ASI Aircraft Manufacturing and Production 3 — Questions and Answers
Question 1: An aircraft manufacturer wants to make a change to an approved design that may affect structural strength. What approval process applies?
- Minor alteration approval through Form 337
- Supplemental Type Certificate (STC) or major design change approval via FAR Part 21 Subpart D (Correct answer)
- A written waiver from the original type certificate holder
- An airworthiness directive amendment from the FAA
Correct answer: Supplemental Type Certificate (STC) or major design change approval via FAR Part 21 Subpart D
Changes affecting structural strength are classified as major changes requiring STC or amended type certificate approval under FAR Part 21 Subpart D.
Question 2: Which regulatory part governs the airworthiness standards for transport category airplanes during type certification?
- FAR Part 23
- FAR Part 25 (Correct answer)
- FAR Part 27
- FAR Part 33
Correct answer: FAR Part 25
FAR Part 25 establishes the airworthiness standards for transport category airplanes, including structural, flight, and system requirements.
Question 3: What is the primary purpose of a Conformity Inspection during the type certification process?
- To verify the prototype conforms to the design data submitted for type certification (Correct answer)
- To check that the production facility meets OSHA safety requirements
- To confirm that the aircraft meets customer delivery specifications
- To validate that avionics software meets DO-178C requirements
Correct answer: To verify the prototype conforms to the design data submitted for type certification
A Conformity Inspection verifies that the test article or prototype physically conforms to the engineering drawings and specifications submitted for type certification.
Question 4: Under the Organization Designation Authorization (ODA) program, what can an ODA Unit Member do that standard company employees cannot?
- Approve engineering changes without FAA review under delegated authority (Correct answer)
- Sign off on maintenance release forms for line operations
- Issue pilot certificates to aircraft test pilots
- Approve aircraft for export to non-BASA countries
Correct answer: Approve engineering changes without FAA review under delegated authority
ODA Unit Members are FAA-authorized individuals within a company who can perform certification and approval functions on behalf of the FAA under delegated authority.
Question 5: What does the term 'production flight test' refer to in the aircraft manufacturing context?
- A test flight required by FAR Part 21.127 to verify each produced aircraft meets its approved type design before delivery (Correct answer)
- A demonstration flight performed for prospective buyers before purchase
- A ferry flight to deliver the aircraft to a customer's location
- An acceptance test flight required by military procurement standards
Correct answer: A test flight required by FAR Part 21.127 to verify each produced aircraft meets its approved type design before delivery
FAR Part 21.127 requires production flight tests for each aircraft produced under a Production Certificate to verify conformity with the approved type design.
Question 6: A supplier provides a batch of fasteners without proper material certifications. Under FAA Order 8120.16, how should the Production Approval Holder treat these parts?
- Accept them provisionally and document the exception in the quality records
- Quarantine them as suspected unapproved parts (SUPs) and initiate an investigation before use (Correct answer)
- Use them only for non-structural applications where material properties are less critical
- Perform sampling inspection and accept the batch if samples pass dimensional checks
Correct answer: Quarantine them as suspected unapproved parts (SUPs) and initiate an investigation before use
Parts lacking proper material certifications must be quarantined as suspected unapproved parts (SUPs) per FAA guidance, and the PAH must investigate before any use.
Question 7: What is the significance of the 'Statement of Conformity' (FAA Form 8130-9) in aircraft manufacturing?
- It certifies that a pilot has completed type-specific training for a new aircraft model
- It is a manufacturer's declaration that an aircraft or part conforms to its approved type design (Correct answer)
- It authorizes a maintenance facility to perform warranty repairs on a new aircraft
- It documents the aircraft's compliance with environmental noise regulations
Correct answer: It is a manufacturer's declaration that an aircraft or part conforms to its approved type design
FAA Form 8130-9 is a Statement of Conformity in which the manufacturer certifies to the FAA that the aircraft or article conforms to its approved type design.
ASI Aircraft Manufacturing and Production 3
An aircraft manufacturer wants to make a change to an approved design that may affect structural strength.
What approval process applies?