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1 CEM DISTRIBUTION CONTROL NO. PCAA APPROVAL NO. CAA/AW/01 PAKISTAN INTERNATIONAL HEAD OFFICE JINNAH INTERNATIONAL AIRPORT KARACHI PAKISTAN Telephone: (92 21) / Facsimile: (92 21) khimipk@piac.aero jar145audit@piac.aero Approved by: Pakistan Civil Aviation Authority Ref: HQCAA/2206/1/AW(Vol-XVII) dated 09 th March 2012 CEM TITLE Edition: 02 Revision: 07 Issue: January 12 Page 1 of 2

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3 PART 1: PREAMBLE CEM Chapter 1-0 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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5 1-1 TABLE OF CONTENTS Part 1 PREAMBLE ISSUE 1-1 Table of Contents Edition 2, Revision Record of Revisions Edition 2, Revision List of Effective Pages Edition 2, Revision Introduction and Structure of Company Exposition Manual Edition 2, Revision 7 Part 2 ORGANIZATIONAL MANAGEMENT ISSUE 2-1 Corporate Commitment by the Accountable Manager Edition 2, Revision Safety and Quality Policy Edition 2, Revision Organizational Structure Edition 2, Revision PIA Engineering Nominated Personnel Edition 2, Revision Duties and Responsibilities of the Nominated Personnel Edition 2, Revision Details of Human Resource Management Edition 2, Revision Notification of Organizational Changes to the CAA (Pak) Edition 2, Revision Amendments Control of Company Exposition Manual (CEM) Edition 2, Revision Engineering Procedures Manual (Divisional) Edition 2, Revision Safety Management System for Approved Maintenance Organisation Edition 2, Revision Authorities delegated by Director Airworthiness Edition 2, Revision 3 Part 3 FACILITIES AND WORKSCOPE ISSUE 3-1 Maintenance Base Facilities Approved by the CAA (Pak) Edition 2, Revision Line Stations Facilities Approved by the CAA (Pak) Edition 2, Revision Approved Workscope of PIA Engineering & Maintenance Edition 2, Revision PIA Aircraft Fleet Maintenance Checks and Intervals Edition 2, Revision Working Conditions of PIA Engineering & Maintenance Facilities MOE 2.7 Part 4 QUALITY ASSURANCE PROCEDURES ISSUE 4-1 Aircraft Certificates Control Procedure Edition 2, Revision Concessions Assessment and Control Procedure Edition 2, Revision Quality Audits in PIA Engineering & Maintenance MOE 3.1 & Quality Audits Follow-up and Records Procedure MOE Quality Audit Authorisations Control Procedure MOE Certifying Staff Trainings and Qualifications Procedures Edition 2, Revision Inspectors / Maintenance Staff Trainings and Qualifications Procedures MOE 3.7 & Specialized Trainings and Authorisations Procedure MOE Competence Assessment Procedure MOE Certifying Staff Authorisation Records Procedure MOE Human Factors Training Procedure MOE Concession Control for Deviation from Organisational Procedures MOE Supplier Evaluation and Subcontract Control Procedure Edition 2, Revision 5 Part 5 AIRWORTHINESS MANAGEMENT PROCEDURES ISSUE 5-1 Returns to the CAA (Pak) on PIA Engineering & Maintenance Activities Edition 2, Revision Reliability Monitoring Programme for Aircraft / Aircraft Components Edition 2, Revision Accident / Incident Reporting and Investigation Procedure Edition 2, Revision Procedure for Surveillance of Fuel Storage Facilities Edition 2, Revision 0 CEM Chapter 1-1 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 2

6 Part 5 AIRWORTHINESS MANAGEMENT PROCEDURES ISSUE 5-5 Procedure to Detect and Rectify Maintenance Errors MOE Calibration Control for Tooling / Test Equipment MOE Maintenance Data Control Procedure MOE Aircraft Maintenance Program Control Procedure MOE Airworthiness Directives Control Procedure MOE Optional Modifications Evaluation and Accomplishment Procedure MOE Special Repairs Procedure for Aircraft / Aircraft Components MOE Critical Tasks and Duplicate Inspections Control Procedure MOE Maintenance Data Inaccuracies / Ambiguities Reporting Procedure MOE Maintenance Records Control Procedure MOE Computerized Records Management Procedure MOE Control of Forms in PIA Engineering & Maintenance MOE 5.1 Part 6 MAINTENANCE PROCEDURES ISSUE 6-1 Aircraft Stores Incoming Inspection and Acceptance Procedure MOE Aircraft Stores Tagging, Storage and Issuance Procedure MOE Tooling / Test Equipment Procurement and Acceptance Procedure MOE Tooling / Test Equipment Handling Procedure MOE Scheduled Maintenance Man-Hour Control Procedure MOE Aircraft / Aircraft Components Maintenance Planning Procedure MOE Maintenance Documentation Usage and Records Completion Procedure MOE Aircraft Components Handling Procedure MOE Aircraft Components Repair Abroad Procedure MOE Shift / Task Handover Procedure MOE Aircraft / Aircraft Components Release to Service Procedure MOE Defects Rectification During Base Maintenance MOE Manufacturers and Maintenance Working Teams Control Procedure MOE Aircraft Related Specific Maintenance Control Procedures MOE Aircraft / Aircraft Components Painting Procedure Edition 2, Revision Aircraft Weighing and Test Flight Procedure Edition 2, Revision 0 Part 7 ADDITIONAL LINE MAINTENANCE PROCEDURES ISSUE 7-1 Aircraft Components and Tooling Control Procedure MOE L Aircraft Servicing / Fuelling / De-Icing Procedure MOE L Defects and Repetitive Defects Control Procedure MOE L Technical Logbook Completion Procedure MOE L Pooled Parts and Loan Parts Control Procedure MOE L Return Procedure for Defective Components, Removed from Aircraft at Line Station MOE L Critical Tasks Control Procedure at Line Station MOE L Onboard Medical Supplies Control Procedure Edition 2, Revision 0 Part 8 APPENDICES ISSUE 8-1 Appendices Edition 2, Revision 7 CEM Chapter 1-1 Edition: 02 Revision: 07 Issue: January 12 Page 2 of 2

7 1-2 RECORD OF REVISIONS Manual holders shall update their copies upon receipt of revisions. Revised pages shall be inserted in the manual and record revision table given below shall be completed. Removed pages must be discarded immediately to avoid any confusion. Upon completion of this Record of Revisions, acknowledgement shall be sent through a signed copy of Manual Status Letter. Revision Insertion Issue Date No. Date By 00 Nov EQA 01 Mar EQA 02 June EQA 03 Sept EQA 04 May 10 Merged with Rev 5 05 March EQA 06 May 11 Merged with Rev 7 07 January EQA Revision No. Issue Date Insertion Date By CEM Chapter 1-2 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 2

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9 1-3 LIST OF EFFECTIVE PAGES PART 1: PREAMBLE Chapter Page No. Edition Revision Issue Date CEM TITLE 1 of January of January of November of November of January of January of January of January of January of January of January of January of January of January of January of January 2012 PART 2: ORGANIZATIONAL MANAGEMENT CHAPTER Page No. Edition Revision Issue Date CEM of November of November of March of March of November of November of March of March of March of March of June of June of January of January of January of January of January of January of January of January of January of January of January of January of January of January of January of January of January of January 2012 CEM Chapter 1-3 Edition: 02 Revision: 07 Issue: January, 12 Page 1 of 4

10 CHAPTER Page No. Edition Revision Issue Date of June of June of November of November of January of January of September of September of September of September of September of September 2009 PART 3: FACILITIES AND WORKSCOPE CHAPTER Page No. Edition Revision Issue Date CEM of November of November of May of May of May of May of May of May of May of May of May of May of May of May of May of May of May of May of May of May of May of May of March of March 2011 PART 4: QUALITY ASSURANCE PROCEDURES CHAPTER Page No. Edition Revision Issue Date CEM of November of November of November of November of November of November 2007 CEM Chapter 1-3 Edition: 02 Revision: 07 Issue: January, 12 Page 2 of 4

11 4-6 1 of January of January of January of January of January of January of March of March of March of March of March of March 2011 PART 5: AIRWORTHINESS MANAGEMENT PROCEDURES CHAPTER Page No. Edition Revision Issue Date CEM of November of November of November of November of January of January of November of November of November of November 2007 PART 6: MAINTENANCE PROCEDURES CHAPTER Page No. Edition Revision Issue Date CEM of November of November of November of November of November of November 2007 PART 7: ADDITIONAL LINE MAINTENANCE PROCEDURES CHAPTER Page No. Edition Revision Issue Date CEM of November of November of November of November 2007 PART 8: APPENDICES CHAPTER Page No. Edition Revision Issue Date CEM of November of November of January of January of January of January of January of January 2012 CEM Chapter 1-3 Edition: 02 Revision: 07 Issue: January, 12 Page 3 of 4

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13 1-4 INTRODUCTION AND STRUCTURE OF INTRODUCTION Company Exposition Manual is developed on the recommendations of the Competent Authority. This Exposition includes procedures, means and methods with reference to quality assurance, airworthiness management and aircraft / aircraft components maintenance, transposing applicable PCAA regulations, laid down in ANO-001-AWRG PURPOSE Purpose of Company Exposition Manual (CEM) is to present the PCAA, clear picture of maintenance facilities and organizational policies / procedures, followed by all personnel, while performing maintenance on aircraft / aircraft components. Compliance with these organizational procedures shall finally demonstrate fulfilment of the applicable PCAA regulations STRUCTURE Company Exposition Manual has been structured, for ease of use, as follows: Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part CROSS REFERENCE TABLE Preamble Organizational Management Facilities and Workscope Quality Assurance Procedures Airworthiness Management Procedures Maintenance Procedures Additional Line Maintenance procedures Appendices Cross reference table presented below shows relationship of requirements laid down in the ANO-001-AWRG with the Company Exposition Manual chapters: Clause ANO-001-AWRG CEM Chapter MOE Reference D Chief Executive Statement List of nominated personnel Duties & Responsibilities of the nominated Senior personnel Organization charts Scope of facilities 3-1, Quality Control Part 4 Part 3 7 Training programs 4-6, 4-7, ,3.8, Other requirement of Airworthiness Directorate (if any) 4-1, 4-2, 5-1, 5-2, 5-4,6-15,6-16, 7-8 N/A D7.2 CEM Review D7.3 CEM Amendment and Distribution D7.4 Copies of CEM / amendment to Airworthiness Directorate D7.5 Compliance with the CAA (Pak) requirements D7.6 SMS Requirements laid down in AWNOT-072-AWRG CEM Chapter 1-4 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 4

14 ANO-001-AWRG (Appendix B ) CEM Chapter MOE Reference Para Subject a Scope of Approval b Organizational procedures and quality systems Part 4,5,6,7 Part 2,L2,3 c Engineering Manpower resources d Working hours of Engineering staff e Description of Facilities 3-1, f Names and Duties of nominated personnel 2-4, g Competence assessment of maintenance personnel h Maintenance records 5-14, 5-15, ,2.14,2.21 i Release to Service 6-11, j Certifying staff and Certification Authorization 4-6, k Additional requirement by the Operator l Reporting requirement as per AWN # m Maintenance data receiving and distribution in Organization a Company name, document title and reference number Title Page b Amendment identification c Approval by Chief Executive d Distribution list e CEM Administration responsibility f Table of Contents Purpose of CEM Premises, Facilities and undertaking 3-1, Terms of Approval and Company Capability list Nominated personnel and their Duties & Responsibilities 2-4, Organization charts Notification to the CAA (Pak) regarding changes Facilities and associated equipment 3-1, a Quality program, policy and Audit system 4-3, 4-4, ,3.2,3.3,3.6 b Product design & development control N/A N/A c Modification and repair procedure 5-9, 5-10, , 2.11, 2.12 d Concession procedure e Evaluation and defect investigation 5-5, , 2.25 f Reliability Program g Subcontractors control h Manufacture and process control i Control of stock and handling of non-conforming parts , 2.3 j Tool, test equipment control 5-6,6-3, , 2.4, 2.5 k Process control l Technical records , 2.21 m Technical publications, SB evaluation 5-8, ,2.11,2.12 n Overhaul, modification and repair of aircraft components 6-7, , 2.16 o Test flight procedure p Training 4-6, 4-7, ,3.8,3.11 q Appendices CEM Chapter 1-4 Edition: 02 Revision: 07 Issue: January 12 Page 2 of 4

15 1-4.5 DISTRIBUTION a) External Distribution Control No. E01 b) Internal Distribution Addressee Director Airworthiness, HQ Airworthiness Directorate, Civil Aviation Authority, Jinnah International Airport, Karachi, Pakistan. Control No. Addressee Format P01 Managing Director, PIA Compact Disc P02 Deputy Managing Director, PIA Compact Disc P03 Director (Engineering & Maintenance) Compact Disc P04 Director (Procurement & Logistics) Compact Disc P05 Chief Engineer (Quality Assurance) Hard copy P06 Chief Engineer (Airworthiness Management) Hard copy P07 Chief Engineer (Maintenance Operation Centre) Hard copy P08 Chief Engineer (Engineering Business Development) Hard copy P09 Chief Engineer (HR Training) Hard copy P10 Chief Engineer (Line Maintenance) Hard copy P11 Chief Engineer (Base Maintenance) Hard copy P12 Chief Engineer (Cabin Maintenance) Hard copy P13 Chief Engineer (Engine Overhaul) Hard copy P14 Chief Engineer (Aerospace Overhaul) Hard copy P15 Chief Engineer (Avionics Overhaul) Hard copy P16 General Manager (Procurement) Compact Disc P17 General Manager (Logistics) Compact Disc P18 Chief Engineer (PIA SSB Flying Academy) Compact Disc P19 Deputy Chief Engineer (Quality Audit) Hard copy P20 Deputy Chief Engineer (QA) Maintenance Hard copy P-21 Reserved CEM Chapter 1-4 Edition: 02 Revision: 07 Issue: January 12 Page 3 of 4

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19 2-1 CORPORATE COMMITMENT BY THE ACCOUNTABLE MANAGER The exposition manual and associated referenced manual defines the organization, procedures and personnel responsibilities in accordance with the requirements laid down by Pakistan Civil Aviation Authority. These procedures are approved by the undersigned and will be complied with all the times. It is further understood that CAA Pakistan under CAR 94 reserves the right to suspend, revoke or limit this organization approval, if the Competent Authority has any evidence that the procedures are not fulfilled or standards are not held. The Organization will ensure that in respect of all work performed under the terms of this Approval, adequate human resources, appropriate facilities and proper equipment are utilized and the approved procedures are adopted. The exposition manual shall be reviewed by the organization on yearly basis. Changes required as result of internal reviews or Airworthiness Directorate surveillance audits shall be forwarded to the Competent Authority for approval. Copies of all amendments shall be furnished promptly to all whom the manual has been issued. All amendments to exposition manual shall be finalized by Chief Engineer (Quality Assurance) with the consent of undersigned prior to submission for approval. An amendment, approved by the Competent Authority shall be incorporated into the exposition manual. Captain Nadeem Khan Yusufzai Managing Director, PIAC For and on behalf of Pakistan International Airlines Corporation CEM Chapter 2-1 Edition: 02 Revision: 05 Issue: March 11 Page 1 of 2

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21 2-2 PIA HEALTH, SAFETY, ENVIRONMENT & QUALITY POLICY CORPORATE POLICY STATEMENT PIA Corporate Health, Safety, Environment & Quality Policy states as: All PIA employees are committed to providing distinctive air transport services and satisfying global needs and expectations of our customers through continual improvement of: Quality of our services and processes with a view of enhancing customer satisfaction and loyalty Occupational health and safety of all personnel, aircraft, equipment and facilities Environmental quality, prevention of pollution, energy and resource conservation, reduction of waste and adoption of environment friendly practices Whilst complying with all Health, Safety, Environment and Quality system regulatory and other requirements to which the Airlines subscribes Simply stated our organizational goal is efficient provisioning of highest service quality, with no harm to people, property or environment DEPARTMENTAL POLICY STATEMENT PIA Engineering & Maintenance Safety and Quality Policy states as: Airworthiness and Quality Maintenance of aircraft and aircraft components is our highest priority. We are committed to continuously improve the quality of all our products and services to our customers satisfaction. This includes safety, reliability, performance and customer values. Recognizing safety as a prime consideration at all times, we will ensure good maintenance practices through the application of human factor principles, and encouraging personnel to report maintenance related errors / incidents. Compliance with procedures, regulations, quality and safety standards, and cooperation with quality auditors is the responsibility of all personnel of PIA Engineering & Maintenance. CEM Chapter 2-2 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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23 2-3 ORGANIZATIONAL STRUCTURE PIA CORPORATE STRUCTURE CE SSB Flying Academy PIA ENGINEERING & MAINTENANCE Chief Engineer Line Maintenance Chief Engineer Base Maintenance Chief Engineer Engine O/H Chief Engineer Aerospace O/H DIRECTOR ENGINEERING & MAINTENANCE DEPUTY MANAGING DIRECTOR Chief Engineer Airworthiness Management Chief Engineer Maint. Operation Centre Chief Engineer Engg. Business Development Chief Engineer HR, Training & Automation DIRECTOR PROCUREMENT & LOGISTICS General Manager Procurement Chief Engineer Avionics O/H Chief Engineer SSB Flying Academy General Manager Logistics CEM Chapter 2-3 Edition: 02 Revision: 05 Issue: March 11 Page 1 of 4

24 2-3.3 ENGINEERING QUALITY ASSURANCE CHIEF ENGINEER QUALITY ASSURANCE Deputy Chief Engineer Maintenance QA In-charge QA Base / OH Shops In-charge QA Ramp / Cabin AIRWORTHINESS MANAGEMENT DIVISION Deputy Chief Engineer (Maintenance Program & Reliability) Deputy Chief Engineer (Technical Publications & Records) Deputy General Manager (Facility) MAINTENANCE OPERATION CENTRE Deputy Chief Engineer Rotable Planning Deputy Chief Engineer Examinations Deputy Chief Engineer (QA) North - Islamabad CHIEF ENGINEER MAINTENANCE OPERATION CENTRE Deputy Chief Engineer Material Management ENGINEERING BUSINESS DEVELOPMENT Technical Assistant to Chief Engineer (QA) Deputy Chief Engineer Human Factors Deputy Chief Engineer (QA) North - Lahore CHIEF ENGINEER AIRWORTHINESS MANAGEMENT Deputy Chief Engineer (Aerospace) TSE Line Maintenance Deputy Chief Engineer (Avionics) TSE Line Maintenance Deputy Chief Engineer TSE Base Maintenance Deputy Chief Engineer TSE (PPOH) Deputy Chief Engineer TSE (Aerospace) O/H Deputy Chief Engineer TSE (Avionics) O/H Deputy Chief Engineer Scd. & Check Planning CHIEF ENGINEER ENGINEERING BUSINESS DEVELOPMENT Deputy Chief Engineer Quality Audit In-charge QA Audit Planning In-charge QA Standards In-charge QA Airworthiness Deputy Chief Engineer (Airframe) Engineering Deputy Chief Engineer (Avionics) Engineering Incharge Modification Planning Deputy Chief Engineer Repair Abroad Deputy Chief Engineer (Sales) A/C Maintennace Deputy Chief Engineer (Sales) Comp Maintenance Deputy Chief Engineer Projects & Marketing CEM Chapter 2-3 Edition: 02 Revision: 05 Issue: March 11 Page 2 of 4

25 2-3.7 LINE MAINTENANCE DIVISION CHIEF ENGINEER LINE MAINTENANCE Deputy Chief Engineer Line Stations Deputy Chief Engineer North Islamabad (AS) Deputy Chief Engineer North Islamabad (AV) Deputy Chief Engineer Lahore BASE MAINTENANCE DIVISION Deputy Chief Engineer Planning & Development Deputy Chief Engineer Structure Repair & Mod Deputy General Manager Hangar Equipment Maintenance ENGINE OVERHAUL DIVISION Deputy Chief Engineer (Planning) PowerPlant O/H Deputy Chief Engineer Planning Deputy Chief Engineer Jinnah Terminal Shift In-charge Deputy Chief Engineer GE90 / CF6 / CFM Deputy Chief Engineer B777 (AS) CHIEF ENGINEER ENGINE OVERHAUL AEROSPACE OVERHAUL DIVISION Deputy Chief Engineer A Shift In-charge B Shift In-charge C Shift In-charge D Deputy Chief Engineer Bay I (AS) Deputy Chief Engineer Bay III (AS) Deputy Chief Engineer IFE Base Maintenance Deputy Chief Engineer B747 / 737 (AS) Deputy Chief Engineer A310 / ATR (AS) Deputy Chief Engineer IFE Line Maintenance CHIEF ENGINEER BASE MAINTENANCE Deputy Chief Engineer Bay II (AS) Deputy Chief Engineer Aircraft Overhaul (AS) Deputy Chief Engineer Aircraft Furnishing Deputy Chief Engineer PW / RB / APU / LG CHIEF ENGINEER AEROSPACE OVERHAUL Deputy Chief Engineer B777 (AV) Deputy Chief Engineer B747 / 737 (AV) Deputy Chief Engineer A310 / ATR (AV) Deputy Chief Engineer Aircraft Appearance Deputy Chief Engineer Test & QEC Buildup Deputy Chief Engineer Shift - A Deputy Chief Engineer Shift - B Deputy Chief Engineer (Planning) Aerspace O /H Deputy Chief Engineer Repair & M odification Deputy Chief Engineer Deputy Chief Engineer Shift - C Deputy Chief Engineer Shift - D Deputy Chief Engineer Bay I & III (AV) Deputy Chief Engineer Bay II & ACOH (AV) Deputy Chief Engineer Fuel & M iscellaneous H y d ra u lic & W h e e l / B ra k e Pneum atic O /H Deputy G eneral M anager W orkshop Equipm ent Maintenance CEM Chapter 2-3 Edition: 02 Revision: 05 Issue: March 11 Page 3 of 4

26 AVIONICS OVERHAUL DIVISION CHIEF ENGINEER AVIONICS OVERHAUL Deputy Chief Engineer Deputy Chief Engineer Deputy Chief Engineer (Planning) Avionics O/H Instrument O/H Electric O/H HR TRAINING DIVISION SSB FLYING ACADEMY DIVISION PROCUREMENT & LOGISTICS DEPARTMENT General Manager Procurement Deputy General Manager Purchases CHIEF ENGINEER HR TRAINING Deputy Chief Engineer HR Training CHIEF ENGINEER SSB FLYING ACADEMY Deputy Chief Engineer SSB Flying Academy DRECTOR PROCUREMENT & LOGISTICS General Manager Logistics Deputy General Manager Stores Deputy Chief Engineer Radio O/H CEM Chapter 2-3 Edition: 02 Revision: 05 Issue: March 11 Page 4 of 4

27 2-4 PIA ENGINEERING NOMINATED PERSONNEL GENERAL Purpose of this chapter is to provide organizational designations and nominated personnel involved in management of maintenance activities on aircraft / aircraft components in PIA Engineering Department NOMINATED PERSONNEL Managing Director, PIA is the Accountable Manager of PIA Engineering & Maintenance having overall responsibility for running the Organisation. Accountable Manager has basic understanding of the CAA (Pak) regulations and responsibilities that fall upon him, under the CAA (Pak) Approval. Director (Engineering & Maintenance) is Deputy to the Accountable Manager for the CAA (Pak) Approval. Managing Director, PIA designates Chief Engineer (Quality Assurance) with the responsibility of effective quality assurance and associated feedback reporting system. Director (Engineering & Maintenance), alongwith Chief Engineers / General Manager (Procurement & Logistics) shall ensure that the Organisation is in compliance with the CAA (Pak) regulations. Nominated personnel are competent to demonstrate relevant knowledge and adequate extent of experience related to aircraft / aircraft component maintenance and managerial activities NOMINATED PERSONNEL APPROVAL BY THE CAA (PAK) Chief Engineer (Quality Assurance) shall submit, under confidential cover, credentials of all nominated personnel to the Competent Authority for prior Approval. Such approval by the CAA (Pak), in original, shall be archived by Technical assistant to Chief Engineer (Quality Assurance). For any Executive Appointments and officiating arrangements in the Organization, the CAA (Pak) letter HQCAA/2229/AW (VOL-III) dated March 4, 1993 shall be complied as under: i. The post of Deputy Chief Engineer is excluded from the ambit of Executive Appointments. ii. All appointments of Chief Engineer and Director (Engineering & Maintenance) shall require prior approval of the Competent Authority with the provision that incumbent meets the prescribed qualification criteria. iii. All officiating arrangements, exceeding one month, to the post of Chief Engineers and Director (Engineering & Maintenance) shall also require prior Approval of the CAA (Pak). For lesser periods, only intimations shall be given to the local Airworthiness office and Headquarters of the CAA (Pak). iv. All personnel deployed for officiating arrangements must meet promotion criteria for that post. CEM Chapter 2-4 Edition: 02 Revision: 02 Issue: June 08 Page 1 of 2

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29 2-5 DUTIES AND RESPONSIBILITIES OF THE NOMINATE PERSONNEL Purpose of this Chapter is to detail duties and responsibilities of the following nominated personnel, for accomplishment of all maintenance activities while ensuring that PIA Engineering & Maintenance Organisation shall remain in compliance with the PCAA regulations: Managing Director, PIA Deputy Managing Director Director (Engineering & Maintenance) Chief Engineer (Quality Assurance) Chief Engineer (Airworthiness Management) Chief Engineer (Maintenance Operation Centre) Chief Engineer (Engineering Business Development) Chief Engineer (HR Training) Chief Engineer (Line Maintenance) Chief Engineer (Base Maintenance) Chief Engineer (Cabin Maintenance) Chief Engineer (Engine Overhaul) Chief Engineer (Aerospace Overhaul) Chief Engineer (Avionics Overhaul) Chief Engineer (SSB Flying Academy) General Manager (Procurement) General Manager (Logistics) CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 18

30 2-5.1 MANAGING DIRECTOR, PIA Managing Director, PIA shall be the Accountable Manager for PIA Engineering & Maintenance regarding maintenance activities under the PCAA Organisation Approval. The Accountable Manager shall be responsible to: i. Establish PIA Engineering & Maintenance, endorse Corporate Commitment as per CEM Chapter 2-1 and define Safety and Quality Policy for the Organisation. ii. Designate Deputy Managing Director to assist the Accountable Manager on issues related to the PCAA Organisation Approval. iii. Implement an independent quality assurance system and appoint Chief Engineer (Quality Assurance) for effective surveillance of organisational activities to highest standards of airworthiness and quality. iv. Appoint / promote / transfer Directors, Chief Engineers, General Managers, Deputy Chief Engineers and Aircraft Engineers on operational / maintenance requirements. v. Ensure that required manpower resources, facilities, tooling, test equipment and spares are available to perform maintenance and additional task that may be undertaken. Approve plans and finances for maintenance capability enhancement in the Organisation. vi. Administrate Management Reviews with Deputy Managing Director, Director (Engineering & Maintenance), Director (Procurement & Logistics) and Chief Engineer (Quality Assurance) to check progress on corrective actions and overall organisational performance, in terms of quality. vii. Ensure that all payments related to the PCAA Organisation Approval, prescribed by PCAA, are paid within agreed frame of time. viii. Assure free access for PCAA personnel to PIA Engineering & Maintenance facilities, whenever called for in respect to PCAA Organisational Approval. ix. Validate the applications, for purpose of notification regarding any change in the organisational setup, before submission to PCAA. x. Operate within specific Statutory / Regulatory / Corporate directives for all PCAA Organisation Approval related activities and conform strictly to safety and operational requirements. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 2 of 18

31 2-5.2 DEPUTY MANAGING DIRECTOR Deputy Managing Director shall assist the Accountable Manager for PIA Engineering & Maintenance regarding maintenance activities on PIA fleet under PCAA Organisation Approval. Acting as deputy to the Accountable Manager, Deputy Managing Director shall be responsible to: i. Accomplish the Safety and Quality Policy of PIA Engineering & Maintenance, established by the Accountable Manager, throughout the Organisation. ii. Establish a Quality System for the Organisation to ensure that all activities are accomplished to the highest standards of airworthiness and workmanship. iii. Recommend appointments / promotions / transfer of Directors, Chief Engineers, General Managers, Deputy Chief Engineers and Aircraft Engineers. iv. Assist the Accountable Manager on issues related to the PCAA Organisation Approval and to deputize during absence of the Accountable Manager. v. Attend management reviews, in the capacity of Deputy to Accountable Manager, to check the progress of corrective actions. vi. Appraise and provide required manpower resources, facilities, tooling, test equipment and spares to perform all scheduled and unscheduled maintenance tasks. Review and recommend to the Accountable Manager all plans and finances for maintenance capability enhancement in the Organisation. vii. Recommend all payments related to the PCAA Organisation Approval, prescribed by PCAA and apprise Accountable Manager for disbursement of such payments within agreed frame of time. viii. Provide free access for PCAA personnel to PIA Engineering & Maintenance facilities, whenever called for in respect to PCAA Organisational Approval. ix. Recommend any change in the organisational setup to the accountable Manager, for purpose of notification before submission to PCAA. x. Operate within specific Statutory / Regulatory / Corporate directives for all PCAA Organisation Approval related activities and conform strictly to safety and operational requirements. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 3 of 18

32 2-5.3 DIRECTOR (ENGINEERING & MAINTENANCE) Director (Engineering & Maintenance) shall assist the Accountable Manager on issues related to the PCAA Organisation Approval of PIA Engineering & Maintenance. While, reporting to the Deputy to Accountable Manager, Director (Engineering & Maintenance) shall be responsible to: i. Manage organisational activities, fulfilling corporate commitment by Accountable Manager and implementing Safety and Quality Policy in the Organisation, complying with the PCAA regulations. ii. Recommend appointment / promotion / transfer of Chief Engineers, Deputy Chief Engineers and Aircraft Engineers to Deputy Managing Director. However, transfer of Deputy Chief Engineers / Aircraft Engineers, within department, shall be approved by Director (Engineering & Maintenance). iii. Review requirements related to human resource, facilities, equipment, spares and maintenance capability enhancement. Such requirements must be brought into the Knowledge of Deputy Managing Director without any delay. iv. Collaborate with Chief Engineer (Quality Assurance) for implementation of an effective quality assurance system in the Organisation to ensure that all activities are accomplished to the highest standards of airworthiness. v. Participate in Management Reviews to present progress on corrective / preventive actions and overall organisational performance, in terms of quality. Ensure corrective actions implementation in timely manner against any finding, observed by personnel from PCAA / Engineering Quality Assurance during quality audits / ramp inspections / spot checks. vi. Ensure that required facilities, tooling, test equipment and spares are procured, maintained and utilised as per the PCAA regulations. vii. Ensure that all required maintenance on PIA fleet shall be performed and certified in accordance as per standard required by PCAA regulations and organisational procedures. Records of maintenance performed shall be archived, in a safe / secure location, for the permissible period. viii. Establish system for review of all applicable technical standards, in order to maintain airworthiness of aircraft / aircraft components and associated systems. ix. Initiate approval for fee and charges related to the PCAA regulations Approval beforehand, ensuring the payments are made within the agreed frame of time. x. Make arrangements for free access of personnel from PCAA to PIA Engineering & Maintenance facilities, whenever called for in respect to PCAA Organisational Approval. xi. Represent PIA Engineering & Maintenance in an authorised position for all correspondences with PCAA and other organisations. xii. Propose plans for organisational capability enhancement in PIA Engineering & Maintenance and supervise timely accomplishment of all such approved plans. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 4 of 18

33 2-5.4 CHIEF ENGINEER (QUALITY ASSURANCE) Chief Engineer (Quality Assurance) is designated by the Accountable Manager for surveillance of all activities ensuring that Organisation remains in compliance with the regulations laid down by the PCAA. Chief Engineer (Quality Assurance) is authorised to manage Company Approvals (qualifications) system for the Organisation, under the delegated powers by the PCAA Airworthiness Directorate. Main responsibilities are to: i. Implement independent quality assurance system for surveillance of all organisational activities as per the PCAA regulations, through an annual plan for procedure and product audits. ii. Administrate processes of scheduled / unscheduled audits, spot checks and ramp inspections. Conduct audits, request corrective actions against findings and generate audit reports to communicate quality related matters to the Accountable Manager, Deputy Managing Director and Director (Engineering & Maintenance). iii. Participate in Management Reviews to present progress on the remedial actions against significant findings, maintaining effective feedback system on quality and implementation of remedial actions by respective divisions. iv. Develop Company Exposition Manual, control its subsequent amendments and submit amendments to PCAA for Approval. v. Manage effective technical qualifications system for AME Licences / Company Approvals applications processing in close liaison with the PCAA and conduct examinations for various categories of Company Approvals. vi. Issue Certification Authorisations to maintenance personnel, fulfilling requirements as per laid down organisational procedures and control such authorisations in the Organisation. Manage Certification Authorisations records and maintain List of Certifying Staff for PIA Engineering & Maintenance. vii. Evaluate and approve plans, contents, pre-qualification rules and durations for any initial and continuation training with regular review of organisational procedures effectiveness. viii. Evaluate and approve suppliers / subcontractors for inclusion in Approved Vendors List (AVL), administer suppliers / subcontractors follow up and monitor the quality of subcontracted tasks. ix. Appraise and present the Company Capability List (CCL) of PIA Engineering & Maintenance and its revisions to PCAA whenever called for. x. Report an un-airworthy condition to PCAA and request for concession in justified cases, if deemed necessary. xi. Ensure free access for PCAA personnel to PIA facilities, in relation to the aircraft / aircraft component maintenance, whenever called for in respect to PCAA Organisational Approval. xii. Devote maximum time to activities for continual improvement, in respect of quality assurance concept. Supervise personnel assigned with duties in the division. xiii. Represent PIA Engineering & Maintenance in his authorised position for all correspondences with the Authorities and other organisations. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 5 of 18

34 2-5.5 CHIEF ENGINEER (AIRWORTHINESS MANAGEMENT) Chief Engineer (Airworthiness Management) shall be Incharge for development of all aircraft / aircraft component maintenance specifications, modifications control and reliability engineering activities. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Provide required engineering support for maintenance and inspection activities. Evaluate Airworthiness Directives / mandatory modifications, Service Bulletins, unscheduled tasks and Engineering Change Orders (ECOs) related to aircraft / aircraft components, providing complete work instructions and procedures. iv. Supervise development of maintenance specifications for maintenance tasks according to Work Order. Checking that required maintenance is carried out as per contract with customer, certified in compliance with current applicable regulations / procedures and deferred tasks have been justified. v. Ensure that controlled maintenance data for aircraft / aircraft components shall be available, throughout the Organisation. Administer technical libraries, update definitions and acquire all required documentation from Authorities, manufacturers and approved sources. vi. Review requirement of tooling / equipment / material required against scheduled maintenance / maintenance data and advise concerned division. Moreover, manage approvals for alternates against justified requirements generated by production areas. vii. Develop maintenance specifications for aircraft / aircraft components, maintained by the Organisation, according to Work Order and obtain necessary approval from PCAA for any proposed change. viii. Ensure maintenance records completion, management of records archiving and issuance of such record to customer in accordance with the contract. ix. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). x. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. xi. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. xii. Report without any delay, to Chief Engineer (Quality Assurance), Accountable Manager and Competent Authority in case of an unairworthy condition. Conduct investigations of all technical delays / incidents / accidents and monitor repeated defects under intimation to PCAA. xiii. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Airworthiness Management division. xiv. Represent PIA Engineering & Maintenance in his authorised position for all the correspondences with other organisations. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 6 of 18

35 2-5.6 CHIEF ENGINEER (MAINTENANCE OPERATION CENTRE) Chief Engineer (Maintenance Operation Centre) shall act as coordinator for all divisions to ensure effectiveness of major production planning activities in the Organisation. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Manage Company Capability List (CCL) and shop allocations for all components being maintained by PIA Engineering & Maintenance. Each revised list must be submitted to Chief Engineer (Quality Assurance) for appraisal and onward submission to PCAA for Approval. iv. Manage provisioning of rotables, repairables, spares and materials as per the requirements for maintenance, forwarding demands to Procurement & Logistics division. v. Maintain database of applicable tooling / test equipment required by maintenance divisions according to the scope of work. vi. Manage annual hangar visits plan for all checks on aircraft including customer aircraft ensuring compliance of safety and airworthiness requirements within required frame of time. Conduct pre-dock meetings for review prior to the aircraft base check. Revise all such plans and groundings, if required and issue revisions accordingly. vii. Coordinate with divisional heads, for cost analysis, to finalise proposal on the annual budget. Submit such proposed budget for the approval of Accountable Manager. viii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. ix. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. x. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. xi. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Maintenance Operation Centre. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 7 of 18

36 2-5.7 CHIEF ENGINEER (ENGINEERING BUSINESS DEVELOPMENT) Chief Engineer (Engineering Business Development) shall coordinate with all relevant divisions of PIA Engineering & Maintenance for maintenance activities on Customers aircraft / aircraft components. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Develop and implement marketing / sales plans for the Organisation in an effective manner to achieve defined objectives and target revenues. Promote engineering & maintenance services and conduct surveys to explore market related to quality engineering & maintenance services. iv. Develop feedback system to achieve customers satisfaction, regarding aircraft / aircraft components maintenance activities and suggest improvement in services to the Accountable Manager. v. Administer all maintenance contracts with customer organisations in most effective manner. Manage overall control on customers work orders for aircraft / aircraft component maintenance. vi. Participate in administration of organisational capability enhancement projects to attain status of self-sufficient organisation for maintenance on aircraft / aircraft components as per the PCAA Organisation Approval. vii. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). viii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. ix. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. x. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or a deviation from organisational procedures and ultimately to the Accountable Manager. xi. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Engineering Business Development division. xii. Represent PIA Engineering & Maintenance in his authorised position for all correspondences with the customer organisations and other related agencies. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 8 of 18

37 2-5.8 CHIEF ENGINEER (HR TRAINING) Chief Engineer (HR Training) shall coordinate with all divisions of PIA Engineering & Maintenance for manpower resources, trainings and automation services for technical areas. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and competence of the personnel is assessed in this regard. iii. Evaluate required manpower resources and skills for intended scope of work in coordination with divisional heads. Prepare selection criteria and obtain approval of the Accountable Manager for such induction. iv. Prepare master Man-Hour Plan in liaison with Chief Engineers and review plan every three months. Notify to the Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours. v. Ensure appropriate training need analysis for management and other personnel in the Organisation. Establish pre-qualification rules for trainings and annual plans for initial and continuation trainings on annual basis. Review effectiveness of training processes through feedback system. vi. Establish continuous liaison with Data Processing department for provisioning and regular updating of PIA Aircraft Maintenance Management Information System (PAMMIS) in the Organisation. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of any deviation from organisational procedures and ultimately to Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Human Resource Training. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 9 of 18

38 2-5.9 CHIEF ENGINEER (LINE MAINTENANCE) Chief Engineer (Line Maintenance) shall be Incharge for line maintenance activities, defined under the PCAA Organisation Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Develop and implement plans to provide optimum aircraft utilisation effectively ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks. iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR Training) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours. vi. Ensure that all maintenance including defect rectification and aircraft appearance, in Line Maintenance division, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to PCAA. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Line Maintenance division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 10 of 18

39 CHIEF ENGINEER (BASE MAINTENANCE) Chief Engineer (Base Maintenance) shall be the Incharge for heavy maintenance on aircraft and the aircraft structures, defined in the intended scope of work under the PCAA Organisation Approval. Maintenance of different types of mechanically operated ground support equipment, rigs, docks and trestles as well shall also be administered by the same position. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Provide heavy aircraft maintenance to PIA and / or Customer as per organisational Hangar Visit Plan ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks. iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR Training) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours. vi. Ensure that all maintenance including major checks, overhaul and modifications, in Base Maintenance division, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to PCAA. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Base Maintenance division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 11 of 18

40 CHIEF ENGINEER (CABIN MAINTENANCE) Chief Engineer (Cabin Maintenance) shall be Incharge for appearance (cabin cleaning, disinfecting, hygiene control, etc.) and furnishing (cabin renovation, surface protection, interior upkeep, aircraft painting, etc.) of the aircraft, defined in intended scope of work, under PCAA Organisation Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Develop and implement plans to provide aircraft appearance / furnishing effectively and efficiently ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks. iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR, Training & Automation). v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR, Training & Automation) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available manhours. vi. Ensure that maintenance on cabin appearance / furnishing items during aircraft line / base maintenance is performed in accordance with approved maintenance data and the tooling / equipment are calibrated as per organisational procedures / standards acceptable to PCAA. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to the Cabin Maintenance division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 12 of 18

41 CHIEF ENGINEER (ENGINE OVERHAUL) Chief Engineer (Engine Overhaul) shall be Incharge for component-level maintenance on engines and APUs, defined in intended scope of work, under the PCAA Organisation Approval. Maintenance of all types of mechanical plants and workshop equipment shall be administered by the same position as well. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Develop and implement plans to provide off-wing maintenance on engines and APUs ensuring required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks. iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR Training) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours. vi. Ensure that all components maintenance is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to PCAA. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Engine Overhaul division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 13 of 18

42 CHIEF ENGINEER (AEROSPACE OVERHAUL) Chief Engineer (Aerospace Overhaul) shall be Incharge for the component-level maintenance on landing gears, hydraulic, pneumatic, fuel and auxiliary components, defined in intended scope of work, under the PCAA Organisation Approval. Maintenance of all types of mechanical plants and workshop equipment shall be administered by the same position as well. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Develop and implement plans to provide off-wing maintenance on landing gears, hydraulic, pneumatic, fuel and miscellaneous auxiliary components ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks. iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR Training) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours. vi. Ensure that all components maintenance is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to PCAA. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Aerospace Overhaul division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 14 of 18

43 CHIEF ENGINEER (AVIONICS OVERHAUL) Chief Engineer (Avionics Overhaul) shall be Incharge for component-level maintenance on instrument, electrical and radio / radar and auxiliary components, defined in intended scope of work, under the PCAA Organisation Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Develop and implement plans to provide maintenance on instrument, electrical, radio / radar and auxiliary components ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks. iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR Training) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours. vi. Ensure that all components maintenance is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per the organisational procedures / standards acceptable to PCAA. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Avionics Overhaul division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 15 of 18

44 CHIEF ENGINEER (SSB FLYING ACADEMY) Chief Engineer (SBB Flying Academy) shall be Incharge of the maintenance activities at PIA SBB Flight Academy under the PCAA Organisation Approval. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Develop and implement plans to provide optimum aircraft utilisation effectively ensuring that required facilities, tooling / equipment, materials and associated means are available for all scheduled and anticipated tasks. iv. Define manpower, skills and training needs for intended scope of work in liaison with Director (Engineering & Maintenance) and Chief Engineer (HR Training). v. Prepare divisional Man-Hour Plan in liaison with Chief Engineer (HR Training) and review plan every three months. Notify to Accountable Manager through Chief Engineer (Quality Assurance) any critical shortfall in available man-hours. vi. Ensure that all maintenance including defect rectification, at PIA SSB Flying Academy, is performed in accordance with the approved maintenance data and tooling / equipment are calibrated as per organisational procedures / standards acceptable to PCAA. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of an unairworthy condition or deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to PIA SSB Flying Academy. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 16 of 18

45 GENERAL MANAGER (PROCUREMENT) General Manager (Procurement) shall be Incharge for procurement of all aircraftrelated stores required during aircraft / aircraft component maintenance. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Maintain Approved Vendors List (AVL) for components being maintained by PIA Engineering & Maintenance. Each revised list shall be submitted to Chief Engineer (Quality Assurance) for appraisal. iv. Manage procurement of aircraft rotables, consumables, materials and tooling / test equipment and maintenance services from approved suppliers / contractors in accordance with Approved Vendor List (AVL). v. Keep close liaison with Chief Engineer (Maintenance Operation Centre) on regular basis for procurement support related to aircraft / aircraft component maintenance, including all AOG / Critical requirements. vi. Ensure that adequate security of information and transparency is adopted during market research and procurement process in an ethical manner to safeguard interest of the Organisation within the statutory framework. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of a deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Procurement & Logistics division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 17 of 18

46 GENERAL MANAGER (LOGISTICS) General Manager (Logistics) shall be Incharge for storage, handling and distribution of aircraft-related supplies to maintenance personnel during aircraft / aircraft component maintenance. Main responsibilities are to: i. Administer entire division in conformity with contents of Safety and Quality Policy and corporate commitment made by the Accountable Manager. ii. Ensure that all personnel and management of the division are fully aware of organisational procedures, know their obligation to such procedures and check the skill of personnel. iii. Ensure that aircraft rotables, consumables, materials and tooling / test equipment and maintenance services are received from approved suppliers / contractors in accordance with Approved Vendor List (AVL) and Purchase / Repair orders. iv. Keep close liaison with Chief Engineer (Maintenance Operation Centre) on regular basis for procurement & logistics support related to aircraft / aircraft component maintenance, including all AOG / Critical requirements. v. Ensure that adequate security measures are adopted to protect all aircraft-related stores against fire and deterioration during storage and at various stages of their handling. vi. Identify slow moving / surplus / obsolete / dead inventory, provide assistance for perpetual inventory / physical stocktaking and arrange disposal of surplus / scrapped aircraft components / spares as per organisational procedures. vii. Participate in Audit and implement corrective actions against all findings in timely manner. Attend Management Reviews to present detailed progress on corrective / preventive actions, if required by the Accountable Manager. viii. Conduct regular meetings to ensure effective coordination of sectional activities. Plan all activities regarding implementation of organisational procedures. ix. Report without any delay, to Chief Engineer (Quality Assurance), in case of a deviation from organisational procedures and ultimately to the Accountable Manager. x. Initiate all possible actions to enhance divisional performance, including proposals on issues that affect the Organisation although not directly related to Procurement & Logistics division. CEM Chapter 2-5 Edition: 02 Revision: 07 Issue: January 12 Page 18 of 18

47 2-6 DETAILS OF HUMAN RESOURCE MANAGEMENT GENERAL PIA Engineering & Maintenance shall ensure that sufficient manpower is available for all maintenance activities. Process of manpower resources, in a sequential manner, shall be based on following: Manpower assessment Recruitment of new personnel (based on manpower assessment) Training needs Analysis MANPOWER ASSESSMENT Chief Engineer (concerned) shall initiate manpower assessment process for next calendar year, in the month of October. Each divisional head shall determine required man-hours for the division, to develop Divisional Man-hour plan. Such plan shall be submitted to Deputy Chief Engineer (HR, Training & Automation). Following shall be the basis for assessment of required man-hours: Scheduled work load pattern Hangar visit plan Availability of ground time Estimated man-hour per employee Skills / specialized services required With inputs from all divisions, Master Man-hour Plan for Organization shall be developed by Deputy Chief Engineer (HR, Training & Automation) and finalized by Chief Engineer (HR, Training & Automation), under Ref. No: E&M/CE(P&P)/MHP. Chief Engineer (HR, Training & Automation) shall assess manpower requirements with existing Human Resource Budget (HRB) of PIA Engineering & Maintenance in order to propose changes, if any. Human Resource Budget (HRB) is maintained by Deputy General Manager (HR) Engineering, under Ref. No: E&M/AM/HRB. Such HRB contains following information: Location Designation, Cadre (Technical / Administrative / Support) Expertise (Specialized Skill / Trade) Sectional Strength and Total Strength (No. of employees at division level) Upon receipt of required manpower proposal from Chief Engineer (HR, Training & Automation), Deputy General Manager (HR) Engineering shall draft amendments, if required, in existing HRB for next calendar year and submit to the management for approval. Approved HRB for next calendar year shall then be distributed to each Chief Engineer through Deputy General Manager (HR) Engineering RECRUITMENT / PROMOTION / REDESIGNATION OF PERSONNEL Recruitment of personnel for the Organization shall be based on approved HRB for each calendar year. Recruitment policy for personnel shall be referred to PIA Personnel Policies Manual. PIA Engineering & Maintenance, in accordance with the policies defined, shall select and appoint maintenance staff on permanent or contractual basis. Contractual maintenance staff shall be personnel, working under supervision by the CEM Chapter 2-6 Edition: 02 Revision: 02 Issue: June 08 Page 1 of 2

48 qualified and authorised PIA Engineering & Maintenance personnel. Criteria for promotion / re-designation, to the cadre of Deputy Chief Engineer and above, shall be based on technical qualifications and experience, in accordance with regulations laid down by the CAA (Pak). Job Description Manual of PIA Engineering department clearly defines educational / technical qualifications and related work experience requirements for each senior position TRAINING NEEDS ANALYSIS Training requirements shall be analysed for personnel, at all levels, in the Organization. Training plan shall be developed for Initial (Basic / Type) and Continuation / Re-current trainings as per the procedures detailed in CEM Chapter 4-6 & Chapter DETAILS OF TOTAL MANPOWER Details for number of staff distribution in each division as per specialized skills / trades are demonstrated in the Master Man-hour plan. However, number of staff in various sections keeps on changing, depending on operational requirements. CEM Chapter 2-6 Edition: 02 Revision: 02 Issue: June 08 Page 2 of 2

49 2-7 NOTIFICATION OF CHANGES IN ORGANIZATION S SCOPE / LOCATION / FACILITIES / NOMINATED PERSONNEL TO THE CAA (PAK) With due consent of Accountable Manager, Chief Engineer (Quality Assurance) shall be responsible for notification of any change concerning organization s scope / location / Facilities / nominated personnel to the Competent Authority NOTIFIABLE CHANGES Following are the changes, subject to notification to the Competent Authority: Name of the Organization Location of the Organization Scope of the CAA (Pak) Approval Nominated Personnel specified in CEM Chapter 2-4 Facilities, equipment, tools, material, procedures, work scope and certifying staff that could affect the approval PROCEDURE Chief Engineer (Quality Assurance) shall inform the Competent Authority for any of the above-mentioned changes. For required change, an application shall be made through a letter requesting change alongwith justification thirty days ahead of incorporation date. Proposed amendment shall be submitted to the Competent Authority alongwith letter. In case of Accountable Manager change, a new statement for Corporate Commitment shall be signed by the successor for submission to the Competent Authority INCORPORATION OF AMENDMENT In general, changes shall not be effective before notification and receipt of Approval from the Competent Authority. For an unforeseen change of nominated personnel, the Competent Authority shall be notified within shortest possible time, but not later 72 hours from the date of change occurred. Chief Engineer (Quality Assurance) shall be responsible to notify such change to the Competent Authority. CEM Chapter 2-7 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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51 2-8 AMENDMENTS CONTROL OF (CEM) MANAGEMENT OF CEM Company Exposition Manual (CEM) procedures have been approved by Accountable Manager, as per corporate commitment in CEM Chapter 2-1. Under delegated authority, Chief Engineer (Quality Assurance) shall control amendment process of this Exposition alongwith all associated maintenance procedures and submit any amendment in this context to PCAA, for approval KNOWLEDGE OF CEM Chief Engineer / General Manager (concerned) shall ensure that personnel of respective divisions are well acquainted with contents / application of Company Exposition Manual (CEM) and associated procedures concerning job roles assigned to the individuals. Personnel in the Organisation are equally responsible to notify respective Deputy Chief Engineers / Deputy General Manager for any improvement / change in the manual. Any typographic error or ambiguity in a procedure shall be reported without any delay. In all cases, after initial assessment, respective Deputy Chief Engineer / Deputy General Manager shall forward recommendations to Deputy Chief Engineer (Quality Audit) for evaluation of an amendment for compliance with PCAA regulations APPROVAL OF CEM AMENDMENTS An amendment in Company Exposition Manual (CEM), affecting scope of PCAA Approval, must be submitted to PCAA for approval, prior to its incorporation. Deputy Chief Engineer (Quality Audit) shall recommend proposed amendment to Chief Engineer (Quality Assurance), if found compliant with PCAA regulations. Chief Engineer (Quality Assurance) shall submit copies of affected pages from Company Exposition Manual (CEM), containing proposed amendments, with application for Amendment. Whenever an alteration is recommended by PCAA in proposed amendment, Chief Engineer (Quality Assurance) shall prepare an acceptable revision for re-submission to PCAA. An amendment, such as correction due to typo-error within text, not affecting the prime intent of any procedure in Company Exposition Manual (CEM), shall be considered as Minor Amendment. Such proposed amendment shall be submitted to Chief Engineer (Quality Assurance) for indirect approval. However, Chief Engineer (Quality Assurance) shall notify such indirect approval to PCAA for endorsement at the earliest, through revised Company Exposition Manual (CEM) pages under a covering letter INCORPORATION OF AMENDMENT Upon grant of approval from the PCAA for an amendment affecting scope of PCAA Approval, Chief Engineer (Quality Assurance) shall authorise Deputy Chief Engineer (Quality Audit) to issue an amendment. Deputy Chief Engineer (Quality Audit) shall maintain records for all amendments. Letter of Approval from PCAA (in original) and stamped page of amendment shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance). Individual change requires revision number modification. Whereas, a complete new CEM Chapter 2-8 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 2

52 edition of Company Exposition Manual (CEM) shall be developed for several changes. Chief Engineer (Quality Assurance) shall submit the new draft of Company Exposition Manual (CEM) under a covering letter, requesting PCAA for approval DISTRIBUTION OF CEM AND ITS AMENDMENTS a) Paper Format For distribution of Company Exposition Manual (CEM), Deputy Chief Engineer (Quality Audit) shall issue a Manual Control Number (Refer CEM Chapter 1-4) to each controlled copy for traceability. Deputy Chief Engineer (Quality Audit) shall despatch amended pages to Main Technical Library for preparation and distribution of copies to all addressees, as per distribution list (Refer CEM Chapter 1-4) alongwith Manual Status Letter, in duplicate. Reference of the Competent Authority s Approval shall be mentioned on title page of each copy. An amendment shall be incorporated by inserting new (amended) page and replacing existing page. Margin line, on left-side, will identify latest revision on each affected page. Each manual holder, upon incorporation of amendment, shall complete the Record of Revisions (Refer CEM Chapter 1-2). Each holder of Company Exposition Manual (CEM) shall retain original Manual Status Letter in beginning of Manual. Previous Manual Status Letter and obsolete pages must be discarded to avoid any confusion. Whereas copy of effective letter, duly signed by holder, shall be returned to Main Technical Library as acknowledgement for receipt and incorporation of particular amendment. Upon receipt of Manual Status Letters from all manual holders, Incharge Main Technical Library shall archive the letters and inform Deputy Chief Engineer (Quality Audit) accordingly. b) Electronic Copy Format Company Exposition Manual (CEM) and all associate maintenance procedures shall be available in electronic copy format on organisational intranet ( for secured accessibility through corporate accounts. Deputy Chief Engineer (Quality Audit) shall arrange in-time updates of electronic copy alongwith revision of Company Exposition Manual (CEM) in hard copy format. Certifying Staff shall be trained on amendments in Company Exposition Manual (CEM), through continuation training program. Each manual holder shall communicate any amendment in Company Exposition Manual (CEM) to personnel of respective division. Printing of Company Exposition Manual (CEM) is allowed within the Organisation for ease of consultation / references / trainings. However, responsibility to ensure updates shall remain with the possessor of printed copy. Such individual printed copy shall be authorised by Chief Engineer (concerned). CEM Chapter 2-8 Edition: 02 Revision: 07 Issue: January 12 Page 2 of 2

53 2-9 ENGINEERING PROCEDURES MANUAL (DIVISIONAL) PURPOSE To define PIA Engineering & Maintenance policies regarding management and control of Engineering Procedures Manual at divisional level GENERALITIES Engineering Procedures Manual being an associated document to Company Exposition Manual (CEM) shall be developed by each division of PIA Engineering & Maintenance. Chief Engineer (concerned) shall ensure that contents are in conformance to the PCAA regulations and procedures elaborated in Company Exposition Manual (CEM). Engineering Procedures Manual shall be controlled and revisions to be distributed from Chief Engineer (concerned) Secretariat as per distribution list (Engineering Procedures Manual Part 1). Following shall be the structure of Manual: Part 1 PREAMBLE Part 2 DIVISIONAL ORGANIZATION, FACILITIES AND WORK SCOPE Part 3 FUNCTIONS, DUTIES AND RESPONSIBILITIES Part 4 PROCESSES AND DOCUMENTS a) Part 1 PREAMBLE This Part shall be developed to provide general overview of divisional manual. Format shall be similar as of Company Exposition Manual (Part 1 Preamble ). b) Part 2 DIVISIONAL ORGANIZATION, FACILITIES AND WORKSCOPE This Part shall contain following sub-parts (chapters): Divisional Structure Organizational charts for the division Human Resource Details of manpower at all level in the division Facilities Major installations and equipment Workscope as per Approval Schedule issued by PCAA Airworthiness Directorate. Sub-parts (chapters) shall contain further details of organizational structure (all cadres), human resource, facilities at divisional level and relevant workscope, as mentioned in Company Exposition Manual and related to the division. c) Part 3 FUNCTIONS, DUTIES AND RESPONSIBILITIES This Part shall contain the following sub-parts (chapters): Main and Specific Function section-wise details Duties and Responsibilities at all levels, covering divisional functions d) Part 4 PROCESSES AND DOCUMENTS This Part shall contain the following sub-parts (chapters): Processes & Flowcharts CEM Chapter 2-9 Edition: 02 Revision: 03 Issue: September 09 Page 1 of 2

54 Sample of internal documents / forms, being used in the division Processes / Flowcharts shall describe processes specific to the division, not mentioned in Company Exposition Manual (CEM). However, if a process is found common for two or more divisions, recommendation for addition of such process in Company Exposition Manual (CEM) shall be made as per CEM Chapter APPROVAL PROCESS Chief Engineer (concerned) shall submit Engineering Procedures Manual (EPM) for the division and its subsequent revisions to Chief Engineer (Quality Assurance) for review of contents. Review shall be based on the PCAA regulations and Company Exposition Manual (CEM), approved by the competent Authority. Chief Engineer (Quality Assurance) shall approve Engineering Procedures Manual of relevant division under delegated authority by the Director Airworthiness, provided the document is found in compliance with above-mentioned criteria and amendment is not affecting the PCAA Approval Schedule. Chief Engineer (Quality Assurance) shall send intimation for such approvals to the PCAA Airworthiness Directorate for regularization. An amendment, affecting the PCAA Approval Schedule or being in contradiction with the PCAA regulations, shall be reviewed by Chief Engineer (Quality Assurance) and if deemed necessary shall be submitted to the PCAA Airworthiness Directorate for policy decision. Such amendment shall not be effective unless an approval is granted by the Director Airworthiness. Upon approval of the manual or its subsequent amendment, Chief Engineer (Quality Assurance) shall authorise Chief Engineer (concerned) to distribute the document as per distribution list of relevant manual. Deputy Chief Engineer (Quality Audit) shall manage records related to Engineering Procedures Manual (EPM) in the Organisation, archiving manuals (original), subsequent amendments, related correspondence and the approval copies. CEM Chapter 2-9 Edition: 02 Revision: 03 Issue: September 09 Page 2 of 2

55 2-10 SAFETY MANAGEMENT SYSTEM FOR APPROVED MAINTENANCE ORGANISATION PURPOSE To define policies in implementation of the ICAO Safety Management System, in PIA Engineering & Maintenance as per ANO , issued by the PCAA PROCEDURE a) General Safety Management System (SMS) is a systematic approach for managing the safety, including necessary organisational structures, accountabilities, policies and procedures. Safety of flight is primarily dependant on Airworthiness of aircraft. Safety management in the area of aircraft / aircraft components maintenance, inspection, repair and overhaul are therefore vital to flight safety. The term safety in aircraft context is often considered to have two connotations. One emphasizes on the process to guarantee that Organisation provides airworthy aircraft for flight operations while second promotes the process for ensuring industrial safety and hygiene for protection of personnel, facilities and equipment but linked with Occupational Health and Safety (OHS) issues. Safety Management System deals with operational safety and works on the following methodology: Identifies safety hazards Ensures remedial action implementation, necessary to maintain safety performance Fosters continuous monitoring and regular assessment of safety performance Aims at continuous improvement of overall performance of the SMS Implementation of Safety Management System in PIA Engineering & Maintenance shall be based on policies and procedures as defined in PIA Safety Management System Manual, duly approved by the Competent Authority. b) Organization for Safety Management System Director (Engineering & Maintenance) shall be responsible to implement non-punitive safety culture, ensuring that the Organisation remains in compliance with ANO and shall demonstrate relevant knowledge and adequate extent of experience related to aircraft / aircraft component maintenance and managerial activities. Chief Engineer (Quality Assurance) shall act as Safety Manager for the Organisation, providing assistance for system development and surveillance for Safety Management System requirements, laid down in the ICAO Safety Management Manual. Chief Engineers shall be responsible for implementation of Safety Management System (SMS) in their respective divisions. Personnel at divisional level shall be involved for system implementation with regular hazard identification and risk assessments. c) Training Trainings for Safety Management System (SMS) shall be provided to personnel in the Organisation prior to their involvement in system implementation. Chief Engineer (HR, Training & Automation), in coordination with all divisional heads, shall perform Training CEM Chapter 2-10 Edition: 02 Revision: 03 Issue: September 09 Page 1 of 2

56 Need Analysis (TNA). General Manager (Corporate Safety & Quality Assurance) shall arrange such trainings in coordination with Chief Engineer (HR, Training & Automation). d) Hazard Identification and Risk Management Hazard identification process must take place within a non-punitive / just safety culture as per PIA Safety Management System (SMS) Manual, Chapter-6. Chief Engineer (concerned) shall formulate Safety Action Groups to perform hazard identification and risk management in the division. e) Records Hazard identification and risk management activities shall be recorded in the form of safety risk registers, reporting forms and meeting minutes. Chief Engineer (concerned) shall ensure effective development, updating and archiving of records. A controlled copy shall be sent to General Manager (Corporate Safety & Quality Assurance) for oversight, consolidation and management / facilitation of safety database. Chief Engineer (Airworthiness Management) shall ensure administration of all technical records pertaining to aircraft / aircraft maintenance as per CEM Chapter Deputy Chief Engineer (Technical Services Engineering) concerned shall manage technical investigations and archive all records. Technical Assistant to Chief Engineer (Quality Assurance) shall control records for technical qualifications and authorisations in the Organisation. CEM Chapter 2-10 Edition: 02 Revision: 03 Issue: September 09 Page 2 of 2

57 2-11 AUTHORITIES DELEGATED BY DIRECTOR AIRWORTHINESS PURPOSE To define the authorities delegated by Director Airworthiness to Chief Engineer (Quality Assurance) for surveillance of all activities, pertaining to aircraft / aircraft component maintenance in the Organisation, on behalf of the Competent Authority PROCEDURE a) General Surveillance of PCAA Approval for large organisations, involved in aircraft / aircraft components maintenance, requires considerable number of activities to be performed by the Competent Authority. In order to establish effective surveillance and efficient assessment system for PIA Engineering & Maintenance, Director Airworthiness may delegate a number of authorities to Chief Engineer (Quality Assurance). Chief Engineer (Quality Assurance), being responsible to monitor all activities in the Organisation for compliance with regulations laid down by the PCAA, is authorised to perform the following tasks for Airworthiness Directorate. i. Issuance of Aircraft Engineer s Inspection Authorisation (AEIA) Class-I Company Approvals for specific aircraft types (Line / Base Maintenance) and aircraft components being maintained by the Organisation. Inspection Permit (Class II) shall also be issued to certify inspection on piece-part level during component maintenance and receiving incoming stores. ii. Approval of Engineering Procedures Manuals (Divisional) and their subsequent amendments provided the documents are found in compliance with regulations laid down by the PCAA and Company Exposition Manual (CEM). Intimation for such approvals shall be sent in a timely manner to the Airworthiness Directorate. iii. Approval of revisions and amendments to General Engineering Manual (GEM) / Examination Manual for technical qualifications in the Organisation, with intimation to the Airworthiness Directorate. iv. Issuance of One Time Approval / Temporary Approval for release of aircraft component, not covered under regular Company Approval category. v. Evaluation / Approval of vendors for all stores related to aircraft / aircraft component maintenance. vi. Issuance of One Time Approval of vendor in justified situations. vii. Arrangement for access to supplier s facility for audits by the Competent Authority with prior notification. viii. Surveillance of technical handlings at line stations for renewal of approvals by the Competent Authority. A re-inspection of facilities shall be arranged in every fiveyear period or whenever deemed necessary by the Airworthiness Directorate. ix. Assessment of all aspects regarding concession request for aircraft maintenance schedule or Airworthiness Directive / mandatory modification, particularly impact of safety / airworthiness of aircraft / aircraft component, justification presented by the Organisation and completeness of request. x. Oversight on incident / accident reporting and tracking of technical investigations to keep the Competent Authority well informed alongwith relevant documents / information. CEM Chapter 2-11 Edition: 02 Revision: 03 Issue: September 09 Page 1 of 2

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59 PART 3: FACILITIES AND WORKSCOPE CEM Chapter 3-0 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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61 3-1 MAINTENANCE BASE FACILITIES APPROVED BY THE PCAA ENGINEERING & MAINTENANCE PREMISES AT KARACHI PIA Engineering & Maintenance has its main maintenance base at JINNAH International Airport Karachi, where maintenance is performed on aircraft / aircraft components, under the PCAA Approval, as per approved maintenance programme for each aircraft. Total covered area of PIA Engineering & Maintenance facilities, located at Karachi, is m 2. Premises, facility and scope of undertaking is presented as follows: PREMISES LINE MAINTENANCE I (Bays 1 & 2) 9260 m 2 Refer Plan [3-1.1/A] & [3-1.1/B] LINE MAINTENANCE - II (Bays 1 & 2) 3450 m 2 Refer Plan [3-1.1/A] & [3-1.1/C] ANNEX between LINE MAINTENANCE I & II 2600 m 2 Refer Plan [3-1.1/A] & [3-1.1/C] AIRCRAFT O/H HANGAR 3370 m 2 Refer Plan [3-1.1/A] & [3-1.1/D] FACILITY 2 bays each 49 m x 41m; 5241-m 2 area for Aircraft Appearance, Stockroom, Tool Store, offices, etc. Aircraft components being wrapped in packing material for dust protection. Ear muffs / plugs are provided to maintenance personnel for noise protection. Adequate lighting is being provided. Portable fire fighting equipment is available with centrally controlled fire alarm system. Compressed air outlets & electric power pits for 115 VAC / 400 Hz are available. 2 bays (37 m x 31m and 37m x 23 m); 1450-m 2 area for Support Shops, Stockroom, Tool store, offices and amenities. Metallic storage racks are available for aircraft components. Dust protection is achieved by wrapping in packing material. Adequate lighting is being provided. Earplugs are available for noise protection. Portable fire extinguishers are placed with centrally controlled fire alarm system. Compressed air outlets & electric power pits for 115 VAC / 400 Hz are available. NDT Shop, Battery Shop, Avionics Stockrooms, Cardex Control section. dust / weather protection is provided through proper air-conditioning in shops. Portable fire extinguishers are available with centrally controlled fire alarm system. Compressed air and electric powers (115 VAC / 400 Hz, 28 Volts DC) with standby generator. 1 bay 49 m x 15 m; 1450-m 2 area for support shops, Tool Store, offices and amenities. Weather / dust protection by closing doors. Ground water drains are available. Adequate lighting is provided with emergency electrical power for offices and hangar. Earplugs are available for noise protection. Foam type fire fighting system is available with centrally controlled fire alarm system. Racks are available for storage of parts. Compressed air outlets & electric power pits for 115 VAC / 400 Hz are available SCOPE OF UNDERTAKING Line maintenance on B777, B747 & B737 series aircraft. B747: Upto Check A. B777 & B737: Up to and incl. Check A. Aircraft Appearance. Stockroom SR 81 for aircraft consumables Line maintenance on A310, A300 & ATR42 series aircraft. A310, A300 & ATR42: Upto and incl. Check A. Stockroom SR A1 for aircraft rotables Battery Shop. NDT Shop. Cardex Control & Technical records. Stockroom SR 14 for consumables. Stockroom SR 26 for rubberized material. Heavy maintenance and Major checks of B737 & ATR42 aircraft. CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 1 of 14

62 ISPAHANI HANGAR m 2 Refer Plan [3-1.1/A] & [3-1.1/E] STRUCTURE REPAIR SHOP (Structures / Composites) 2543 m 2 Refer Plan [3-1.1/E] Hangar (135 m x 96 m) to accommodate two aircraft simultaneously with complete docking m 2 area for support shops, Tool Stores, Stockrooms (Flight Pack, aircraft consumables, aircraft tyres and raw material), offices and amenities with paint booths. Movable hangar doors to ensure weather / dust protection in adverse weather condition. Water drains are available. Hangar is well ventilated for appropriate working. Adequate lighting available with standby support. Noise protection is achieved by use of earplugs. Medium expansion foam fire fighting system. Compressed air, 115VAC / 400Hz power, water, central vacuum cleaning, fuel tank purging, service lifts and overhead cranes are available. Shop, offices, tool store and amenities. Shop is provided with dust / weather protection and comfortable working conditions. Adequate water drains are available. Adequate illumination is available. Portable fire extinguishers are available with centrally controlled fire alarm system. Compressed air / electrical Power supply of 220 Volts 50 HZ available with overhead cranes. Racks available for storage of structural Parts. AIRCRAFT Seats, Galleys, Renovation, PAX survival FURNISHING SHOP equipment, Upholstery shops are air-conditioned for 3200 m 2 dust / weather protection. Stockroom for aircraft component / material (furnishing). Refer Plan [3-1.1/E] Plastic Repair, Sign & Art, Interior Paint shops, Tool Store, Work control centre and Check shift are well ventilated for working atmosphere, providing dust / weather protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air / electrical Power supply of 220 Volts 50 HZ available with overhead cranes. ENGINE O/H Specialized shops, offices and amenities including, SHOP machine tools, heat treatment and processing area m 2 Stockrooms for aircraft component / material (Engine / APU / landing gear) and Chemicals. Refer Plan [3-1.1/A] & Shop is dust / weather protected. [3-1.1/F] Adequate water drains are available. Adequate illumination is being provided. Sections are isolated to suppress noise. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks are available for storage of parts and spares. Movable trolleys are also available. Storage of complete engine is also facilitated. Compressed air / electrical Power supply of 220 Volts 50 HZ available with overhead cranes. Heavy maintenance and Major checks of: B747: Check A & D B777: Check C A300 & A310: Check D and 4 / 8 yearly checks. Painting of aircraft exterior, Livery and Decals (complete). Stockroom- SR B2 for consumables Stockroom- SR 09 for aircraft tyres Structural Repairs / Modifications on B747, A300, A310, B737 & ATR42 aircraft. Repairs on ducts and floor panels. Stockroom SR 80 for raw material Maintenance on: Seats (crew / PAX). Survival equipment Galleys and Toilets. Stitching of curtains / seat covers. Cargo fencing repair. Painting of aircraft interior / placarding. Stockroom B3 for consumables Maintenance of all Powerplants as per CEM Chapter 3-3. Landing gears of A300, A310, B737 & ATR42 series aircraft. Wheel assemblies of B777, B747, A300, A310, B737 & ATR42 series aircraft. Stockroom SR 04 for chemicals Stockroom SR 45 for consumables CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 2 of 14

63 Q.E.C BUILD-UP SHOP 2200 m 2 Refer Plan [3-1.1/A] JET ENGINE TEST COMPLEX 1240 m 2 Refer Plan [3-1.1/A] APU TEST BENCH 30 m 2 Refer Plan [3-1.1/A] COMPONENT O/H SHOP 3500 m 2 (Fuel & Misc. / Hyd., Brakes & Brakes) Refer Plan [3-1.1/A] & [3-1.1/C] PNEUMATIC O/H SHOP 2300 m 2 Refer Plan [3-1.1/A] & [3-1.1/G] RADIO O/H SHOP 1050 m 2 Refer Plan [3-1.1/A] & [3-1.1/C] Offices, stores and required amenities. Shop is provided with dust / weather protection. Adequate water drains are available. Adequate illumination is available. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air / electric powers are available. Overhead Cranes are also available. Test cell, preparation area, control room, fuel room and amenities. Shop is provided with dust / weather protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with centrally controlled fire alarm system. Adequate racks available for storage of parts. Electric power is available. Shop is providing dust / weather protection and comfortable working conditions. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks are available for storage of parts / spares. Electric power is available. Final build-up of all Powerplants as per CEM Chapter 3-3. Testing of engine: CF6-50, CF6-80C2, CFM56-3 Testing of APUs fitted on B747, A300 & B737 series aircraft. Shop equipment, offices, stores and amenities. Shop is provided with dust / weather protection. Adequate water drains are available. Maintenance on: Fuel, Hydraulic & Misc. system components and Adequate illumination is available. Brake assemblies fitted on Sections are isolated to suppress noise. B777, B747, A300, A310, Portable fire extinguishers are available with B737 & ATR42 series centrally controlled fire alarm system. aircraft. Racks available for storage of parts / spares. Electric power is available. Shop equipment, offices, aircraft consumables Maintenance on: (pneumatic) Stockroom, store and amenities. All Pneumatic and airconditioning Shop is provided with dust / weather protection. system Adequate water drains are available. components of B747, Adequate illumination is available. A300, A310, B737 & Sections are isolated to suppress noise. ATR42 series aircraft. Portable fire extinguishers are available with Stockroom SR 89 for centrally controlled fire alarm system. consumables Racks available for storage of parts / spares. Compressed air / power supplies (115 VAC & 28 Volts DC) are available with Standby generator. Shop equipment, offices, stores and amenities. Maintenance on: Shop is provided with dust / weather protection. Wireless, radar & video Adequate water drains are available. system components of Adequate illumination is available. B747, A300, A310, B737 & Sections are isolated to suppress noise. ATR42 series aircraft. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air / power supplies (115 VAC & 28 Volts DC) are available with Standby generator. CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 3 of 14

64 INSTRUMENT O/H SHOP 1850 m 2 Refer Plan [3-1.1/A] & [3-1.1/C] ELECTRICAL OVERHAUL SHOP 2500 m 2 Refer Plan [3-1.1/A] & [3-1.1/C] TOOL MANUFACTURE SHOP 540 m 2 Refer Plan [3-1.1/A] & [3-1.1/F] WORKSHOP EQUIPMENT MAINTENANCE 1270 m 2 Refer Plan [3-1.1/A] & [3-1.1/F] HANGAR EQUIPMENT MAINTENANCE 840 m 2 Refer Plan [3-1.1/A] Shop equipment, offices, stores and amenities. Shop is air-conditioned for dust / weather protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks available for storage of parts / spares. Compressed air and power supplies (115 VAC & 28 Volts DC) are available with Stand by generator. Shop equipment, offices, stores and amenities. Shop is air-conditioned for dust / weather protection. Adequate water drains are available. Adequate illumination is available. Sections are isolated to suppress noise. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks are available for storage of parts / spares. Compressed air and power supplies (115 VAC & 28 Volts DC) available with Stand by generator. Shop, equipment including machine tools and fitting benches, offices, stores and amenities. Shop is adequately ventilated to ensure working of personnel is not impaired. Adequate water drains are available. Adequate illumination is available. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks / Stands available for storage of parts. Pneumatic & Electric powers are available with standby arrangements. Shop equipment, offices, stores and amenities. Shop is ventilated for suitable working atmosphere, providing dust and weather protection. Adequate water drains are available. Adequate illumination is available. Individual areas are isolated to suppress noise. Portable fire extinguishers are available with centrally controlled fire alarm system. Racks are available for storage of parts / spares. Pneumatic & Electric powers are available. Shop equipment, offices, stores and amenities. Working area is in open space so dust protection is achieved by wrapping the parts in packing material. Water drains are available. Illumination is available. Earplugs are available in the stores. Portable fire extinguishers are available. Racks available for storage of parts and spares. Pneumatic & Electric powers are available. Maintenance on: Instruments of B747, A300, A310, B737 & ATR42 series aircraft. Maintenance on: Electrical components of B747, A300, A310, B737 & ATR42 series aircraft. Manufacture, repair and modification of special tools and fixtures. Periodic maintenance on overhead cranes, fixed equipment and air compressors Supply of dry air and nitrogen gas Stockroom SR 06 for bulk storage (in stores building) Maintenance of ground support equipment (GPU, rig, dock, trestle, etc.) CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 4 of 14

65 3-1.2 ENGINEERING & MAINTENANCE PREMISES AT ISLAMABAD PIA Engineering & Maintenance has its mini maintenance base for ATR aircraft upto check C at Benazir International Airport Islamabad. Moreover, the Organisation has capability for B777 series aircraft maintenance upto Service Check 1 & 2 and upto Layover Check for A aircraft in accordance with the PCAA approved aircraft maintenance schedule. Facilities at Islamabad, comprise of one bay hangar for aircraft maintenance alongwith associated shop, cabin appearance, cardex control & technical records, battery shop, tool store, stockroom, technical library, offices and other amenities. Adequate lighting is provided with emergency electrical power for offices and hangar. Compressed air outlets and electric power pits for 115 VAC / 400 Hz are available. Portable fire extinguishers requirement is assessed in accordance with scope of work to be performed and required serviceable equipment in sufficient number are arranged by Fire section. Personal Protection Equipment (PPEs) are accessible to maintenance personnel during aircraft maintenance and support functions ENGINEERING & MAINTENANCE PREMISES AT LAHORE PIA Engineering & Maintenance has maintenance setup, at Allama Iqbal International Airport Lahore, with maintenance capability for B777 series aircraft upto Service Check 1 & 2 and upto Layover Check for A aircraft in accordance with the PCAA approved aircraft maintenance schedule. Facilities at Lahore, comprise of maintenance control, aircraft appearance, Cardex Control, Tool store, Stockroom, Technical Library, offices and amenities. Adequate lighting is provided with emergency electrical power for offices and other areas. Portable fire extinguishers requirement is reviewed in accordance with workscope and required equipment in serviceable condition is arranged by Fire section. Personal Protection Equipment (PPEs) are accessible to personnel during aircraft maintenance activities HANGAR OCCUPATION / AIRCRAFT HANAGAR VISIT PLAN Projected Hangar Visit Plan shall be prepared in accordance with aircraft maintenance schedule and availability of hangar bays on yearly basis, by Planning Officer. Deputy Chief Engineer(Schedule & Check Planning) shall check and submit Hangar Visit Plan for review and approval of Chief Engineer (Maintenance Operation Centre). Approved plan is issued under the Ref. No. E&M/CE (P&P)/HVP. Annual Hangar Visit Plan shall be reviewed on quarterly basis and may be revised to accommodate for the following also: i. For line maintenance, major jobs upon requirement, ii. For customer s aircraft major checks iii. For contingencies and reasons beyond control Revised Hangar Visit Plan and its subsequent amendments / revisions (alongwith revision status) shall be transmitted to all concerned for planning and further actions APRON An apron covering an area of approx. 121,000 m2 is located in front and on the eastern side of ISPAHANI Hangar, at Karachi. It provides eight additional parking / maintenance CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 5 of 14

66 bays and two run-up bays. Run-up bays are provided with blast deflectors to divert engine exhaust and noise suppression. Parking / maintenance bays and run-up points are provided with service point for compressed air and 400 Hz AC power pits. Apron is well illuminated with tower mounted high-pressure sodium vapour floodlights. Ground markings and lightening fixtures are as per JEPPESSEN Manual TECHNICAL LIBRARIES Technical Libraries setup comprise of a main Technical Library at Karachi that receives all publications from the authorities / regulatory bodies, manufacturers and vendors. In addition to hard copies, the literature is also available on manufacturers Compact Discs. Main Technical Library has qualified librarians, assigned with functions of ordering required maintenance data, performing inventory check and maintaining all data in updated status. Facilities such as personal computers and printers are also available. Relevant maintenance data for each aircraft / aircraft component is made available in different sections of the Organisation at maintenance base (Karachi) and sub libraries at line stations (Islamabad and Lahore). CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 6 of 14

67 [3-1.1/A] PIA ENGINEERING & MAINTENANCE (KHI) CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 7 of 14

68 [3-1.1/B] LINE MAINTENANCE - I [1.8.2] LINE MAINTENANCE I 1- Bay 2 Line Maint -I 2- Bay 1 Line Maint I 3- Stock Room 4- Stock Room 5- Aircraft Appearance 6- Tool Stores 7- Offices CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 8 of 14

69 [3-1.1/C] [1.8.3] LINE LINE MAINT. MAINTENANCE II / COMPONENT II / AVIONICS OVERHAUL OVERHAUL / AVIONCS / COMPONENT OVERHAUL OVERHAUL 1- Line Maint LINE II MAINT Bays II BAY 2- Component & Hydraulic Shop 3- Instrument O/H 4- Instrument O/H Ext. 5- Radio Overhaul 6- Stock Room 7- Offices 8- Planning & Projects 1 CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 9 of 14

70 [3-1.1/D] [1.8.4] BASE AIRCRAFT M AINTENANCE AFT OVERHAUL O/H H HANGAR (HANG AR # 3) CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 10 of 14

71 (ISPHAHANI HANGAR) [3-1.1/E] ISPAHANI HANGAR [1.8.5] BASE ISPAHANI MAINTENANCE HANGAR (HANGAR # 4) ISPAHANI HANGAR 1- Hangar Area 2- Tools Store / Technical Library 3- Structure Repair Shop 4- Time Office / Change Over 5- Composites Repair Shop 6- Stock Room 7- Aircraft Furnishing (Level 2) 8- Flight Pack Section CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 11 of 14

72 [3-1.1/G] [1.8.7] PNEUMATIC PNEUMATIC OVERHAUL COMPLEX COMPLEX [3-1.1/F] ENGINE OVERHAUL / / TOOL MANUFACTURING SHOP SHOP CEM Chapter 3-1 Edition: 02 Revision: 06 Issue: May 11 Page 12 of 14

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75 3-2 LINE STATION FACILITIES APPROVED BY THE CAA (PAK) PURPOSE To define PIA Engineering & Maintenance policies regarding aircraft maintenance at line stations approved by the CAA (Pak) and maintenance on PIA aircraft, provided by the foreign agencies / personnel PROCEDURE a) General Line station shall be a location, other than maintenance base, at which line maintenance activities are performed on an aircraft under the CAA (Pak) Approval. Such a line maintenance location shall be capable of aircraft transit checks upto minor maintenance, approved by the Competent Authority. All maintenance on PIA aircraft shall be certified by Aircraft Engineer (Production) concerned holding an appropriate Certification Authorisation for the particular type of aircraft. At some foreign line stations, availability of PIA Engineering & Maintenance Certifying Staff may be found impracticable. In such cases, maintenance on PIA aircraft may be subcontracted to Technical Handling Agencies. Such foreign agency / personnel shall be approved / authorised by the Competent Authority upon satisfactory survey of the facilities of Technical Handling Agency. b) PIA Line Stations All line stations shall be approved by the Competent Authority for maintenance on PIA aircraft. A List of line stations, where aircraft transit checks are being performed on PIA aircraft, shall be maintained by Deputy Chief Engineer (Line Stations). Such list shall clearly provide information regarding agencies / personnel performing any maintenance with limitations on different aircraft types. List of line stations shall be reviewed and updated on operational requirements within the approved scope of work. An amendment in the list shall be proposed through Chief Engineer (Line Maintenance) to Chief Engineer (Quality Assurance). c) Technical Handling Agency Approval Process For approval of Technical Handling Agency to perform maintenance on PIA aircraft, Chief Engineer (Quality Assurance) shall submit application on Form CAAF-113-AWXX to the Competent Authority. Upon satisfactory survey, by the Competent Authority, of relevant facilities and appropriateness of personnel to perform technical handling, the approval will be issued on Form No. CAAF-018-AWXX, separately for each 'Type' of Aircraft. Aircraft Engineer (Quality Assurance) shall assist the Competent Authority for such inspections. Chief Engineer (Quality Assurance) shall submit annual report for renewal of Technical Handling Agency approval. Such report shall be based on continued surveillance of the Technical Handling Agency s performance over that period and quality audits of line station as per annual quality audit plan. A re-inspection of the facilities shall be organized after an interval of three years or whenever deemed necessary by the Competent Authority. CEM Chapter 3-2 Edition: 02 Revision: 06 Issue: May 11 Page 1 of 2

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77 3-3 WORK SCOPE OF PIA ENGINEERING & MAINTENANCE GENERAL PIA Engineering & Maintenance shall carry out maintenance that includes any one or combination of overhaul, repair, inspection, replacement, modification or defect rectification of aircraft / aircraft components, under the PCAA Approval WORKSCOPE Summary of maintenance to be carried out under the PCAA Approval, mentioning classes, rating and the limitations is given as under: a) Aircraft AIRCRAFT ENGINES LEVEL OF MAINTENANCE LINE BASE Boeing 707 JT3D Boeing JT8D ---- Boeing CFM56 Boeing CF6-50 / JT9D Boeing RB211 Boeing ER / LR GE90 Boeing ER GE90 Airbus A300B4 CF6-50 Airbus A Series CF6-80 / PW 4152 Fokker F27 RR DART 528 / 532 De-Havilland DHC6-300 PW PT6A-27 ATR PW 127E Cessna 172 Lycoming O-320-H2AD b) Engines and APUs RATING Turbine APU SCOPE OF WORK LIMITATION QEC Insp Build-up Test Mod Repair Modules Overhaul PW PT6A-27 series (Hot Section) PW JT3D series PW JT9D series ---- RR DART 528 / 532 series GE CF6-50 series (Modules) GE CF6-80 series (Modules) CFMI CFM56-3B series (Modules) PW 4000 series ---- GE 90 series ---- Lycoming O-320-H2AD ---- TSCP 700 series GTCP 660 series GTCP series GTCP / 500 series CEM Chapter 3-3 Edition: 02 Revision: 06 Issue: May 11 Page 1 of 4

78 c) Aircraft Components other than Complete Engines or APUs Aircraft components of B777, B747, B737, A310, A300, ATR42 and Cessna 172 series shall be referred in Company Capability List alongwith Shop Allocation List, maintained on PIA Aircraft Maintenance Management Information system (PAMMIS) DESCRIPTION OF ACTIVITIES AREA OF ACTIVITY AIRCRAFT ENGINES / APUs COMPONENTS BASE LINE COMPANY CAPABILITY LIST DESCRIPTION The maintenance activities include: Scheduled Heavy maintenance. Unscheduled maintenance. Repair and Inspection work. Major Checks up to CHECK D. Modifications, Major and Minor. Application of approved repairs Incorporation of ADs, SBs. Limited scope of fabrication as per maintenance data provided by the Manufacturer / TC holder. The line maintenance activity covers: Servicing Pre-flight / Transit Daily, Weekly and Layover Checks Rectification of Defects Activities comprise: Scheduled and Unscheduled maintenance. Routine Inspections. Defect Rectification in accordance with the AMM, EMM or Approved Documentation. Testing, Repair and Overhaul. Activities comprise: Bench test, repair and overhaul of aircraft components other than Engines and APUs. Company Capability List of PIA Engineering & Maintenance shall be maintained by Chief Engineer (Maintenance Operation Centre), under reference # E&M/CE(MOC)/CCL. The list shall provide following information: ATA Chapter No. LRU Control No. Description Part No. Vendor code Shop allocation Type of Repair Company Capability list shall be compiled by integrating capabilities, for maintenance on relevant components, from all divisions through respective Chief Engineers. This list shall be submitted to Chief Engineer (Quality Assurance) for approval, against the approved workscope. Approved list shall be available online (PIAC website, Deputy Chief Engineer (production) concerned shall maintain Shop Capability List for CEM Chapter 3-3 Edition: 02 Revision: 06 Issue: May 11 Page 2 of 4

79 respective section, endorsed by Chief Engineer (concerned). Company Capability List shall be printed for presentation to the Competent Authority, whenever called for. Deputy Chief Engineer (production) concerned shall review Company Capability list, available online, on regular basis. An amendment in Company Capability List, may be addition / deletion of any component from list, enhancement / reduction of work scope (maintenance level) or a combination of both. a) Amendment affecting scope of approval Chief Engineer (Quality Assurance) shall evaluate any amendment in the Company Capability List affecting the scope of approval, forwarded by Chief Engineer (concerned) alongwith proper justification. A letter from Chief Engineer (Quality Assurance) and two copies of proposed amendments shall accompany the request for approval. Upon receipt of approval from the Competent Authority, Chief Engineer (Quality Assurance) shall then authorise Chief Engineer (Maintenance Operation Centre) to include amendments and update the Record of Revisions accordingly in the Company Capability List. Record for amendments (letter of agreement, revised Approval Certificate, etc.) shall be archived by Chief Engineer (Quality Assurance). Chief Engineer (Maintenance Operation Centre) shall transmit a feedback regarding incorporation to originator. b) Amendment not affecting scope of approval Amendments in Company Capability List such as addition / deletion of any component in already approved category, decrease in maintenance level for already listed components or correction of details (Part Number, Nomenclature, LRU Control Number, ATA Chapter, etc.) shall be considered as amendments not affecting the scope of approval and shall be authorized by Chief Engineer (Quality Assurance). Deputy Chief Engineer (production) concerned shall initiate the Request For Change in CCL / Capability Enhancement with following details and forward the filled / signed form to Chief Engineer (concerned) for review / verification: Rating, ATA Chapter and LRU Control No. Part number and Nomenclature CMM Reference Level of maintenance Workshop involved in maintenance Justification for amendment (addition / deletion / correction) Chief Engineer (concerned), upon verification, shall submit the Request For Change in CCL / Capability Enhancement form to Chief Engineer (Quality Assurance) for approval. Chief Engineer (Quality Assurance) shall assess whether submitted amendment request, with required information, is not affecting the scope of approval. Upon such confirmation, Chief Engineer (Quality Assurance) shall approve the amendment. All such amendments shall be communicated to the PCAA on monthly basis. Approval shall be communicated to Chief Engineer (Maintenance Operation Centre) for inclusion of amendments in Company Capability List. Originals of amendment requests are retained with Chief Engineer (Maintenance Operation Centre), whereas copies of these are sent to the originator for their record. CEM Chapter 3-3 Edition: 02 Revision: 06 Issue: May 11 Page 3 of 4

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81 3-4 PIA AIRCRAFT FLEET MAINTENANCE CHECKS AND INTERVALS PURPOSE To define PIA Engineering & Maintenance policies regarding the administration of maintenance checks and their intervals for aircraft under the PCAA Approval PROCEDURE a) General PIA Fleet Maintenance Checks and Intervals, developed by Deputy Chief Engineer (Maintenance Program & Reliability), shall be utilized for effective production planning during aircraft maintenance checks in PIA Engineering & Maintenance PIA FLEET MAINTENANCE CHECKS AND INTERVALS Type of Line Checks Routine Checks Major Checks * C of MR Aircraft Transit Layovers A B C MID - D 'D' Issuance ** Daily check Transit Service check1 As per PCAA B / (Outstation 250FH 75 days / days days ANO & Base) Service check FH Requirements 500FH Daily check Transit 36 elapsed Hrs. Not As per PCAA 6000 FH / (Outstation Weekly Check exceeding years ANO B Months & Base) Not exceeding 8 600FH Requirements elapsed days Daily check 36 elapsed Hrs. Transit Weekly Check Not As per PCAA B FH / (Outstation Not exceeding 8 exceeding years ANO Combi 18 Months & Base) elapsed days 600FH Requirements 110 FH 225 FH Transit (Outstation *** Layover ) Pre-flight 36 elapsed Hrs. As per PCAA 500 FH / 6000 FH / A (12 Weekly Check Months 24 Months 6 Yearly 12 Yearly ANO elapsed (8 calendar Requirements Hrs. at Days) Base) Transit Turnaround As per PCAA B (Outstation (First Flight from 4000 FH / 250 FH 1000 FH FH ANO & Base) KHI,LHE,ISB, 15 Months Requirements PEW) Daily check ATR elapsed Hrs. Transit Line check Check 4C As per PCAA (Outstation 500 FH FH 48 elapsed Hrs 20,000 FH ANO & Base) Weekly Check Requirements 7 calendar Days Pre-flight Operation Operation Operation Operation As per PCAA Cessna (Prior to ---- Check 1 Check 2 Check 3 Check 4 ANO N first flight of (50 FH) (100 FH) (150 FH) (200 FH) Requirements the day) * Certificate of Maintenance Review (C of MR) must be completed and signed by the PCAA authorized person, after base check or before validation / renewal of Certificate of Airworthiness (C of A) and subsequently after every three months. C of MR shall be retained for two years from its date of issue. ** Before first flight of the day from KHI. Before 48 elapsed hours at ISB / LHE, if away from KHI. *** In case, aircraft completes 36 elapsed hours at line station, layover check shall be performed when aircraft returns to base. CEM Chapter 3-4 Edition: 02 Revision: 05 Issue: March 11 Page 1 of 2

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83 PART 4: QUALITY ASSURANCE PROCEDURES CEM Chapter 4-0 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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85 4-1 AIRCRAFT CERTIFICATES CONTROL PROCEDURE PURPOSE To define PIA Engineering & Maintenance policies regarding control of release certificates related to aircraft / aircraft components PROCEDURE a) Certificate of Release to Service (CRS) Certificate of Release to Service (CRS) shall be issued after overhaul, repair, replacement, scheduled maintenance task, modifications and mandatory inspection have been carried out in accordance with requirements prescribed by manufacturers of aircraft / aircraft component. i. Line Maintenance Certificate of Release to Service in Line Maintenance is given on Technical Log Slip after carrying out a pre-flight check / required maintenance / defect rectification on aircraft in accordance with applicable maintenance data by appropriately authorised Certifying Staff. ii. Base Maintenance Certificate of Release to Service in Base Maintenance is given on Task Card / ARO after carrying out required maintenance tasks / subtask on aircraft in accordance with applicable maintenance data by appropriately authorised Certifying Staff. iii. Overhaul Shops Certificate of Release to Service in Overhaul Shops is given on LRU Tracking Tag / Serviceable Tag (blue) after carrying out required maintenance on aircraft component in accordance with approved maintenance data by appropriately authorised Certifying Staff. b) Maintenance Release (MR) Maintenance Release (MR) shall be issued for an aircraft subsequent to a major check completion. Maintenance Release is issued to certify that all maintenance work, specified in the approved maintenance schedule, have been completed in accordance with applicable maintenance data. Maintenance Release shall only be issued when CRS for all task / sub-tasks, required by Check-Work-Package, have been signed. Maintenance Release is issued by a Certifying Staff authorised by Chief Engineer (Quality Assurance) to issue Maintenance Release for a particular aircraft. List of such authorisations shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance). Maintenance Release shall be issued in duplicate and one copy shall be carried on board the aircraft and other is to archived with Technical Records. c) Certificate of Maintenance Review (C of MR) Certificate of Maintenance Review (C of MR) shall be issued for an aircraft after a major check or before Validation / Renewal of Certificate of Airworthiness and subsequently after every three months. The certificate is issued to certify that all maintenance CEM Chapter 4-1 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

86 specified in approved maintenance schedule, mandatory modifications and all other mandatory requirements have been appropriately carried out within specified time period and documented accordingly. The certificate shall be issued in duplicate, one copy shall be carried on board the aircraft and other is to be archived with maintenance records. Certificate of Maintenance Review shall be issued alongwith C of MR Status Report and C of MR Renewal Record Sheet as sampled in ANO Appendix J. Airworthiness Directorate, CAA (Pak), shall authorise to an appropriately qualified / experienced Aircraft Engineer holding full set A & C or full set X & R to issue C of MR. CAA (Pak) approved Chief Engineer / Deputy Chief Engineer shall only be considered as authorised persons for issuance of C of MR. Technical Assistant to Chief Engineer (Quality Assurance) shall maintain such list of authorisations. d) Certificate of Fitness for Flight (C of FF) Certificate of Fitness for Flight (C of FF) shall be issued prior to Test Flight, to certify that aircraft and aircraft systems are airworthy and the aircraft is fit to perform a test flight in accordance with requirements prescribed by the manufacturer and regulations of the CAA (Pak). Certificate of Fitness for Flight shall be issued by a Certifying Staff authorised by Chief Engineer (Quality Assurance). List of such authorisations shall be maintained by Technical Assistant to Chief Engineer (Quality Assurance). The certificate shall be valid for a period of seven days from the date of its issue and shall be retained for two years. e) Certificates Onboard Following aircraft certificates are carried onboard. All such certificates have validity dates and are subjected to renewal Certificate of Airworthiness (C of A) Maintenance Release (MR) Certificate of Maintenance Review (C of MR) Certificate of release to service (on aircraft Technical Log) Certificate of Registration Air Operator Certificate Insurance Certificate. Noise Certificate Certificate of Radio Installation Licence for Radio set Operators Weight and Balance Schedule Certifying Staff issuing Certificate of Release to Service (CRS) for aircraft in Line Maintenance, shall verify above-mentioned certificates on board. CEM Chapter 4-1 Edition: 02 Revision: 00 Issue: November 07 Page 2 of 2

87 4-2 CONCESSION ASSESSMENT AND CONTROL PROCEDURE PURPOSE To define PIA Engineering & Maintenance policies for concessions sought from the Competent Authority regarding deviations from aircraft maintenance schedule, overhaul and test schedule, instructions of Overhaul / Repair Manuals or other mandatory requirements GENERALITIES Induction of new aircraft / aircraft component, hold-up of aircraft spare in unavoidable circumstances are examples of situations, where it is very difficult for the Organization to manage qualified personnel for Maintenance Certification, follow Aircraft Maintenance Schedule or comply with the schedule / mode for an Airworthiness Directive (AD) or mandatory requirement. Whenever such an exigency arises, PIA Engineering & Maintenance shall submit an application to the Competent Authority for concession, clearly defining specific period of time to facilitate / continue the operation without compromising on the safety / airworthiness standards. Instance, whereby a concession is requested shall be categorized under the following main areas: Unavailability of qualified personnel for maintenance certification on aircraft / aircraft component. Deviation from approved aircraft maintenance schedule / overhaul life of aircraft component. Deviation from the Airworthiness Directives / mandatory modification in terms of specified time schedule / mode of compliance PROCEDURE Before submission of application for concession, Chief Engineer (concerned) must adopt all measures to resolve the situation at divisional level. If not viable, Technical Assistant to Chief Engineer (Quality Assurance) shall be contacted to prepare a case for concession, providing all relevant information. Prior to submission of an application regarding concession for aircraft maintenance schedule or Airworthiness Directive / mandatory modification, Chief Engineer (Quality Assurance) shall thoroughly assess all aspects, particularly the impact of safety / Airworthiness Standards of the aircraft / aircraft component. Chief Engineer (Quality Assurance) shall formally submit a request for grant of concession to the CAA (Pak) Airworthiness Directorate through the respective field office on form CAA-056 (in duplicate), furnishing complete justification of case, one week prior to the affectivity date. Scope of concession shall be exercised upon receipt of Approval from the Competent Authority. After the endorsement of subject concession, Technical Assistant to Chief Engineer (Quality Assurance) shall communicate the authorisation to all concerned in the Organization. All concession cases shall be serially numbered for tracking purposes. Each case for concession shall be followed up and subsequently shall be recorded and archived by Technical Assistant to Chief Engineer (Quality Assurance) CONCESSION TERMINATION REPORT CEM Chapter 4-2 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

88 Upon expiry of granted concession or whenever such requirement stands concluded, Chief Engineer (Quality Assurance) shall submit a Concession Termination Report (CTR) to the respective CAA (Pak) field office. A copy of the Concession Termination Report (CTR) shall also be archived with the respective case file. Technical Assistant to Chief Engineer (Quality Assurance) shall clearly communicate such termination to all concerned at the same time, who have previously been informed of granted concession, to avoid any ambiguity. Record for such communication shall be maintained at the office of Technical Assistant to Chief Engineer (Quality Assurance). CEM Chapter 4-2 Edition: 02 Revision: 00 Issue: November 07 Page 2 of 2

89 4-6 CERTIFYING STAFF TRAININGS AND QUALIFICATION PROCEDURES PURPOSE To define PIA Engineering & Maintenance policies regarding technical trainings and qualifications procedures for certifying and support staff in aircraft / aircraft component maintenance areas. This procedure outlines process for issuance, revalidation, extension and withdrawal of certification authorisations to certifying staff, related to the PCAA approved workscope PROCEDURE a) General Procedure for Technical Trainings Trainings for all personnel in the Organisation shall be arranged in accordance with annual training plan, approved by Chief Engineer (HR Training). Deputy Chief Engineer (HR & Training) shall disseminate information for inputs from different sections for development of annual training plan. Trainings shall be subcontracted to PIA Training Centre, approved by PCAA. Courses are based on the ICAO Annexure-1 and maintenance data from Original Equipment Manufacturer (OEM). Basic courses in applicable categories are approved by PCAA for application of LWTR in relevant category. Type courses, for aircraft maintenance, are approved by PCAA as well for Aircraft Maintenance Engineer s (AME) License type ratings in applicable categories and Aircraft Engineer s Inspection Authorization (AEIA) Class-I Company Approval. For component maintenance, aircraft type course may be considered applicable for shop approval. However, specific shop courses shall be developed on following criteria: An aircraft system course, extracted from approved aircraft type course Shop course, developed from applicable maintenance data Deputy Chief Engineer (Production) concerned shall review shop course for adequacy with category of Aircraft Engineer s Inspection Authorization (AEIA) Class-I Company Approval, in coordination with Deputy Chief Engineer (Technical Services Engineering) concerned. Recommendations for Course syllabus and profile of proposed Mentor / Instructor shall be submitted to Chief Engineer (Quality Assurance) for approval. It shall be ensured that Mentor / Instructor for a particular category of company approval is a senior level certifying staff, having five years certification experience in total, of which at least one year certification experience must be in similar category. Preference shall be given to certifying staff, trained / qualified at OEM / Vendor facility. Approved shop course shall be conducted, at PIA Training Centre, for adequate number of trainees. Whenever, it is not viable to conduct such training at PIA Training Centre due to lesser number of attendees, such shop course may be conducted within the shop by an approved Instructor / Mentor. In general, induction trainings shall preferably be arranged at OEM / Vendor facility upon induction of new aircraft / aircraft component. In addition to these trainings on aircraft / aircraft components, training on associated equipment / tooling shall also be conducted. CEM Chapter 4-6 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 6

90 Human factor, aviation legislation and organizational procedures trainings shall be imparted to certifying staff and support staff involved in aircraft / aircraft component maintenance. b) Specific Procedure for Technical Qualifications on Aircraft Upon successful completion of approved basic course in applicable category from PIA Training Centre, approved by PCAA and obtaining relevant practical maintenance experience on aircraft, in accordance with the ANO-XXLC-015, maintenance staff shall be eligible to apply for LWTR. LWTR in applicable category and successful completion of approved type course shall enable maintenance staff to apply for Aircraft Maintenance Engineer s (AME) License examination. Qualifications shall be Aircraft Maintenance Engineer s (AME) License issued by PCAA. Such qualification shall be prerequisite for promotion of maintenance personnel to cadre of Aircraft Engineer in PIA Engineering & Maintenance. Aircraft type endorsements are issued by PCAA on Cessna 172N, B , A and B / whereas, Aircraft Engineer s Inspection Authorization (AEIA) Class-I Company Approval on A300B4 and B / -300 shall be issued by Chief Engineer (Quality Assurance), under the delegated powers of PCAA Airworthiness Directorate. Aircraft Maintenance Engineer s (AME) License is valid for a period of two years and shall be renewed by PCAA subject to compliance with conditions that License holder remained engaged on type of work that either falls within scope of license or comes directly / indirectly under scope of PCAA Airworthiness Directorate for a period of atleast six months during last two years. Application for renewal of Aircraft Maintenance Engineer s (AME) License alongwith original license (CAA Form 29) shall be submitted to Technical Assistant to Chief Engineer (Quality Assurance) for verification and onward submission to PCAA. Renewal application for License shall be received one months in advance from date of expiry of particular License. c) Specific Procedure for Qualifications on Aircraft Components Aircraft Engineer s Inspection Authorisation (AEIA Class-I) Company Approval shall be issued by Chief Engineer (Quality Assurance) for aircraft components in overhaul shops. Such company approval shall be prerequisite for promotion of maintenance personnel to cadre of Aircraft Engineer in PIA Engineering & Maintenance. Maintenance personnel, involved in aircraft component maintenance, shall be provided complete applicable trainings (both basic and shop type courses) and substantial handson experience for particular Aircraft Engineer s Inspection Authorisation (AEIA Class-I) Company Approval category. Deputy Chief Engineer (production) concerned shall administer provisioning of all trainings and mandatory practical experience in relevant category to maintenance personnel. Application for Aircraft Engineer s Inspection Authorisation (AEIA Class-I) Company Approval shall be submitted with documentary evidence alongwith Experience Record book on Form CAAF-144-AWXX. Such record shall demonstrate applicant's experience that covers a representative selection of items appropriate to the category / type of equipment applied for. CEM Chapter 4-6 Edition: 02 Revision: 07 Issue: January 12 Page 2 of 6

91 d) Experience Record Experience Record Book (ERB) shall be used by maintenance personnel, working on aircraft / aircraft component, to demonstrate practical maintenance experience. This conforms to the requirement for proper experience verification, laid down by the PCAA for technical qualification examinations. Such relevant practical experience of atleast six months shall also be submitted for initial issue of certification authorisation. e) General Procedure for Certification Authorisation In the Organisation, acquiring only the Aircraft Maintenance Engineer s (AME) License / Aircraft Engineer s Inspection Authorization (AEIA) Class-I Company Approval, does not authorise such qualified personnel for certification, unless issued with a certification authorisation, stating the scope of authorisation and limitations (if any). Certification Authorisation shall be issued by Chief Engineer (Quality Assurance), clearly defining Scope of such authorisation alongwith limitations (if any). Prior to issuance of certification authorisation, it shall be verified that the nominee: i ii iii iv Holds valid Aircraft Maintenance Engineer (AME) License, issued by PCAA or Aircraft Engineer s Inspection Authorization (AEIA) Class-I Company Approval, issued by Engineering Quality Assurance, in accordance with ICAO Annexure-1. Has completed initial Human Factors, Aviation Legislation and organisational procedures trainings. Has been involved in actual relevant aircraft / aircraft component maintenance for at least six months in consecutive two years on required scope (for initial issue or extension in certification authorisation). For certification authorisation renewal / revalidation, the nominee must be involved in actual certification. Has been assessed for competence related to certification authorisation scope by Deputy Chief Engineer (Production) concerned. For special cases, where such authorisation is required for management personnel, such declaration shall be signed by their superiors. For practical purposes, Line Maintenance certifying staff and Base Maintenance support staff shall be considered equivalent in the Organization. However, certifying personnel must hold an appropriate certification authorisation to exercise its privileges. An appropriate certification authorisation shall be in respect with permanent place of duty. In case of temporary transfer / placement, an approval shall be sought from Chief Engineer (Quality Assurance) for up to three-months period. For certifications at line stations, certifying staff must hold valid certification authorisation in any category such as Line Maintenance certifying staff, Base Maintenance support staff or Base Maintenance certifying staff. f) Continuation Training Continuation training for each certifying / support staff shall be imparted within two-year period for continued validity of certification authorisation, covering following subjects: i ii iii iv Aviation Legislation Human Factors in Aviation Relevant technology updates (aircraft / aircraft components) Organizational procedures Continuation training for certifying / support staff is accomplished through a combination CEM Chapter 4-6 Edition: 02 Revision: 07 Issue: January 12 Page 3 of 6

92 of classroom training, recurrent sessions and issuance of technical publications such as Quality Alerts / Advisories, Technical Notices, Human Factors Bulletins, etc. Contents / syllabi of such trainings shall be based on the following: Amendments / changes in regulations and organisational procedures Human factor issues, incident reports and audit findings Airworthiness Directives, Service Bulletins, Service Letters, etc Relevant technology updates and amendments in maintenance data Deputy Chief Engineer (HR & Training) shall prepare annual programme with respect to classroom trainings for certifying staff and support staff. Chief Engineer (HR Training) shall approve programme and monitor progress of such continuation training. Training material for continuation training on aviation legislation and organisational procedures is formulated by Deputy Chief Engineer (Quality Audit). However, training material on human factors shall be developed by Deputy Chief Engineer (Human Factors). Chief Engineer (Quality Assurance) shall approve training syllabi and nominate personnel to impart such trainings. Deputy Chief Engineer (HR & Training) shall archive all training records for each certifying / support staff. Technology updates such as Airworthiness Directives / Service Bulletins / modifications and Technical Notices shall be discussed during Recurrent Training sessions, held in every section on scheduled basis. Such trainings shall be imparted as per scope of certification authorisations for a particular group of certifying and support staff. Deputy Chief Engineer (production) concerned, in liaison with Deputy Chief Engineer (Technical Services Engineering) concerned, shall review recurrent training need for certifying staff and support staff and plan such trainings against sectional manpower. Shift / leave rosters shall also be reviewed so that no staff is overlooked, while planning these sessions. Plan shall be reviewed after six months to address deviations (if any) and accommodate personnel, who could not be scheduled for such training previously. Deputy Chief Engineer (production) concerned shall submit nominal roll of recurrent training attendees to Deputy Chief Engineer (HR & Training). Such records of certifying staff shall be used for verification of continuation training during issue / extension / revalidation of certification authorisation. All sectional Incharges shall keep copies of training records, being an auditable document. g) Issuance of Certification Authorisation Deputy Chief Engineer (production) concerned shall raise Certifying Staff Assessment Form for certification authorisation to maintenance personnel. It shall be ensured that nominee is involved in at least six months of actual relevant aircraft / aircraft component maintenance experience in last consecutive two years on required scope of certification authorisation. Same shall be verified by concerned Technical Services section through Certifying Staff Experience Record Book. Deputy Chief Engineer (production) concerned shall submit request for certification authorisation, providing particulars of maintenance staff, trainings record from HR & Training section and declaration for competence assessment to Deputy Chief Engineer (Quality Audit). Upon satisfactory assessment, Deputy Chief Engineer (Quality Audit) shall forward Assessment Form with required attachments for issuance of certification authorization. For candidate, who could not qualify such verification / assessment at any stage, Deputy CEM Chapter 4-6 Edition: 02 Revision: 07 Issue: January 12 Page 4 of 6

93 Chief Engineer (Quality Audit) shall return the Assessment Form to Initiator with appropriate remarks / findings. Chief Engineer (Quality Assurance) shall issue certification authorisation, defining the scope / limitations of authorisation (if any). Upon issuance of certification authorisation, original Assessment Form with appropriate remarks, shall be archived by Technical Assistant to Chief Engineer (Quality Assurance) in individual s record file. A copy of authorisation shall be recorded in certifying staff record file. Following information shall be given on each individual authorisation: Name of certifying staff (Aircraft Engineer) Scope of authorisation Limitations (if any) Certifying staff are issued with authorisation stamp bearing certification authorisation number. It is the prime responsibility of stamp holder to make all possible efforts for security against any loss or misuse of such stamp. Certifying staff, upon query, shall present certification authorisation to the Competent Authority / Quality Auditors within 24 hours. Validity of certification authorisation, issued to individual, shall be clearly mentioned on the authorisation. In general, certification authorisation shall be issued for a period of two years to all certifying staff. h) Revalidation of Certification Authorisation Revalidation of certification authorisation shall be performed every two years from date of issue, unless otherwise mentioned on the authorisation. Such revalidation shall be processed in a similar manner to that of initial issue and shall be limited to previous scope of the authorisation. Certifying staff shall utilize Certifying Staff Experience Record Book to demonstrate concurrency of relevant certification experience on scope of certification authorisation and the same shall be verified by concerned Technical Services section. i) Extension in Scope of Certification Authorisation Extension in scope of certification authorisation shall be requested by Deputy Chief Engineer (production) concerned, on Assessment Form, for certifying staff enhancing technical qualification and fulfilling other applicable requirements such as involvement in at least six months of actual aircraft / aircraft component maintenance experience in last consecutive two years on required extension. Same shall be verified by concerned Technical Services section through Certifying Staff Experience Record Book. Deputy Chief Engineer (production) concerned shall submit request for extension in certification authorisation, providing particulars of maintenance staff, trainings record from HR & Training section and declaration for competence assessment to Deputy Chief Engineer (Quality Audit). Upon satisfactory assessment, Deputy Chief Engineer (Quality Audit) shall forward Assessment Form with required attachments for issuance of certification authorization with extended scope. Chief Engineer (Quality Assurance) shall issue a revised certification authorisation to certifying staff, defining amended scope / limitations (if any). Upon issuance of revised certification authorisation, original Assessment Form with appropriate remarks, shall be archived by Technical Assistant to Chief Engineer (Quality Assurance). CEM Chapter 4-6 Edition: 02 Revision: 07 Issue: January 12 Page 5 of 6

94 j) Limitation, Suspension and Revocation of Certification Authorisation Whenever any condition for revalidation of certification authorisation is not met, or for any reason, on rationale after due investigation, such authorisation can be limited / suspended / revoked by Chief Engineer (Quality Assurance). Following conditions may lead to limitation / suspension / revocation of certification authorisation: Certification has been performed for an aircraft / aircraft component beyond scope / limitation of authorisation. Upon exclusion of an aircraft type from workscope, approved by PCAA. Certification authorisation bearing scope for only type being excluded should be revoked. Continuation training has not been provided to certifying staff during last two consecutive years. Certifying staff has not been found utilising the issued authorisation for at least six months in last two consecutive years. Failing in competence assessment may also be a reason. Technical Assistant to Chief Engineer (Quality Assurance) shall notify for decision to concerned individual, through Deputy Chief Engineer (production) concerned. A copy of this notification shall be placed in individual s record file. In case of limitation, revised certification authorisation shall be issued, upon return of previous one. If certification authorisation is suspended / revoked, certifying staff must return issued authorisation to Technical Assistant to Chief Engineer (Quality Assurance) for amendment of certifying staff record. Re-issuance of suspended / revoked authorisation shall be processed in a similar manner as for the initial issuance of certification authorisation. k) Withdrawal of Certification Authorisation Certification authorisation is withdrawn, for certifying staff resigning from service or leaving the Organisation. Such individual shall be asked to return issued authorisation alongwith authorisation stamp for clearance from Technical Assistant to Chief Engineer (Quality Assurance). Chief Engineer (concerned) shall inform Chief Engineer (Quality Assurance) for transfer, promotion, resignation, retirement, etc. of certifying staff at the earliest but not later than three working days. Technical Assistant to Chief Engineer (Quality Assurance) shall amend certifying staff record for certification authorisation withdrawn and archive all returned authorisations, acknowledgements and stamps. CEM Chapter 4-6 Edition: 02 Revision: 07 Issue: January 12 Page 6 of 6

95 4-13 SUPPLIER EVALUATION AND SUBCONTRACT CONTROL PROCEDURE PURPOSE To describe PIA Engineering & Maintenance policies regarding suppliers evaluation, qualification, inclusion in Approved Vendor List (AVL) and performance follow-up of such approved vendors for aircraft components (rotable / repairable / consumable), material (consumable / raw), tools, test equipment and maintenance services PROCEDURE a) General All aircraft components intended to be installed on aircraft / aircraft component (NHA Next Higher Assembly), shall be accompanying applicable authorised release certificate issued by Original Equipment Manufacturer (OEM) or OEM authorised distributor explicitly EASA Form 1, FAA Form or TCA (Refer Company Exposition Manual Chapter 6-1 for details of authorised release certificates). Procurement of aircraft components, material and tooling / test equipment shall be made through Purchase Order, from vendor listed in effective Approved Vendor List (Procurements), maintained by General Manager (Procurement). On the other hand, Repair Orders for maintenance and calibration services shall be made to maintenance providers listed in effective Approved Vendor List (Services), managed by Chief Engineer (Maintenance Operation Centre). Amendment in both lists shall only be made after obtaining approval from Chief Engineer (Quality Assurance). Requisition for aircraft components (parts / consumables) shall be made in order of priority to one of the following sources, as per laid down categorization / sequence: i ii iii iv Original Equipment Manufacturer (OEM) of an aircraft / aircraft component Distributor, recommended / authorised by the OEM in maintenance data Airline / maintenance organization holding approval / acceptance from PCAA Part supplier providing aircraft components / material with applicable authorised certificates from Original Equipment Manufacturer (OEM), PCAA, EASA, FAA or TCCA Approved Maintenance Organisation (Note: aircraft component, obtained from part supplier, shall have clear traceability to the source and back-to-birth history, if applicable.) Material (fabric, adhesives or raw material) and tooling / equipment with approved specifications, not requiring authorised release shall be accepted with Certificate of Conformity from supplier national regulatory authority / Original Equipment Manufacturer (OEM). Suppliers for material and tooling / test equipment, recommended / authorised by Original Equipment Manufacturer (OEM) in maintenance data and approved by Chief Engineer (Quality Assurance) shall be included in Approved Vendor List. Maintenance services may also be contracted to PCAA Approved Technical Handling Agents at line stations, under technical handling agreement, to ensure that aircraft is fit for intended flight. Substantial maintenance on aircraft / aircraft components such as heavy aircraft maintenance and engine overhaul may be outsourced under maintenance contracts to maintenance providers, holding valid PCAA Approval. Other aircraft components and tooling / test equipment shall be sent for repair / calibration to service providers, approved by PIA Engineering Quality Assurance. Customer-provided aircraft components / material for fitment on its own aircraft, with CEM Chapter 4-13 Edition: 02 Revision: 05 Issue: March 11 Page 1 of 6

96 applicable authorised release certificate showing clear traceability, shall be acceptable. Copy of authorised release certificate must be required with customer serviceability documents (certificate / tag) as demonstration of component / material traceability. b) Evaluation for Parts / Material / Tooling Suppliers Prior to inclusion in Approved Vendor List (Procurements), comprehensive evaluation process for vendor shall be implemented. Such vendor shall provide aircraft components with applicable authorised certificates from Original Equipment Manufacturer (OEM), EASA, FAA, TCCA or PCAA Approved Maintenance Organisation. Original Equipment Manufacturer and its distributor, recommended / authorised in the maintenance data shall directly be included in Approved Vendor List, upon receipt of initial request from General Manager (Procurement). However, relevant documents showing traceability shall be provided with such request. Chief Engineer (Quality Assurance), upon receipt of initial request from General Manager (Procurement), shall despatch Vendor Approval Questionnaire (Form # EM/SD&D/GEN084) to potential supplier for evaluation of scope. All essential information and relevant documents, provided by potential supplier, shall be reviewed by Deputy Chief Engineer (Quality Audit) for conformance to statuary and organizational requirements. Subsequent to evaluation, supplier s data shall be presented to Chief Engineer (Quality Assurance) on Supplier Qualification and Follow-up Sheet (Form # EM/SD&D/GEN087) alongwith recommendation. Chief Engineer (Quality Assurance) shall issue Vendor Approval Certificate (Form # EM/MP&R/GEN083) clearly stating desired scope and limitations. Original shall be despatched to qualified vendor through General Manger (Procurement). Copies shall be distributed within the Organisation for information / records. All vendor approval records shall be controlled and archived by Deputy Chief Engineer (Quality Audit). Qualified supplier shall be included in the Approved Vendor List (Procurements) for following categories: i ii iii Aircraft parts and spares Raw and consumable materials Tools and Equipment Whenever there arises urgent need of aircraft part / material / tool / equipment to meet operational requirement and availability of such item is only viable from unapproved source, General Manager (Procurement) shall submit request for One Time Approval of Vendor alongwith relevant information to Chief Engineer (Quality Assurance). Purchase Order for particular item shall only be issued after obtaining such approval. Potential vendor shall be evaluated by Deputy Chief Engineer (Quality Audit) on priority on the basis of provided / available information and recommendation shall be made upon satisfactory assessment. Chief Engineer (Quality Assurance) shall issue One Time Approval of vendor to the supplier. c) Evaluation for Maintenance Providers Approved Vendor List (Services) shall be maintained by Chief Engineer (Maintenance Operation Centre) for following categories: i Aircraft Technical handling at line stations CEM Chapter 4-13 Edition: 02 Revision: 05 Issue: March 11 Page 2 of 6

97 ii iii iv v Aircraft heavy maintenance (base check, major repairs, etc.) Engine / APU / landing gear overhaul Aircraft components repair services Calibration services for tools / equipment For aircraft technical handling, Chief Engineer (Maintenance Operation Centre) shall submit request to Chief Engineer (Quality Assurance) for inclusion of Technical Handling Agent in Approved Vendor List (Services). Such request shall accompany pertinent information for organisation and certifying staff alongwith copies of AME licences. Upon successful evaluation, Chief Engineer (Quality Assurance) shall apply to PCAA for approval of Technical Handling Agent. Grant of approval by PCAA shall qualify Technical Handling Agent to be included in Approved Vendor List. For substantial maintenance (heavy aircraft maintenance and engine / APU / landing gear overhaul), Chief Engineer (Quality Assurance) shall perform initial evaluation prior to sending an application to the PCAA. Upon grant of approval by PCAA, maintenance provider shall be considered for inclusion in Approved Vendor List. Original Equipment Manufacturer (OEM) and its authorised vendor, providing aircraft component repair and calibration services for tooling / test equipment shall directly be included in Approved Vendor List, upon issuance of approval by Chief Engineer (Quality Assurance). In such case, request from Chief Engineer (Maintenance Operation Centre) shall accompany relevant documents necessary for evaluation. d) Contracts Management Unless otherwise not possible or not in interest of Organisation, maintenance contracts shall be non-exclusive. For all contracts (exclusive / non-exclusive), the final authority shall be in accordance with effective Schedule of Powers. Deputy General Manager (Finance) Engineering shall provide expertise on financial issues. Draft contract shall be submitted to obtain clearance from Legal department, if deemed necessary. i Contracts with Vendors Chief Engineer (Maintenance Operation Centre), in consultation with Chief Engineer (Quality Assurance), shall manage maintenance contracts for outsourced substantial maintenance such as heavy aircraft maintenance and engine / APU / landing gear overhaul, in addition to technical handling agreements. Once finalised, Chief Engineer (Maintenance Operation Centre) shall sign the maintenance contract on behalf of PIA Engineering & Maintenance, being Operator. It shall be ensured by the Signatory that maintenance contract, made with maintenance provider (Contractor), identify specifically industry standard to be used during maintenance and certification activities. Contracts shall further include: Reference to approval process for Contractor by Operator and Operator s Authority List of facilities including satellite locations where maintenance is to be performed Scope of approvals, technical requirements and level of maintenance Obligations of both parties and their regulatory counterparts on airworthiness issues Reference to Contractor s approved exposition explaining applicable regulations, safety requirements and quality management system Provisioning and control of logistics, turn around times, warranties, etc. Effective reporting process to immediately notify any significant defect to Operator CEM Chapter 4-13 Edition: 02 Revision: 05 Issue: March 11 Page 3 of 6

98 Access to Contractor s facilities for Operator s Quality Assurance / Authority Process for control of deviations from maintenance data Provisioning of technical records to Operator for assessment of achievement of ongoing quality levels ii Contracts with Customer Organisations For maintenance services, contract shall be made with customer organisation. Contracts formulated in accordance with PCAA regulations, shall contain following information: Pertinent aircraft / aircraft component identification Scope of approvals, technical requirements and level of maintenance Obligations of both parties and their regulatory counterparts on airworthiness issues Management of applicable maintenance data Technical records requested by Customer Customer obligations for provisioning of maintenance data, components / material, work order, approved maintenance schedule, defect reporting, release to service and continued airworthiness requirements. Turn around times, warranties, etc. Effective reporting process to immediately notify any significant defect to Customer Reference to Contractor s exposition explaining quality management system Provisioning of technical records to Operator s Engineering for assessment of achievement of ongoing quality levels Contracted maintenance tasks shall never exceed the PCAA approved scope of work / capabilities. Technical aspects of each contract shall be readily available, whenever deemed necessary by the Competent Authority. Chief Engineer (Engineering Business Development) shall draft maintenance contracts, consulting Chief Engineer (Quality Assurance) with regards to PCAA approval. Other divisions may be contacted for issues pertaining to approved Company Capability List, continuing airworthiness and maintenance activities. Upon approval, Chief Engineer (Engineering Business Development) shall sign contract on behalf of PIA Engineering & Maintenance. e) Procurement of Stores Purchase Order for an aircraft component / material / tooling / test equipment shall be generated by Deputy General Manager (Purchase) concerned. For each procurement, a statement requesting appropriate authorised release certificates shall be made on the Purchase Order. Repair Orders, in a similar manner, shall only be generated for maintenance / calibration services by Deputy chief Engineer (Repair Abroad). A statement requesting appropriate authorised release certificates shall be made on the Repair Order. f) Market Research Procurement of aircraft component (rotable / consumable), material (consumable / raw) and tooling / test equipment, etc. shall be made from suppliers listed in Approved Vendor List (Procurements). General Manager (Procurement) shall be responsible for market research of potential suppliers and initiating request to Chief Engineer (Quality Assurance), for evaluation of such supplier. For aircraft / aircraft components maintenance and calibration services for tooling / test equipment, Chief Engineer (Maintenance Operation Centre) shall be responsible for CEM Chapter 4-13 Edition: 02 Revision: 05 Issue: March 11 Page 4 of 6

99 market research and initiating request to Chief Engineer (Quality Assurance), for evaluation of supplier. g) Vendors Follow-up All approved vendors / service providers shall be made obligated to follow Terms & Conditions provided in Vendor Approval Certificate. For any change in Company Name, location or scope of approval, Chief Engineer (Quality Assurance) shall issue a revised Vendor Approval Certificate. Deputy Chief Engineer (Quality Audit) shall control following items for each vendor: Vendor approval questionnaire Supplier correspondences and provided documents Supplier Qualification and Follow-up sheet Certificate of approval (copy) Vendor s qualification for Organisation included in Approved Vendor List (Procurements) shall be reviewed by Deputy Chief Engineer (Quality Audit) every two years. In addition, Technical Assistant to Chief Engineer (Quality Assurance) shall generate monthly report on objections / discrepancies raised during incoming stores inspections. Service providers included in Approved Vendor List (Services) shall be reviewed through PIA Reliability Program for aircraft / aircraft components, in coordination with Technical Services Engineering. General Manger (Procurement) / Chief Engineer (Maintenance Operation Centre) may be informed by Chief Engineer (Quality Assurance) as to whether vendor / service provider qualification shall be maintained, suspended or withdrawn by means of Supplier Qualification and Follow-up Sheet. Record for a particular supplier shall be archived three years from the date, on which the supplier provided last services. An access to Approved Vendor List, Purchase / Repair Orders and supplier s facility for audit with prior notification to Chief Engineer (Quality Assurance) and concerned vendor shall be granted whenever deemed necessary by the Competent Authority. CEM Chapter 4-13 Edition: 02 Revision: 05 Issue: March 11 Page 5 of 6

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101 PART 5: AIRWORTHINESS MANAGEMENT PROCEDURES CEM Chapter 5-0 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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103 5-1 RETURNS TO THE CAA (PAK) ON PIA ENGINEERING & MAINTENANCE ACTIVITIES PURPOSE To define PIA Engineering & Maintenance policies regarding preparation and submission of monthly return on PIA Engineering & Maintenance activities, related to aircraft / aircraft components, to the CAA (Pak) Airworthiness Directorate PROCEDURE a) General It is the statuary requirement of the CAA (Pak) Airworthiness Directorate to submit a monthly Engineering Statistical Return of all aircraft in PIA fleet. The report shall be submitted on CAA form No. RCN/842/Rev-B. b) Engineering Statistical Return Monthly statistical returns shall be prepared by Deputy Chief Engineer (Technical Services Engineering) concerned for maintenance related activities on PIA aircraft / aircraft components at the end of each month. Such returns from all areas shall be compiled and reviewed by Chief Engineer (Airworthiness Management). A monthly report shall be submitted to the Competent Authority by mid of successive month. Following information shall be provided in the monthly statistical return: i. Serviceability of Aircraft ii. iii. Registration mark Type of aircraft Manufacturing serial number Type of engine & serial numbers Base station of the aircraft Certificate of airworthiness expiry date Serviceability in number of days Flight Hours Actual oil & fuel consumption per flying hour in litres Total engine hours since new or complete overhaul Engines Spare Float Number of spare engines Type and serial number Hours / Cycles since new or complete overhaul Particulars of Certifying Staff AME / Approval number Name & description AME endorsement and approvals held Date of joining Date of leaving station Station of present posting iv. Accidents / Incidents / Special Occurrences CEM Chapter 5-1 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

104 Date of occurrence Flight Number Location of occurrence Registration mark Type of aircraft Details of occurrence Rectification Status v. Delays vi. Registration mark Type of aircraft Station Summary of delays (Technical, Non-Technical, Total). Major checks of aircraft and heavy maintenance / overhaul of engines Registration marks Engine type & serial number Check intervals Aircraft weighing date Date of test flight / Engines Tests on Test Bed CEM Chapter 5-1 Edition: 02 Revision: 00 Issue: November 07 Page 2 of 2

105 5-2 RELIABILITY MONITORING PROGRAMME FOR AIRCRAFT / AIRCRAFT COMPONENTS PURPOSE To define PIA Engineering & Maintenance policies regarding reliability monitoring of aircraft / aircraft components through a comprehensive Reliability Programme PROCEDURE a) General To maintain PIA fleet in continued state of airworthiness, it is ensured that all aircraft / aircraft components are maintained as per the approved maintenance schedule. Such schedule necessitates accomplishment of scheduled and unscheduled maintenance tasks to maintain inherent design reliability levels for aircraft / aircraft component. Reliability Programme improves comprehensive maintenance schedule to ensure that adequate maintenance is being performed at proper intervals to prevent any system deterioration and restore aircraft's inherent reliability. PIA maintenance schedule utilizes three maintenance types (Hard Time, On-Condition and Condition Monitoring). i. Hard Time Preventative means, in which known deterioration of an item is limited to an acceptable level by performing maintenance at intervals related to time in service (calendar time, number of cycles / landings, etc.). Prescribed actions normally include servicing and such other actions as overhaul, repair, replacement in accordance with maintenance data so that the affected aircraft system / component / structure is replaced / restored to such a condition that it can be released to service for a further specified period. ii. On-Condition On-condition is also preventative method, but in this case, aircraft system / component / structure is inspected / tested at specified intervals to determine condition. such an inspection may reveal need for servicing action. Basic reason for such maintenance is to remove an aircraft system / component / structure before its failure in service. iii. Condition Monitoring Condition Monitoring is not a preventative maintenance. Statistical data obtained from operational assessment is collected, analyzed and interpreted on a continuing basis as means of implementing corrective actions. b) PIA Reliability Programme PIA Reliability Programme is based on information system, enabling data on acquired maintenance experience from aircraft maintenance schedule, collected, compiled and analyzed to ascertain condition of aircraft and appropriate requirement is initiated for realization at proper intervals to improve aircraft's inherent reliability. The programme is clearly defined in Technical Performance and Reliability Program Document (TPRPD), developed in accordance with the AWNOT-066-AWXX and duly approved by the Pakistan CAA. CEM Chapter 5-2 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 2

106 Reliability Review Board (RRB) shall be formed to review each preceding month's performance on the basis of weak areas identified for aircraft systems and components of PIA fleet. Performance status shall be reviewed and corrective measures for improvement are suggested. Reliability Review Board (RRB) meeting shall be held each month, under the chair of Chief Engineer (AWM), under the delegated authority of Chief Engineer (Quality Assurance). However, a nominee from Engineering Quality Assurance shall attend such meetings as an Observer. Minutes of meetings shall be prepared and instructions shall be circulated to all concerned for recommended corrective actions. Open points shall be discussed in forthcoming meetings till the appropriate closure. Reliability Control Board (RCB) is established to review the effectiveness of Reliability Programme and functioning of Reliability Review Board (RRB). Reliability Control Board (RCB) is headed by Chief Engineer (AWM), under the delegated authority of Chief Engineer (Quality Assurance). However, Chief Engineer (Quality Assurance) or his nominee being member of Reliability Control Board (RCB) shall attend meetings, held on quarterly basis to review preceding quarter's performance. Reliability data is collected for aircraft / aircraft components for overall surveillance. Analysis of collected data shall also indicate performance and effectiveness of PIA maintenance schedule. Information collected under Reliability Programme shall vary according to actual needs. Collected data is sorted and analysed by Deputy Chief Engineer (Maintenance Program & Reliability). It shall be assured that any adverse defect rate, trend or apparent failure is identified. Such aircraft / aircraft components data shall be summarized for review by Deputy Chief Engineer (concerned) as per allocation of aircraft / aircraft components. Deputy Chief Engineer (concerned) shall prepare and submit report, against each investigation providing justifications, to Reliability Review Board (RRB). Deputy Chief Engineer (Maintenance Program & Reliability) shall prepare instructions for actions to be taken on identified aircraft / aircraft components, finalized by PIA Reliability Control Board (RCB). These instructions shall then be despatched to Deputy Chief Engineer (concerned) for follow-up of corrective measures implementation. With support of Reliability Programme, aircraft maintenance schedule shall be amended and submitted to the PCAA for Approval. CEM Chapter 5-2 Edition: 02 Revision: 07 Issue: January 12 Page 2 of 2

107 5-3 ACCIDENT / INCIDENT REPORTING AND INVESTIGATION PROCEDURE PURPOSE To define PIA Engineering & Maintenance policies for reporting of accident / incident / reportable defect arising within or outside Pakistan, to the Competent Authority. Investigations procedure, followed by initial reporting of accident / incident / reportable defect defines policies to determine the root cause in view of establishing appropriate corrective actions to prevent recurrence PROCEDURE a) General Accident / incident / reportable defect on PIA owned / operated aircraft shall be immediately reported to the Competent Authority by Deputy Chief Engineer (Technical Services Engineering Line Maintenance) concerned giving following information using fastest means available: Type, Nationality and registration mark of aircraft. Name of the Pilot in command of aircraft. Date and time when the accident/incident occurred Last departure point, intended landing point of aircraft and the nature of flight. Location of the accident with reference to some easily defined geographical point. Number of fatalities (if any) and injured, where possible names of each individual. Nature and cause of the accident as far as known. Extent and type of damage to the aircraft. Investigations are carried out with not to ascribe blame but to determine exact causes for identifying corrective actions to prevent recurrence. Investigation shall be objective and exhaustive, final report must be precise and concise with recommendations addressed to relevant division / department. Personal opinions should be avoided. b) Reporting of Defect All reportable defects shall be reported on Form CAA-055 to Airworthiness Field office alongwith investigation report and necessary action taken to prevent recurrence, within 48 hours of the occurrence. CAA (Pak) Airworthiness Notice No. 09 shall be used for ready reference of reportable defects. If nature of reportable defect is such that immediately threatens safety of aircraft / personnel (onboard) / equipment, requires rectification before further flight / operation or calls out inspection of other aircraft for such defect, defect must be reported to Airworthiness Field office within 24 hours of finding of defect. If Investigation of reportable defect could not be concluded within reporting time, the defect shall initially be reported alongwith progress reports. Final report shall be submitted on completion of the investigation. Defective aircraft component / material shall be held for further investigation by the Competent Authority. However if defective part is required urgently for rectification and reuse, request shall be made to Airworthiness field Office for grant of permission. c) Investigation Process CEM Chapter 5-3 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

108 Deputy Chief Engineer (Technical Services Engineering) concerned shall generate an incident report, after obtaining all relevant details encompassing accident / incident / reportable defect. A comprehensive response is sought from Deputy Chief Engineer (production) concerned with an agreed target date. Following shall be considered significant while performing investigations: Precise timings of all events / activities / conditions Immediate spot check Photographic documentation of evidence / events and conditions Removal and quarantine of FDR / CVR if necessary Interviews of witnesses Quarantine of all evidence Following guidelines shall be adhered to for raising an incident report: Nature of defects shall, as far as possible, reflect exact wordings of original report. Report shall be itemised for ease of reference. Photographs, diagrams shall be included for ease of understanding. Reliability of affected component shall be reviewed. If defect involves component, requiring disassembly by some other organization, incident report shall be left open or pending till a technical report is received. Conclusion shall identify the cause of accident / incident / reportable defect. Corrective actions shall be recommended to relevant division / department. Deputy Chief Engineer (Technical Services Engineering) concerned shall forward draft of incident report to Chief Engineer (Quality Assurance) who shall submit finalized report to the Competent Authority alongwith relevant documents / information. Chief Engineer (Quality Assurance) shall despatch a copy of report to Deputy Chief Engineer (Technical Services Engineering) concerned for records. Deputy Chief Engineer (Technical Services Engineering) concerned shall coordinate with Deputy Chief Engineer (production) concerned for implementation of the corrective action. CEM Chapter 5-3 Edition: 02 Revision: 00 Issue: November 07 Page 2 of 2

109 5-4 SURVEILLANCE PROCEDURE FOR FUEL STORAGE FACILITIES PURPOSE To define PIA Engineering & Maintenance policies regarding surveillance of fuel storage at the suppliers facilities PROCEDURE a) Generalities Surveillance of fuel storage facilities includes periodic spot checks to ensure availability of acceptable quality of fuel for aircraft refuelling. Sample check at delivery point of supplier storage facility is required on must basis, if quality check of the fuel at refuelling is inadequate. If the repeated contamination of fuel is observed on refuelling, it is necessary to direct the supplier for a sample to be taken from fuel storage facility. b) Process Deputy Chief Engineer (AS) Technical Services Engineering Line Maintenance shall administer spot checks for fuel storage facilities surveillance on regular basis. Aircraft Engineer (AS) Technical Services Engineering Line Maintenance shall perform recorded spot checks of fuel storage facilities. Following checks shall be performed during such surveillance visit: Inspection of fuel storage tanks for rust, etc. Results of Millipore test of fuel Traces for water in the fuel during storage Filter / separator availability and its inspection / check interval with proper recording must be ensured. Such a filter / separator used while transferring fuel from storage to the fuel vehicle. Any special checks performed by supplier on fuel storage after calamities like heavy rain / flooding, etc. Deputy Chief Engineer (AS) Technical Services Engineering - Line Maintenance shall maintain results of such spot checks. Any significant fuel contamination shall be considered as Reportable Defect and must be reported by Deputy Chief Engineer (AS) Technical Services Engineering Line Maintenance to the Competent Authority on Form CAA-055 (Refer CEM Chapter 5-3). CEM Chapter 5-4 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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111 PART 6: MAINTENANCE PROCEDURES CEM Chapter 6-0 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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113 6-15 AIRCRAFT / AIRCRAFT COMPONENTS PAINTING PROCEDURE PURPOSE To define PIA Engineering & Maintenance policies regarding painting / striping / polishing / finishing / refinishing / of aircraft / aircraft components so as to avoid any possibility that could cause an unairworthy condition for aircraft / aircraft component PROCEDURE a) Paint Jobs Requiring Certificate of Release to Service (CRS) Following are tasks, but not the only tasks, related to painting / striping / polishing / finishing / refinishing work that requires a separate Certificate of Release to Service: Painting on control surfaces and critical lifting surfaces Painting in area with critical orifices, like pitot and static ports Painting involving mandatory markings Finishing of Radome, antenna and composites used in primary / secondary surfaces Extensive polishing of surfaces where fastener head dimension are critical Conversion from paint finish to polished metal In case, painting on the entire aircraft or large portion of aircraft is required, separate Task card / ARO shall be generated for each of the subtask mentioned above. b) Certificate of Release to Service (CRS) Certifying Staff, holding appropriate category Airframe rating, shall issue Certificate of Release to Service after successful completion of paint job. Any other signatory would require CAA (Pak) Airworthiness Directorate authorisation to issue such Certificate of Release to Service. Certifying Staff, issuing such Certificate of Release to Service, shall take responsibility of the process, ensuring that: Bill of work (in form of Task card / ARO) is available for each paint job being performed and that no paint job is carried out without an available Bill of work. Approved maintenance data is available and is being referenced. Instructions from paint manufacturer are available and being complied with. Before commencing paint job, work force is briefed according to Bill of work and is supervised throughout the process. Weight and balance requirements for control surfaces, being painted, have been catered for as per approved maintenance data. Provisioning was made for corrosion detection after removal of paint. Corrosion inhibition compounds, removed by solvents / paint removers, have been appropriately restored in areas adjacent to those being repainted. Excessive paint thickness is avoided to evade possible hindrance to NDT techniques In case of inadvertent placard / marking deletion, proper restoration has been made. Paint Checklist has been followed and signed accordingly by personnel, supervising the paint job. c) Additional Information Following are the cases of potential damage / hazards and must be avoided: i. Inadvertent placard / marking deletion, failure to renew them or comply with required specification (Registration marks, mandatory door markings and break-in CEM Chapter 6-15 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

114 zone identification). ii. Blockage of vents / drains and other openings by debris, masking tape and residues of paint remover, paint or particle blast material. Possible ingress of water into fuel tanks through vent apertures or filler cap seals when using high-pressure hoses for washing down. iii. Jamming of flight control and landing gear mechanisms by preparation treatments and paint. iv. Inadequate finishing schemes of manufacturer for antennas and Radomes. v. Damage caused during preparation work that could adversely affect structural integrity of the aircraft, such as: Reduction in fastener head size by uncontrolled use of power tools and abrasive media. Surface scratching by use of paint scrapers. Degrading of composite surface by abuse of particle blasting technique. Aluminium surface contamination by steel wool particles. Use of incorrect chemical paint strippers. vi. Damage of transparencies, composites and sealants by solvent / paint removers due to inadequate protection and / or retention of these products in crevices. vii. Loss of current mass balance moments on flight control surfaces. viii. Uncontrolled variations to aircraft basic weight. ix. Variation to surface profile and aerodynamic smoothness at critical points such as surface leading edges, by uncontrolled use of fillers or excessive paint thickness. x. Effects of excessive paint thickness on Non Destructive Testing techniques such as Eddy Current / Ultrasonic Inspection. d) Painting / Finishing on Aircraft Components Complete painting / finishing of aircraft components shall be carried out as per relevant instructions detailed in approved maintenance data. If separate maintenance data does not exist, as in case on various interior panels of aircraft, then relevant instructions in Aircraft Maintenance Manual (AMM) or instruction of Deputy Chief Engineer (production) concerned paint shop are to be followed. Such paint jobs shall be initiated using Fractional Work Order and concluded by signing Work Accomplishment advice at the bottom of Fractional Work Order. CEM Chapter 6-15 Edition: 02 Revision: 00 Issue: November 07 Page 2 of 2

115 6-16 AIRCRAFT WEIGHING AND TEST FLIGHT PROCEDURE PURPOSE To define PIA Engineering & Maintenance policies regarding Aircraft Weight and Balance check in accordance with Aircraft /Maintenance Schedule and test flights requirements to avoid any possibility that could cause an unairworthy condition for aircraft / aircraft component PROCEDURE a) Aircraft Weight and Balance Repeat determination of weight and centre of gravity of aircraft shall be accomplished in accordance with the maintenance program or if considered necessary in the light of a flight reported snag or as and when required by the PIA Flight Operations. As per the CAA (Pak) regulations, if the basic weight is estimated to have changed by more than 0.5 percent of maximum certified take-off weight or if the centre of gravity is estimated to have changed by more than 0.5 percent of MAC (mean aerodynamic chord) then the aircraft shall be re-weighed physically. It shall be the responsibility of the PIA Flight Operations to keep a complete, current and continued record of changes in empty weight and empty centre of gravity. PIA Engineering & Maintenance shall also keep records of performed weight and balance. At least two working days before the estimated release date of the aircraft from a major check, Chief Engineer (Base Maintenance) sends advice to Flight Operations and to Deputy Chief Engineer (Technical Services Engineering) Base Maintenance indicating expected release date of aircraft and flight on which it is scheduled to depart after release, together with following data. List of all Modifications and Engineering Change Orders (ECOs) incorporated or any configuration change, noting against each the resultant change in basic weight and the change in basic moment. List of all significant structure repairs carried out, noting against each the respective change in basic weight and the change in basic moment. Weighing and determination of centre of gravity is carried under supervision of Deputy Chief Engineer (Technical Services Engineering) Base Maintenance. Representatives of PIA Flight Operations and Competent Authority are present during weight and balance activity. Records of activity are shall be maintained by Deputy Chief Engineer (Technical Services Engineering) Base Maintenance. b) Test Flight A ground and flight test is performed after completion of a heavy maintenance visit. A flight test will also be performed if a problem cannot be duplicated on ground by means of standard maintenance checks, or if maintenance manual calls for it after a maintenance action. In consultation with the Chief Pilot Technical (Flight Operations department) a test flight plan will be defined. Chief Engineer (Quality Assurance) shall authorize for Test Flight. A test flight plan may also be defined in consultation with customer in case where operator is different from PIA. CEM Chapter 6-16 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

116 i. Authority The call for Test Flight of an aircraft can be raised by any of the following: Aircraft Engineer (Line Maintenance / Base Maintenance) concerned Deputy Chief Engineer (Line Maintenance / Base Maintenance) concerned Chief Engineer (Line Maintenance / Base Maintenance / Quality Systems) Chief Pilot (Technical) Test Flight report will be given by the pilot on the standard Flight Operations Proforma for the aircraft type as appropriate or on the Aircraft Technical Log for the information/record for further necessary action by PIA Engineering and Maintenance personnel. Necessary number of Aircraft Engineers (concerned) may be on board the aircraft for observation or for recording purposes during the Test Flight. ii. Applicability Test flight shall be carried out for the following case: Following upon major maintenance, repair, conversion or modification which may effect the operation or flight characteristics of an aircraft. For the purpose of performance evaluation with respect to flight characteristics, fuel consumption, engine power checks etc. To facilitate in trouble shooting a reported defect in a system or component if the fault could not be reproduced during the prescribed ground checks. Following upon repair done to the aircraft as a result of major damage. On specific requirement by Chief Engineer (Quality Assurance) On specific requirement by Chief Pilot (Technical) iii. Limitation A Test Flight is not to be carried out unless : A valid "Certificate of Fitness for Flight" has been issued following major maintenance. A Certificate of Maintenance Review is in force. The test flight has been called out or authorized by an appropriate authority The Aircraft Technical Log book and other relevant documents as required are on board the aircraft. It should be realized that the act of normal maintenance and/or replacement of standard parts and or components during the course of routine inspection and certification does not normally constitute grounds for a test flight. CEM Chapter 6-16 Edition: 02 Revision: 00 Issue: November 07 Page 2 of 2

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119 7-8 ONBOARD MEDICAL SUPPLIES CONTROL PROCEDURE PURPOSE To define PIA Engineering & Maintenance policies regarding control of medical supplies on-board the aircraft in case of an unforeseen emergency during the flight PROCEDURE a) Generalities All aircraft shall carry, medical supplies, sufficient for the treatment of injuries and other medical emergencies to the occupants, likely to occur, in flight or in case of accident / incident. Two types of medical supplies should be provided: First aid kit for carriage in all aircraft. Medical kit for carriage where aircraft is authorized to carry 250 passengers or more. It is essential that required first aid kits be distributed as evenly as practicable in the passenger compartment and should be readily accessible to cabin crew. In view of possible use of medical supplies outside aircraft in an emergency situation, they should be located near an exit. b) Contents of First Aid Kit Medical supplies should be contained in a metal box plainly marked with a Red Crescent and the words "First Aid" or "Medical Aid", as the case may be painted on it in English and Urdu Language. The boxes must be sealed and seal shall be checked by Certifying Staff on daily basis before releasing the aircraft. First aid kit is intended for emergency use only and is supplementary to medical kit carried by cabin crew for use in-flight. If medical kit is not carried on flight, then the contents of first aid box shall be replenished as early as practicable and first aid kit shall be resealed. Following shall be the contents of Aircraft First Aid Kit: A handbook on first aid "Ground-air visual signal code for use by survivors" Materials for treating injuries Ophthalmic ointment A decongestant nasal spray Insect repellant Emollient eye drops Sunburn cream Water-miscible antiseptic/skin cleanser Material for treatment of extensive burns Oral drugs such as analgesic, antispasmodic, central nervous system stimulant, motion sickness medications An artificial plastic airway and splints c) Contents of Medical kit Following Equipment should be part of Medical Kit: One pair of sterile surgical gloves Sphygmomanometer CEM Chapter 7-8 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

120 Stethoscope Sterile scissors Haemostatic forceps Haemostatic bandages or tourniquet Sterile equipment for suturing wounds Disposable syringes and needles Disposable scalpel handle and blade Drugs such as coronary vasodilators, analgesics, diuretics, anti-allergies, injectable steroids, sedatives, ergometrine, injectable broncho-dilator, etc. Where compatible with regulations of appropriate authority a narcotic drug in injectable form d) Certification of the First Aid / Medical Kit Contents of each kit should be checked at intervals of three months and expired / inadequate items shall be replaced. Serviceability of contents should be duly certified by a Medical Officer. Also a copy of list of medicines should be carried in the container. CEM Chapter 7-8 Edition: 02 Revision: 00 Issue: November 07 Page 2 of 2

121 PART 8: APPENDICES CEM Chapter 8-0 Edition: 02 Revision: 00 Issue: November 07 Page 1 of 2

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123 8-1 APPENDICES Pakistan CAA Certificate of Approval EASA Part 145 Approval Certificate Jordan CARC Foreign Maintenance Organization Approval GACA Saudi Arabia Certificate of Approval CEM Chapter 8-1 Edition: 02 Revision: 07 Issue: January 12 Page 1 of 6

124 8-1.1 PCAA APPROVAL CERTIFICATE CEM Chapter 8-1 Edition: 02 Revision: 07 Issue: January 12 Page 2 of 6

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127 8-1.2 EASA PART 145 APPROVAL CERTIFICATE CEM Chapter 8-1 Edition: 02 Revision: 07 Issue: January 12 Page 5 of 6

128 8-1.3 JORDAN CARC FOREIGN MAINTENANCE ORGANIZATION APPROVAL GACA SAUDI ARABIA CERTIFICATE OF APPROVAL CEM Chapter 8-1 Edition: 02 Revision: 07 Issue: January 12 Page 6 of 6