ASI Aircraft Manufacturing and Production 2 — Questions and Answers
Question 1: Under FAR Part 21, what is required before a manufacturer can begin production of a type-certificated aircraft?
- A letter of authorization from the local FSDO
- A Production Approval Holder (PAH) authorization such as a Production Certificate (Correct answer)
- Written approval from the aircraft's original designer
- A temporary airworthiness certificate for the prototype
Correct answer: A Production Approval Holder (PAH) authorization such as a Production Certificate
FAR Part 21 requires a manufacturer to hold a Production Approval, most commonly a Production Certificate (PC), before producing type-certificated aircraft.
Question 2: What document defines the exact configuration of an aircraft as approved during type certification?
- Aircraft Flight Manual (AFM)
- Type Certificate Data Sheet (TCDS) (Correct answer)
- Airworthiness Directive (AD)
- Maintenance Manual
Correct answer: Type Certificate Data Sheet (TCDS)
The Type Certificate Data Sheet (TCDS) records the approved configuration, limitations, and applicable regulations for a type-certificated aircraft.
Question 3: Which quality system standard is most commonly referenced by the FAA for aviation manufacturing quality management?
- ISO 9001
- AS9100 (Correct answer)
- MIL-STD-1520
- ANSI Z1.4
Correct answer: AS9100
AS9100 is the aerospace-specific quality management system standard recognized by the FAA and industry for aviation manufacturing.
Question 4: A manufacturer discovers a non-conforming part that passed inspection and was installed in a delivered aircraft. What is the first required action under FAR Part 21?
- Issue a service bulletin immediately
- Notify the FAA and initiate corrective action under the Production Approval Holder's quality system (Correct answer)
- Ground the aircraft until the part is replaced
- Quarantine all similar parts in current inventory
Correct answer: Notify the FAA and initiate corrective action under the Production Approval Holder's quality system
FAR Part 21.3 requires Production Approval Holders to notify the FAA of any defect or non-conformance that may present an unsafe condition and to initiate corrective action.
Question 5: What is the purpose of a First Article Inspection (FAI) in aviation manufacturing?
- To verify that a new supplier's facility meets environmental standards
- To confirm that the first unit produced from a new or revised process conforms to design requirements (Correct answer)
- To perform a pre-delivery customer acceptance flight
- To validate the aircraft's airworthiness certificate before sale
Correct answer: To confirm that the first unit produced from a new or revised process conforms to design requirements
A First Article Inspection (FAI) verifies that a production process is capable of producing parts that fully conform to engineering drawings and specifications.
Question 6: Under FAR Part 21, which category of parts requires the most stringent traceability documentation from a Production Approval Holder?
- Standard hardware such as AN bolts and MS nuts
- Life-limited parts and critical safety components (Correct answer)
- Interior furnishing components
- Ground support equipment parts
Correct answer: Life-limited parts and critical safety components
Life-limited parts and critical safety components require complete traceability documentation because failure could cause catastrophic aircraft loss.
Question 7: What is the role of Designated Manufacturing Inspection Representatives (DMIRs) in aircraft production?
- They perform final customer delivery inspections on behalf of buyers
- They are FAA-authorized individuals who perform inspections and make airworthiness determinations at manufacturing facilities (Correct answer)
- They manage the supplier qualification program for Production Approval Holders
- They issue export airworthiness certificates for aircraft sold abroad
Correct answer: They are FAA-authorized individuals who perform inspections and make airworthiness determinations at manufacturing facilities
DMIRs are FAA-designated individuals at manufacturing facilities authorized to perform inspections and issue airworthiness approvals on behalf of the FAA.
ASI Aircraft Manufacturing and Production 2
Under FAR Part 21, what is required before a manufacturer can begin production of a type-certificated aircraft?