ASI - Aviation Safety Inspector Aircraft Manufacturing and Production Questions and Answers

Question 1

What is the primary authorization granted to the holder of a Production Certificate (PC) under 14 CFR Part 21?

Accepted Answer

To obtain a U.S. airworthiness certificate for products manufactured in conformity with the type design, without further showing.

Answer

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?

Accepted Answer

A non-conformity with the approved Production Quality System, potentially affecting the airworthiness of products.

Answer

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?

Accepted Answer

Verifying that the supplier's quality system meets the requirements established and approved as part of the PC holder's own quality system.

Answer

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?

Accepted Answer

The manufacturer has FAA approval for both the design and production of the ELT article to a minimum performance standard.

Answer

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?

Accepted 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.

Answer

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.

(ASI) Aviation Safety Inspector Certification Practice Test

(ASI) Aviation Safety Inspector Certification Practice Test

ASI - Aviation Safety Inspector Aircraft Manufacturing and Production Questions and Answers