ASI - Aviation Safety Inspector Aircraft Manufacturing and Production Questions and Answers 1 — Questions and Answers
Question 1: What is the primary authorization granted to the holder of a Production Certificate (PC) under 14 CFR Part 21?
- To approve new type designs for aircraft and engines.
- To obtain a U.S. airworthiness certificate for products manufactured in conformity with the type design, without further showing. (Correct answer)
- To issue Supplemental Type Certificates (STCs) for modifications to any aircraft.
- To perform major repairs and alterations on products they manufacture.
Correct answer: To obtain a U.S. airworthiness certificate for products manufactured in conformity with the type design, without further showing.
14 CFR Part 21, Subpart G, specifically § 21.145, grants the holder of a Production Certificate the privilege of obtaining an airworthiness certificate for their products without having to demonstrate conformity for each individual product. This is because the FAA has already determined that the manufacturer's approved quality system ensures that every product will conform to the approved type design.
Question 2: An ASI is auditing a Production Certificate holder's facility and discovers that the company's approved quality control manual has not been updated to reflect a recently implemented automated inspection system. This system is being used to accept or reject critical parts. Which of the following best describes this situation?
- An acceptable practice as long as the new system is more efficient than the old one.
- A minor administrative error that can be corrected at the next scheduled manual revision.
- A non-conformity with the approved Production Quality System, potentially affecting the airworthiness of products. (Correct answer)
- A violation that only requires verbal notification to the local Manufacturing Inspection District Office (MIDO).
Correct answer: A non-conformity with the approved Production Quality System, potentially affecting the airworthiness of products.
Under 14 CFR § 21.137, a Production Certificate holder must establish and maintain an FAA-approved quality system. This system, documented in their manual, must reflect the actual processes used. Using an undocumented and therefore unapproved inspection system, especially for critical parts, is a significant non-conformity because it breaks the chain of assurance that products conform to the type design and are safe for operation.
Question 3: Which of the following is a key responsibility of a Production Certificate (PC) holder regarding parts and assemblies sourced from external suppliers?
- Verifying that the supplier's quality system meets the requirements established and approved as part of the PC holder's own quality system. (Correct answer)
- Ensuring every supplier holds its own independent FAA Production Certificate.
- Relying solely on the supplier's certification of conformity without conducting any independent verification.
- Requiring the supplier to submit all parts directly to the FAA for inspection before shipment to the PC holder.
Correct answer: Verifying that the supplier's quality system meets the requirements established and approved as part of the PC holder's own quality system.
According to 14 CFR § 21.137(c), the PC holder's quality system must include procedures for 'Supplier control' to ensure that each supplier-provided product or service conforms to the PC holder's requirements. The PC holder is ultimately responsible for the conformity of all parts, including those from suppliers, and must be able to demonstrate this control to the FAA.
Question 4: A manufacturer produces an aircraft emergency locator transmitter (ELT) under a Technical Standard Order (TSO) authorization. What does this authorization signify?
- The ELT is automatically approved for installation on any specific aircraft model without further evaluation.
- The ELT has been flight-tested and certified by the FAA on a representative aircraft.
- The manufacturer is authorized to deviate from the minimum performance standards outlined in the TSO.
- The manufacturer has FAA approval for both the design and production of the ELT article to a minimum performance standard. (Correct answer)
Correct answer: The manufacturer has FAA approval for both the design and production of the ELT article to a minimum performance standard.
A TSO authorization, issued under 14 CFR Part 21, Subpart O, is both a design and production approval for a specific article. It certifies that the article (e.g., an ELT) meets a specific minimum performance standard established by the FAA. However, a TSO authorization does not grant approval for the installation of that article on a specific aircraft; that requires separate approval via the Type Certificate or a Supplemental Type Certificate.
Question 5: During the type certification process for a new aircraft, an ASI conducts a conformity inspection on the prototype's wing assembly. The inspection reveals that a specific rib is made from a different aluminum alloy than what is specified on the approved type design drawing. What is the immediate implication of this finding?
- The inspection can proceed, and the discrepancy can be documented later as a minor deviation.
- The wing assembly does not conform to the type design, and a Statement of Conformity cannot be issued for it until the discrepancy is corrected or the design data is formally changed. (Correct answer)
- The manufacturer must immediately apply for a Production Certificate to cover the material change.
- The FAA must issue an Airworthiness Directive to address the material substitution.
Correct answer: The wing assembly does not conform to the type design, and a Statement of Conformity cannot be issued for it until the discrepancy is corrected or the design data is formally changed.
The purpose of a conformity inspection is to verify that a product or component physically matches the engineering drawings and specifications that constitute the type design. A discrepancy, such as an incorrect material, means the part does not conform. A Statement of Conformity can only be signed when the article is found to be in full compliance with the approved design data. The issue must be resolved before the part can be certified as conforming.
Question 6: A company that does not hold the Type Certificate for an aircraft wants to manufacture and sell replacement landing gear components for that aircraft. Which type of FAA approval is specifically required for this activity?
- A Technical Standard Order (TSO) Authorization.
- A Supplemental Type Certificate (STC).
- A Parts Manufacturer Approval (PMA). (Correct answer)
- An amendment to the aircraft's original Production Certificate (PC).
Correct answer: A Parts Manufacturer Approval (PMA).
14 CFR Part 21, Subpart K, establishes the process for obtaining a Parts Manufacturer Approval (PMA). This allows a company to produce and sell modification or replacement parts for type-certificated products, even if they are not the original Type Certificate holder. An STC is for a design change, a TSO is for standard parts meeting a minimum performance standard, and a PC is held by the original manufacturer.
ASI - Aviation Safety Inspector Aircraft Manufacturing and Production Questions and Answers 1
What is the primary authorization granted to the holder of a Production Certificate (PC) under 14 CFR Part 21?