ExecuJet MRO Services Malaysia Maintenance Organisation Exposition Notes

Maintenance Organisation Exposition (MOE) Overview and Official Acceptance

• Authority Approval Reference: CAAM/AW/AMO/2016/12, dated 15 March 2024.

• Organisation Information: ExecuJet MRO Services Malaysia Sdn. Bhd, located at Sultan Abdul Aziz Shah Airport, Selangor Darul Ehsan, Malaysia.

• Official Acceptance: The Civil Aviation Authority of Malaysia (CAAM) accepted Maintenance Organisation Exposition reference: EJMA-MOE-CAAM, Issue 04, Revision 01, dated 08 February 2024.

• Key Personnel (Document Control):

  • Compiled By: Aneth Athea Mat Som (Assistant Manager-Compliance).

  • Internally Approved By: Mohd Shahir Ahmad (Compliance Manager).

• Confidentiality Clause: The document is proprietary and cannot be reproduced or transmitted without express written permission from the President of ExecuJet MRO Services.

Document Control and Revision History

• Manual Structure: Segregated into Part 0 (Introduction), Part 1 (Management), Part 2 (Maintenance Procedures), Part L2 (Line Maintenance), Part 3 (Quality System), Part 4 (Operator Procedures), Part 5 (Sample Documents), and Annexes.

• Revision Status:

  • Issue 3, Revision 0: 22 October 2019 (Major revision).

  • Issue 4, Revision 1: 08 February 2024 (Major revision including company logo change and transition from "Manual" to "Publication").

• Major Changes in Issue 4 Rev 01:

  • Transition to electronic distribution for MOE (hardcopy only for CAAM).

  • Inclusion of Regional Vice President - Asia and General Manager - Technical Services roles.

  • Implementation of the Q-Pulse system for document management and Corridor system for logistics and tooling.

  • Establishment of a new facility (Location 2).

  • Updated staff counts (Total: 58 personnel).

Comprehensive Definitions and Acronyms

• AAT: Airworthiness Approval Tag.

• CDCCL: Critical Design Configuration Control Limitation.

• Standard Part: Parts manufactured in complete compliance with established industry/government specifications (e.g., NAS, AN, SAE, ANSI, EN). Specifications must be published for any party to manufacture.

• Consumables: Materials used only once, such as lubricants, cements, compounds, paints, chemicals, dyes, and sealants.

• Raw Materials: Materials requiring further work to become aircraft components (e.g., metals, plastics, wood, fabric).

• Accident: An occurrence where a person is fatally or seriously injured (direct contact, jet blast, or being in a missing/inaccessible aircraft) or the aircraft sustains structural damage affecting flight characteristics.

• Incident: An occurrence other than an accident that affects or could affect flight safety.

• Rotable: Serial numbered parts tracked for life control (hard life or condition monitored).

• Expendable: Items for which no authorized repair procedure exists or repair costs exceed replacement costs.

Management Structure and Personnel Responsibilities

• Nominated Post Holders:

  • Accountable Manager: Ivan Lim Wah Teik (Regional Vice President - Asia).

  • Compliance Manager (Quality & Safety): Mohd Shahir bin Ahmad.

  • General Manager (GM) Maintenance: Suniljit Singh.

• Accountable Manager Duties:

  • Reporting to the President of ExecuJet MRO Services.

  • Ensuring maintenance meets CAAM standards.

  • Ensuring necessary finance, manpower, and facilities are available.

  • Supervising corrective actions and overall quality results.

• Compliance Manager Duties:

  • Establishing an independent quality assurance system.

  • Defining Human Factors principles and training.

  • Managing the qualification and authorization of certifying and support staff.

  • Reporting major failures or defects to CAAM, operators, and manufacturers.

• GM Maintenance Duties:

  • Developing production planning systems.

  • Maintaining man-hour plans and ensuring facility availability.

  • Ensuring tools and equipment used for airworthiness are calibrated.

• Interim Policy: If a manager is absent for more than $10$ consecutive working days, a formal deputy must be announced via memo/fax/email.

Manpower and Resource Allocation

• Total Personnel Count (February 2024): 58 staff members.

• Departmental Breakdown:

  • Management: 1 Accountable Manager.

  • Maintenance: 3 Managers/Supervisors, 35 Certifying/Support Staff and Technicians.

  • Compliance: 4 Auditors (Part 145 & SMS).

  • Supply Chain: 2 Managers/Supervisors, 2 Receiving Inspectors, 2 Tools/Store, 2 Purchasers.

  • Planning: 3 Managers/Supervisors, 4 Planners/Technical Records.

• Reporting Requirements: Any significant shortfall (exceeding $25\%$ of available man-hours over a calendar month) must be reported to the Accountable Manager and Compliance Manager.

Facility Requirements and Environmental Standards

• Location 1 (Skypark Hangar A & B):

  • Hangar A Area: $35445.5\,SQFT$ with $8.8\,M$ clearance.

  • Hangar B Area: $32657.7\,SQFT$ with $8.8\,M$ clearance.

• Location 2 (ExecuJet New Hangar):

  • Area: $143917.45\,SQFT$ with $10\,M$ clearance.

• Work Environment Requirements:

  • Temperature: Must be maintained to not affect worker efficiency.

  • Dust Control: Surface contamination must be visible; if found, exposed systems must be sealed.

  • Lighting: Fluorescent/LED lighting required for effective maintenance.

  • Noise: Protective equipment (earmuffs/earplugs) must be used if noise affects duties.

  • Storage: Multi-zone stores including Goods Receiving, Dispatch, Serviceable, Bonded/Quarantine, and Consumables.

• Workshops: Dedicated Battery Shop (Ni-Cad and Lead Acid) and Tire Shop.

Approved Scope of Work

• Ratings:

  • A1 Aircraft:

    • Bombardier BD-100-1A10 (Challenger 300/350) up to 9600H/192M.

    • Bombardier BD-700 (Global Express/5000/6000) up to 8C.

    • Bombardier CL-600-2B16 (Challenger 604/605/650) up to 96M.

    • Gulfstream G-IV / IV-X up to 120M.

    • Dassault Falcon 7X/8X up to 3C.

    • Falcon 2000EX EASy up to C/72M/3750FH.

  • C5/C14 Components: Electrical Power, Lights, and Landing Gear (limited via EJMA-CP-CLM-CAAM).

• Maintenance Away from Approved Location: Permitted for AOG support of unserviceable aircraft or occasional line maintenance if a contract exists.

/Supplier, Contractor, and Subcontractor Control

• Definitions:

  • Supplier: Provides parts/materials with suitable release documentation.

  • Contractor: Holds CAAM Part 145 approval; performs maintenance under its own approval for EJMA.

  • Subcontractor: Not Part 145 approved; works under EJMA's quality system (e.g., specialized welding, painting).

• Assessment Methods:

  • Contractor: Desktop Audit every $24$ months.

  • Subcontractor: On-site Audit every $12$ months.

  • Suppliers: Desktop audit or ISO 17025 review every $24$ months.

• One-Off Providers: Approved on a case-by-case basis by the Compliance Manager using EJMA-CP-21.

Component and Material Management

• Acceptance Criteria: Components must be released on a CAAM Form 1 or acceptable alternatives (FAA 8130-3, TCCA Form One, EASA Form 1, UK CAA Form 1).

• Receiving Inspection:

  • Verification of physical condition, packaging (e.g., ATA 300), and shelf life.

  • Documents verified against Purchase Orders.

  • Electronic items handled only as per ESD precautions.

• Bogus Parts: Suspected Unapproved Parts (SUP) must be reported to CAAM as Mandatory Occurrences.

• Storage Policies:

  • Bonded Store: Dedicated for serviceable and rotable parts.

  • Quarantine Cage: Secured for unserviceable or non-conforming items.

  • Environment: Main store monitored for temperature and humidity weekly; refrigerators and POL cabinets daily.

• Mutilation of Scrap: Unsalvageable parts must be mutilated (grinding, burning, sawing) to prevent re-entry into the supply chain.

Tooling and Equipment Control

• Calibration Standards: Tools used for airworthiness determination (e.g., torque wrenches, pressure gauges) must be calibrated according to ISO 10012 or OEM standards.

• Tool Register: Managed via the Corridor computer system, tracking ID, description, serial number, and calibration due dates.

• Uncertainty/Failure Management: If a tool fails calibration, the Compliance Manager and Planning Department must review all work performed with that tool during the previous period for potential product recalls.

• Alternate Tooling: Permitted only if the OEM allows it. An equivalency assessment (EJMA-MN-09) must be approved by the Compliance Manager.

• Missing Tools: Report immediately using EJMA-SC-01. A search and stop-work order may be issued until the tool is located.

Maintenance Procedures and Certification

• Critical Maintenance Tasks: Tasks that could directly endanger flight safety if an error occurs (e.g., flight control rigging, engine installation).

  • Error Capturing Method: Requires Independent Inspection by an unauthorized person or Re-inspection in unforeseen circumstances (AOG).

• Release to Service (CRS):

  • Must contain the statement: "The work recorded above has been carried out in accordance with… Malaysian Civil Aviation Regulations… and in that respect the aircraft/equipment is considered fit for release to service."

  • Includes location, date, organization approval number, and the signature/stamp of the authorized Certifying Staff.

• Airworthiness Directives (AD): Mandatory compliance. A CRS cannot be issued if an AD is overdue. Repetitive ADs must be tracked in the technical logbook.

• Work Package Contents: Includes Work Order, Routine Task Cards, Non-Routine Task Cards, Tool/Signature Verification Sheet, and Release Certificate.

Reporting and Quality Feedback

• Mandatory Occurrence Reporting (MOR): Occurrences resulting in unsafe conditions must be reported to CAAM within $48$ hours of the finding.

• Internal Occurrence Report (IOR): Promotes a "Just Culture," protecting staff from blame for honest errors while ensuring accountability for willful violations.

• Audit Findings:

  • Level 1: Serious hazard; operations must cease until corrected.

  • Level 2: Non-compliance that could hazard safety.

  • Level 3: Observed condition demonstrating systematic non-observance of procedures.

• Safety Management System (SMS) Meeting: Conducted monthly to review safety issues, occurrences, and audit statuses.

Personnel Training and Qualification (Annex 1)

• Initial Training Requirements: Includes HF (Human Factors), EWIS (Electrical Wiring Interconnect System), FTS/CDCCL (Fuel Tank Safety), SMS (Safety Management System), Part 145 regulations, and Dangerous Goods.

• Continuation Training: Mandatory every $2$ years for all maintenance and support staff.

• Engine Run-up/Towing: Requires specific OJT ($3$ sessions minimum) and documented practical assessments.