provided he is accompanied by a member of the Stores Staff.




SERVICEABLE, UNSERVICEABLE COMPONENT STAGGER, TROUBLE SHOOTING AND REPAIR PROCEDURE

1. INTRODUCTION

All parts must be labeled as soon as they are removed from an aircraft, except for definitely identifiable parts not requiring repairs. This refers to such obvious items as large panels, fairings, bulkheads, floors etc.

All consumable items (T/L "0") such as AN, AGS disposable filters, seals and similar parts which are to be scrapped need not be labeled, but should be disposed off in the scrap bins provided for this purpose.

2. STORES PROCEDURES

All tracking level 2 and 3 items must only be issued from Bonded Stores when the unit is accompanied with its serviceable "tag" KUK/MAXI/001. As far as T/L 0 and 1 parts are concerned if the issued quantity is less than the certified quantity in the bin, the serviceable tag shall remain attached to the balance quantity in the bin. Shelf Life expiry, if any, must be transcribed to issue documents before issue of the part.

3. UNSERVICEABLE PARTS TL 3, 2 AND 1

A. T/L 3 and 2 Removal/Installation

When an item carrying a "serviceable" label/tag is fitted to an aircraft/assembly, unserviceable portion of serviceable label/identification tag (KUK/MAXI/001) shall be completed by an authorization holder. The Tag Identification shall be attached to the unserviceable part and passed for action "CCRI" in Maxi-Merlin system by authorized staff. Maxi-Merlin is a "Real Time" on line system and it is essential that removal/installation must be actioned without any delay to maintain data integrity in system. Failure to update the system at source will cause a variance in data and will trigger reports with inaccurate information.

B. When transaction "CCRI" is completed, system will indicate routing of the part. Until such time "Direct Loading" facility is set-up in the workshop facility, all items shall be routed to Salvage Stores.





C. T/L 1 unserviceable parts

Authorization holders installing T/L 1 parts shall complete an unserviceable label, attach it to U/S items and pass the same to staff authorized to update Maxi-Merlin system. T/L 1 parts must be inducted into system by transaction PTMP by filling in "T" against "Action Code" and "KWI SLVG" against "Location". The system will allocate a tag number and print the identification tag. Authorization holders shall complete unserviceable portion of this tag and route the part along with tag to salvage stores. Any aircraft part designed as T/L "0", but that could be repaired, must be routed to salvage stores after completing the U/S portion of Identification tag indicating against "Reason for Removal" column as "For updating to T/L 1 & re-certification."

4. SALVAGE STORES

Salvage Stores shall only receive un-serviceable T/L-3 and T/L-2 parts indicating "in transit" and T/L-1 parts at location "KWI SLVG". T/L 0 parts may be received if accompanied by a U/S tag indicating reason for removal as for "updating to T/L 1 and recertification."

A. Stores officers shall confirm the identity of the parts with U/S tags and update Maxi-Merlin system (to receive the part at Salvage Stores) transaction MSRU for T/L - 3 and T/L - 2 parts and pass the tags to component control planner.

B. Component Control Planner shall complete section 2 on reverse side of the U/S Tag and return it to Salvage Stores Officer.

C. Salvage Stores Officer shall then create a work order using transaction "PCUK" and transcribe this number on the U/S tag.

D. Salvage Stores Officer shall attach the label to the unserviceable item. The item shall be then released to the appropriate workshop by transaction PTMP-U or for dispatch to an approved outside repair agency as directed by component control planner.

E. Salvage Stores Officer shall co-ordinate with the Component Control Planner to create a repair order, after transactions PTMP-R, PTPR and PTBR.

F. IVS Entertainment System items marked "RUSH" shall be processed on priority basis.





5. WORKSHOP PROCEDURE

A. Workshop Supervisor shall arrange to collect from Salvage Stores all unserviceable items routed to their respective shops, on a daily basis.

B. On receipt of the items from Salvage Store, an Inspection Report shall be raised and the details entered therein, the report number shall be entered into section 4 of the Identification Tag and all related paper work.

C. After final inspection, if the item is to be released as serviceable, transaction PTMP-F option is to be used to complete the transaction. Maxi-Merlin system will generate a new "serviceable" tag and route the item to controlling location designated for the same.

D. Items declared Beyond Local Repair (BLR) should be routed back to Salvage Store by transaction PTMP-U option, after entering the reason in remarks column at section 4 of Identification tag.

6. QUARANTINE STORES PROCEDURE

A. All items "Failed" by Stores Inspectors, the transaction MSIP, "Failed option" shall be routed to Quarantine Stores (Receipt area). At the time of failure, 3 copies of Failure report will be printed at Stores Issue counter printer.

B. The original copy of the Failure report must be handed over to the concerned buyer, second copy to Quarantine Stores to keep along with the items and the 3rd copy to the Stores Supdt. for follow up action.

C. Stores Officer of Quarantine Stores shall place the item in a suitable bin location and update the same using transaction MSQRT/MSQRX. (The same may be displayed by MSQRD.)

D. When the reason for failure is resolved, Quarantine Stores Officer shall delete the location from Maxi-Merlin system, update the system by transaction MSRU and route the item and all the documents to Stores Inspection for further processing.





7. COMPONENTS REMOVED FOR STAGGER PURPOSE

A. If a component is planned to be removed from a serviceable system for stagger purposes, the following procedure shall be adopted.

B. Component Control shall raise a component change sheet for the component concerned. In addition, they shall also raise a stagger removal label (Form KUK/GEN/1532). Component Control shall fill in the Serial No., Part No., Class Control No., on both these documents. The stagger labels shall be included in the applicable check/work pack if it is to be carried out during a maintenance input.

C. The Authorization Holder responsible for the removal of the component shall ensure that it is properly handled and stamp the stagger label. The following action is to be carried out by the authorized staff in Maxi-Merlin system.

i) Complete Removal/Installation by transaction CCRI with reason code = 03 and SOS flag as "Y" (Yes).

ii) Carry out transaction CCSOS as follows.

iii) To avoid extra handling, delicate instruments may be routed direct to Stores Receipt Section. "Action" code shall be "Pass" and complete other required fields as applicable. MEI Register number shall be entered in Repair Text, along with any other details like "Visual Inspection etc.

a. Stores Officer Receipt Section shall update the system by transaction "MSHI" to credit the items into Bonded Stores.

b. Items passed as serviceable, system will generate a new tag. Authorization Holders shall stamp the stagger and serviceable labels, deleting the words Insp/Overhaul/Repair/Refurbishment/Mod and insert "Visual Inspection" only and attached the stagger label KUK/GEN/1532.

c. For Failed items unserviceable portion of the installed units tag shall be completed as applicable and routed to salvage store.





d. Salvage Stores shall route the component to the applicable workshops for completion of items as necessary on reverse side of form KUK/GEN/1532.

e. Workshops shall complete KUK/GEN/1532 and declare the unit "Serviceable" by transaction PTMP-F.

8. AIRCRAFT PARTS REMOVED FOR TROUBLE SHOOTING

A. Procedure

If any item is removed from a system for trouble shooting and the defect is not rectified, the original item shall be refitted (When the item is serialized), if time permits. If the original item is not refitted, the removed item must be quarantined by transaction CCRI with reason code = 02 and "SOS" flag as "Y" (YES). Removed item must be labeled with a Trouble shooting removal label, KUK/QC/0114 and the item kept in "Suspect Cupboard" of the respective section. The unserviceable portion of identification label shall be completed and passed to Component Control.

B. All items removed shall be recorded in a register which shall be kept in the "Suspect Cupboard". Shift Supervisor shall ensure that all items are properly registered.

C. Component Control shall raise a "Trouble Shooting Monitor Advice" form (EJ/CC/TSM) for each item placed in "Suspect Cupboard" and forward the same to Engineering Services Section on the same day.

D. Engineering Services Section shall fill in the required information and dispatch the form to concerned section within five days from receipt.

E. Based on the information contained in the form, Component Control shall resolve "Quarantine" status by "CCSOS" transaction (to be actioned by authorized personnel) as follows:

i) "Fail" the unit if the defect is confirmed, declare the unit unserviceable, and route the component to salvage stores.

ii) "Pass" the unit if defect is not confirmed. If the removed unit is a delicate instrument, it shall be credited directly to Bonded Stores.





iii) Stores Officer Receipt Section shall update the system by transaction "MSHI" to credit the item into Bonded Stores.

iv) "Fail" the unit if the defect is not confirmed, and if the removed unit requires cleaning/lubrication/blanking etc. by workshop, route the same to the respective workshop.

v) Workshops shall receive those removed units, which did not clear the defect and carry out the necessary task mentioned on the reverse side of Trouble Shooting Removal Label (KUK/QC/0114). The unit may be declared "serviceable" by transaction PTMP-F "Defect Confirmed" flag shall be set as "N" (No) to avoid any effect on reliability of the unit.

vi) The item now may be sent to Bonded Stores after the new identification tag is stamped by authorization holders for "Visual Inspection" only.

vii) Stores Officer Receipt section shall close the transaction by "MSRU".




CERTIFICATE OF AUTHORIZATION, STAMP, AND SCOPE OF AUTHORITY

1. INTRODUCTION The Manager, Quality Control, is authorized to grant authorizations to suitably qualified staff for

the purpose of performing and certifying aircraft maintenance/component overhaul activities on aircraft and associated airborne equipment within the terms of Kuwait Airways approval references.

A) Certificate of Release to Service (CRS) Authorization to issue CRS may be granted by the Manager, Quality Control to appropriately

qualified persons in accordance with KCASR 145.

Such authorization holders may sign a Certificate of Release to Service for maintenance, overhaul, repair, inspection, replacement, modification and tests to aircraft, engines, or equipment in both Line, Hanger, Workshops, NDT, or LAB as applicable. Only Base Maintenance Release Authorization (BMRA) holders may sign the Group CRS for aircraft release from hangar.

B) Certificate of Maintenance Review (CMR) Authorization to issue CMR may be granted to appropriately qualified persons. Such persons

are nominated by the Manager, Quality Control and identified by name in the MOE. 2. RESPONSIBILITIES A. Manager, Quality Control shall:

i) Specify qualifications, training and work experience requirements for staff seeking authorizations.

ii) Specify the subject content of examinations. iii) Organize examinations and notify the DGCA (ASD), Section Managers, and the

Manager, Technical Training of examination dates and authorization paragraphs. iv) Maintain a register of all authorized staff listing their qualifications and authorizations

held. v) Control the issue of Authorization KUK Numbers and Stamps.

vi) Ensure that all authorized staff are issued with certificates detailing the scope, terms, conditions and limitations of their authorizations.





B. Section Heads shall: i) Administer and control applications for authorizations within their area of responsibility.

Arrange appropriate shift changes to enable candidates to attend authorization exams during duty hours.

ii) Ensure that staff recommended for authorizations have the required level of experience,

training, qualifications and technical competence for the authorization sought.

iii) Evaluate staff in their area of control for suitability prior to recommendation for issue of authorization and set criteria for their technical competence.

iv) Monitor the work performance of authorized personnel in order to identify and correct

any deficiencies and to establish any further training requirements. ii) Inform the Manager, Quality Control of any transfer of authorized staff from one

section to another, and change of status of the authorization holders. vi) Ensure all authorization holders complete their respective online recurrent training as

per EQCP Chapter 4. C. Authorization Holders shall: i) Ensure that a current copy of their license is forwarded to the office of the Manager,

Quality Control. ii) Ensure that certification of tasks does not fall outside the scope of their authorization

and their authorization certificates are valid before certification. iii) Ensure completion of tasks and conformance to appropriate approved technical

publications.

iv) Maintain an adequate knowledge of Kuwait DGCA requirements and KAC company procedures applicable to their authorizations.

v) Ensure they are involved in at least 6 months of relevant maintenance experience in any

2 year period and record such experience on the back of their authorization certificate.

vi) Inform the Manager, Quality Control in writing in case they alter their signature.





3. APPLICATIONS FOR AUTHORIZATION A. Applicants for authorizations must use QC Form KUK/806, signed by the concerned Section

Head and, for Kuwaiti Trainee/U.D. Engineers, endorsed by Technical Training (TX). Mechanics and expatriate engineers must also have their applications approved by the Engineering Director. Applicants must enclose all relevant training certificates, related worksheets (Form KUK/GEN/1570), and licenses.

B. The applicant must have completed the practical experience requirements as given in this

chapter for the category of authorization. The minimum practical experience should not include classroom training, military training and leave.

C. Applicants may not apply for more than one paragraph at a time. An exception is made for

Instruments/Integrated Flight Control Systems and Radio Navigation/Radar Systems. Outstation authorization holders are also exempt from this restriction.

D. After assessing an application, Quality Control will decide upon the extent of the necessary

examinations. 4. GENERAL EXAMINATION RULES A. Authorizations shall be restricted to those categories for which the applicant holds basic

aeronautical qualifications.

B. Applicants are required to appear for written, oral, or practical examinations on a date and time specified by Manager Quality Control.

C. The minimum pass mark for written examinations is 75%. D. Regulations and KAC Procedures Examination

i) Initial Authorizations- a. A written multi-choice examination will be given that contains 50 questions. b. Minimum pass mark will be 75%. ii) Subsequent Authorizations- During oral examinations, candidates will be questioned on Air Legislation,

Engineering and Quality Control Procedures, Engineering Bulletins, and Technical Notices.





E. If an applicant fails an examination, they will not be re-examined for at least one month from the date of their result. Only three attempts are permitted for any approval paragraph. If the applicant does not pass in three attempts, they must obtain additional practical experience of three months from the date of the third examination attempt before resubmitting their application. In certain circumstances, depending upon the number of attempts and the standard of knowledge displayed, the Manager, Quality Control may add further requirements.

F. Before submitting an application for a new paragraph, an applicant is required to clear all

outstanding paragraph examinations for which they have sat unsuccessfully. G. Examination results are sent to the candidates Section Head. H. When new aircraft types are introduced, authorizations are initially granted only to

experienced authorization holders who have completed the DGCA approved theoretical, practical, and simulator training (as applicable). Exemptions from Quality Control oral examinations may be given depending upon the circumstances.

General Notes: a. If an authorization holder is away from work for a continuous period of 12 months or more,

they will be re-examined (written and/or oral) in the area of Air Legislation / procedures / documentation and applied practices, before their authority is re-instated.

b. Candidates holding a Kuwait DGCA type rated license may be exempted from all or part of

the examination at the discretion of the Manager, Quality Control. c. Candidates applying for any authorization paragraph should be ready to appear for written,

oral, or practical examinations, and shall make themselves available at the date and time specified by the Manager, Quality Control. Section managers may have to make shift changes as required.

5. AUTHORIZATION STAMPS A. Authorization stamps are issued by the Manager, Quality Control to staff who reach a

satisfactory standard in examinations conducted by the Authorization Review Board. B. Stamps are used for the issue of Certificate of Release to Service (CRS) and any certification

on worksheets. When certifying Technical Log and Supplementary Defect Rectification Forms (SDRF), stamping is not required. A signature and written stamp number is acceptable.





C. Individuals are responsible for the safekeeping of stamps. Loss of stamp must be reported to the Manager, Quality Control in writing through the concerned section head. An administrative charge of KD 10 will be made for a replacement stamp. Damaged, worn or recovered stamps should be returned to the Manager, Quality Control. During the period (normally seven days) when the authorization holder is without a stamp, certifications may be made by signing the work item together with the authorization number until a replacement stamp is issued.

D. A register is maintained by the Manager, Quality Control for the issue of the stamps. E. Upon release from the services of Kuwait Airways, or when a change in the nature of duty

demands such action, st

EQCP-Issue 2-Revision 9 Dated July 2014

Documents

Transcript of EQCP-Issue 2-Revision 9 Dated July 2014