Process Excellance Framework

S.
No
PROCESS NAME
Wet Installation of fasteners
Application of Fay Sealant
Sealant Mixing
Water Tightness Demonstration process
Mixing of adhesive
Protection of FOD sensitive Areas
Fillet sealing
NDI-LPI, Eddy current process
Drilling/Reaming on Metals- Deburring, Score Marks,

Angularity
10
Cold working process
11
Protection of Composite floor/bottom panel
12
Electrical Bonding Test process
13
Paint Mixing
14
Part marking
15
Application of Adhesive
16
Torque tightening process
17
Emergency Egress Hatch ATP
18
Nicks, Scratches, Gouges and Dents
19
Alodine Application
20
APU Drain Leak Test
21
Engine-Drain Leak Test
22
Cabin Heating Hose Pressure Test
23
Flight Control Cable Alignment test process
24
Primer Mixing
25
Hydraulic System Line Flushing Process
26
Hydraulic Pressure Proof Test process
27
Movement of panels and cabin from jig to jig
28
Application of Primer
29
Installation of ICDs
30
Drilling/Reaming on Composites- Deburring, Score

Marks, Angularity
31
Painting
32
Wire Locking process
33
Swaging process
Control & Handling of Air-conditioned room and its
equipment for paint
Movement of cabin to Shipping Fixture and truck
Tube Installation process
Paint Stripping of Metal & Composite parts
34
35
36
37
KEY CHARACTERISTICS
1. Personnel competency
2. Usage of primer or sealant for wet installation of fasteners as per Router / MAPL
3. Sealant records
4. Use of approved cleaners & FOD free condition
5. adequate squeeze out Sealant or primer need to be extruded into the hole and around the surfa
6. inspectors witness usage of sealant or primer.
7. Post cleaning and protection against FOD
8. Operator and inspector sign off after wet installation of fasteners with relevant documentation.
9. Handling of expired seal or primer and post cleaning of the equipment.
10. usage of primer or sealant within its pot life.
11. PPE Aherence
1. Personnel Competency
2. Proper surface preparation
3. PPE Compliance
4. FOD free from chips, burrs, dust and oil.
5. usage of approved cleaners
6. usage of lint free cloth and wiping in single direction.
7. reqd sealant is drawn as per MAPL and Visual aid requirement with the sealant record
8. sealant details (Segment, AOS no, W.O No, Cabin no, Shift, and Date) are entered in the sealant
9. sealant is applied with a roller or brush to form a uniform thickness of approximately .010 inches
pattern across the surface to be coated
10. sealant is spread to a uniform thickness with a spreader or roller. Use enough sealant to obtain
thickness and a Squeeze out for a fillet forming
11. adequate sealant squeeze out from the mating surface edges.
12. application of the temporary fastener if the permanent fasteners are not installed within the as
13. Excess sealant squeeze out shall be faired to form a fillet not less than 1/8 inch wide
14. No FOD , GAP, Un-even thickness, locally uncovered area.
15. clean of any unwanted sealant with a solvent dampened cloth while sealant is soft. Do not app
damage the seal and create a possible leak.
16. recording of the application completed time in the sealant record sheet with sign and stamp. A
completeness and offer to inspection.
1. Use of prescribed sealant as per the standard/procedure.

2. environmental condition during preservation & mixing.
3. mixing environmental condition RH- Max 60%
Temp- 18.33 to 29.44 degree Celsius
4. mix ratio as per the manufacturer instruction I .e Weight ratio ( base to accelerator)
5. Use same Batch of base & catalyst during the mixing.
6. mixed sealant condition to be in uniform colour & steak free condition.
7. traceability of the Batch & Lot of the sealant.
8. Availability of the mixing of the record in form TASL 0200 013.
9. PPE Compliance
10. one batch sealant & catalyst not mixed with the other batch sealant & adhesive.
11. All the specified test been performed during the sealant process
12. Daily FOD check adherence & availability of record.
13. the shelf -life of the sealant before the mixing as pee the COC.
14. Instruments calibration control
15. Freezer temperature control in working and non-working hours
16. Personnel competency and awareness on sealant mixing as per SS 8640, TOP-02-07
17. Awareness on MSDS
18. Record maintenance
19. Non-conformance handling in Sealant mixing
20. Availability of the TOP procedure at the sealant kitchen
21. Shelf life Extension procedure and relevant communication with the supplier.
22. Test specimens preparation as per TOP, Test records upkeeping with specimen
23. Accelerated curing of Test specimen, Temperature control for accelerated curing
24. Hardness records for the specimen
1. Approved & Proved Test equipment

2. optional assemblies installed on the cabin fuselage before water tightness test.
3. dummies are installed on the cabin fuselage before water tightness test.
4. Ambient fluid temp is maintained between 40F to 100F.
5. Fluid used for the test is Fresh water (2.3 gpm for cabin / 2.12 gpm for Drip pan) with a flow rate
6. test duration is 20mins for cabin and 3 mins for Drip pan.
7. test is carried outside then steady wind velocity of 0-7 knots is maintained.
8. work related to the cabin is completed and there are no CF or open NC or DR. 9. QA satisfied wit
relevant optional assemblies are installed.
10. Water Tightness equipment gauges are calibrated
11. lightening arrangement inside the cabin for QA is sufficient
12 . all the open areas of the cabin are closed. both the ends of the fuselage are covered. all the at
points of MRP and the area of MGB Drip pan are covered.
13. Testing fixture positioning is as per the procedure. upper nozzles shall be approximately 67 inch
14. Spray pattern from the nozzles should be satisfactory to QA. Any unsatisfactory spray pattern s
nozzle.
15. test performed in presence of the QA from start to end.
16. water pressure at the nozzles shall be a simulated rainfall rate of 45 to 80 inches per hour for c
17. 10 minutes dwell time is allowed following the shut off of water supply and then QA inspect the
18. all the leakages are identified and recorded.
19. all the leakages observed are repaired as per SS8630
20. no of leakages are more than 5 then retest performed and if no is less than 5 then local test pe
21. local test a pocket to cover the entire leakage area is made using the polythene cover and SM9
22. local test pockets are filled with water and kept on hold for 15 to 20 min and observe for leaks
23. report of the water tightness test is submitted to SAC. Is the test report includes all the location
those leaks.
24. post cleaning of cabin is carried out after removal of all the covers and temporary seals.
25. periodic maintenance of the test equipment is carried out
26. test fluid is periodically checked for contamination and replaced
1. Controlled Preservation & mixing (Temp 25 degrees).

2. Receiving inspection stamp with Date of Mfg and Date of Expiry
3. Availability SS8640 / TOP-02-11 / MSDS at the Adhesive mixing area
4. Calibrated Mixing Equipment
5. Personnel competency
6. Caliberated Weighing Scale
7. PPE Compliance
8. Identification, Traceability of the Adhesives, promoter & Cleaners at Mixing area.
9. Shelf -life Tracking/Extension per COC.
10. Mix ratio as per Manufacturer instruction/SOP
11. Same Batch Mixing of Accelerator and Base with Batch nos record
12. Uniform Mixing of parts A & B with uniform colour and homogeneity.
13. identification on mixed adhesive with Date, Time of mixing and Exp details on a label and affix
14. Availability Adhesive Mixing Record Sheet of latest Rev and witnessed by the inspector.
15. FOD control during mixing
16. Clean as you go
17. Mixing area well ventilated
18. Post mixing cleaning using approved cleaners
19. Daily FOD check adherence & availability of record at the mixing area
20. Qty mixed is less than 450 Grams.
21. handling of Expired material at mixing area.
6. FOD prevention Work instructions specific for each manufacturing area.

7. Periodic selfassessments of each manufacturing area in accordance with written checklists
8. Management review of the FOD Prevention Program on a regular basis to assess the effectivenes
evidence of FOD inspection.
9. Usage of Pareto and/or trend charts to summarize and analyze assessment findings and identify
these charts at work centers to give results to the operators and management.
10. Availability of QM System for reporting FOD incidents to management, investigating root cause
11. existence of a method for formally notifying Sikorsky Aircraft of delivery of product known or s
objects
12. Inspection documentation must contain a FOD check
13. FOD control over its suppliers and vendors
14 . Organization control over Transient personnel and Environmental conditions for controlling FOD
15. Control over Lost items,instrument, gauge and part procedure.
16. protection of FOD sensitive areas during Transportation of panels or cabin from one segment to
17. FOD check by both production and inspection prior to transportation and resting of the cabin o
18. Foams wrapped around all supports of Dolleys, skids and stands needs to be free from FOD oth
of the skins of Lower Tub.
19. Lessons learnt on FOD due to past incidents and action taken against them. Ensure difficult to r
accumulation of burrs and debris.
20 . protection Trough areas of Lower panel using 3 layers to avoid dents at 240 segments to avoid
21 . Customer complaints on FOD and action taken against them.
22. entry to FOD critical areas is restricted and no CF work from the previous stages is being carrie
of the area manager and related Quality inspector of that area.
23. end caps are provided to Hydro line inlets and outlets, Heating Hoses, Tee, Elbow and Unions o
24. Installs connectors for Cables and Wire Harness needs to be protected with Electro Static Disch
25. Drip pan, MGB Bush areas, Sponson Bush areas of C Frames, Spherical Bush areas of Sponson S
against FOD.
26. FOD check before delivery of the cabin by production, Inspection and customer team.
27 . FOD control at Stores, sealant / Adhesive mixing area, paint booth, CPOS area and PPC kitting
28. periodic performance review of all the work centers.
29 . Customer comments, concerns and complaints on FOD if any and action taken against them.
30 . material used for packaging of the cabins or kits are free from FOD.
1. Personnel competency and awareness on Fillet sealing requirements as per SS 8640

2. application of the fillet sealant as per the specification SS8640
3. availability of the relevant document for the sealant and compliance of all characteristics.
4. adequate cleaning & FOD free condition of the sealant application area by operator and concern
5. Usage of approved equipments as per SS 8640 and TOP procedure
6. Preparation for Fillet sealing
A. Cleaning
1.FOD cleaning
2.usage of approved cleaners
3. Usage of Lint free cloth
4. Cleaning performance as per TOP
5. Witnessing of the QC inspector after cleaning.
7 Usage of the approved sealant as per MAPL and Router
8 Recording the details of the sealant with AOS no, Shift, W.O NO, A/C no, Date, Application time w
operator and inspector.
9. Application of the Fillet seal using the gun as per TOP procedure i.e Angle and direction control.
10 . proper fillet seal width is maintained during the application. All the bubbles are faired properly
11 Check for uniform appearance. If any defect noticed after the sealant has cured, shall be cut ou
12 the crowing requirements are maintained (If the thickness of the top plate or offset is the less
the top plate or offset by 0.150 to 0.060)
13 For the butt gap fill by offsetting of 0.150 to 0.060
14. fillet sealed area has to be free from the visual defects
15. Post cleaning and protection against FOD
16. Operator and inspector sign off after Fillet seal application with relevant documentation.
17. Rework in Fillet seal and related documentation.
18. Handling of expired Fillet seal and post cleaning of the equipment.
19. Fillet seal Pot life control at work centers
20 .Repetitive problems in Fillet seal and action taken to control them
21. Adherence of PPE during Fillet seal application.
22. Knowledge of defects in Fillet seal to operators, Supervisors and Inspectors.
23. Effect of Temperature and humidity on Fillet seal application.
a. Level of Qualification
b. Personal duties and responsibilities
c. Limitations
d. Training program
e. Recertification Requirements
f. Requirements for experience
g. Requirements for examinations
h. Records and documentation practices
i. Materials
j. Equipment
35 Level III personnel available for LPI
36 an outside agency utilized for performing the Level III functions
If an outside agency is utilized, has the employer documented the suitability
37 the following 5 levels of NDI personnel available
a. Trainee
b. Level I
c. Level II
d. Level III
e. Instructor
38 a training course outline for each level in place
39 the training course approved by Level III
40 the training course outline address, for each level the following:
a. Principles
b. Products
c. Equipment
d. Operating procedures
e. Techniques
f. Specification codes
g. Training hours
41 the required training hours for level I, II and III for each method as per the customer requiremen
42 evidence of previous training from a previous employer? If yes
a. The training is documented
b. The training has been verified
c) the drill gun withdrawn from the hole with drill motor still running and stopped after coming out
d) the appropriate cleco selected and hole is locked with cleco by using cleco plier
e) the drilling continued in the similar way as detailed above for the remaining holes of the visual a
f) the drilled holes are having surface finish of 250 micro inches AA
Note: i) Install a drill stop if there is a obstruction behind the part being drilled
ii) Use a guide bush when drilling at the curved surface to guide the hole normal to the surface.
iii) Use a backup support of wood or Aluminum to avoid the movement of the thin stack up parts w
iv) If the drilling is done on a skin hole drilling to be started from centre to outward.
9 Step Drilling:
the progressive or step drilling followed if the hole size larger than 0.125 inches to be drilled in Ti o
Aluminum
Note: For drilling 0.500 inches in Aluminum a start drill of #40 followed by drill size of 0.250, 0.375
10 Post Drilling:
a) the shop air disconnected from the drill motor
b) the parts disassembled for deburring and cleaning
c) all the holes cleaned using the chip chaser if it is impractical to disassemble the parts
d) all the holes self inspected by the operator and Inspector
e) the inspectors using the calibrated pin gauge for inspection
f) the relevant operations signed and stamped by operators and inspectors
g) the clean as you go followed by operator
11 Reaming Operation:
a) the reamer of appropriate material and size selected
b) the reamer cutting teeth free from FOD
c) the required RPM as per the material set in drill motor
d) the reamer chucked into the drill motor and tightened properly
e) the reamer cutting flutes dipped in Boe lube cutting fluid
f) the reamer positioned perpendicular to the surface by using the guide bush
g) the reamer passing to full length of the hole
h) the shop air disconnected and reamer manually taken out by rotating in anticlockwise direction
i) the reamer cleaned and dipped again in Boe lube and above steps repeated for remaining holes
j) the holes deburred using the appropriate tool and cleaned for burr
k) the holes chamfered as per the dwg required tolerances (.015-.030 Radius for Titanium and .005
12 Reamed Holes Inspection:
d) the hole cold worked by actuating the puller unit so that mandrel is withdrawn through the slee
e) the actuation of the puller unit is continued until the mandrel is clear of the structure
f) the sleeve removed from the hole and discarded
Note: Re use of the sleeve is not permitted.
g) the cold worked hole verified with combination gauge
h) the above cold work procedure repeated for other holes which are ready
10 Coldworking Hole Finish characteristics:
a) the hole produced by coldworking is of hourglass shape with end of the hole corresponding to th
the mandrel entry end of the hole
b) No Buckling or oil canning of the material adjacent to the hole after cold expansion
Note: Above condition is acceptable only if the hole is filled with a fastener installed with sufficient
buckling.
c) the bore of the hole free of imbedded particles, flaking, tearing, folding and cracking
Note: the presence of a shear discontinuity shall not be cause for rejection of a cold expanded hole
d) the diameter of each hole shall be verified by a trained operator before and after cold expansio
has been accomplished and that final dimension and alignment is in accordance with the requirem
e) the cold working hole is having out of plane distortion (Surface upset)
Note: The above condition is acceptable as long as the installed fastener meets the requirements o
f) the bore of the hole is having axial ridge corresponding to the position of the split in the sleeve
Note: Above condition is acceptable.
g) the shear discontinuities noticed after cold expansion
Note: Above condition is acceptable
h) separation of the faying surfaces beyond 0.005 inches following cold expansion of a stack up of
i) the verification gauge is not pass through the stack up due to spring back in multi material stack
Note: when cold expanding multi-material stack up the cold expansion will not be the same in each
11 Final Reaming:
a) the Final size reamer appropriate to the fastener diameter is selected and loaded onto drill gun
b) the coldworked hole reamed by using the cutting fluid and guide bush at required RPM for the c
Note: Lower RPM needs to be used for any reaming operation
c) the reamer cleaned to remove burrs after reaming without removing from the hole
d) the gun turned off and reamer pulled out by rotating in anti clockwise direction to avoid score m
e) the hole surface finish of 63 micro inches AA is maintained without any score marks
f) the hole is normal to the surface
transportation.
2 Ensure the skins are taken after visual inspection for the Dents after receipt from PPC. Check for
from Stores, PPC to production area
3 Ensure Thick foams are used for protection against core for tool droppings are any other impact d
4 Adherence to Clean As You Go by the employees and ensure that the panel is dent free
5 Ensure the proper training to operators for the handling of lower panel skins against Dents and im
6 Ensure the routers and visual aids of 244 segments have preventive work instructions for protect
7 Ensure the daily check by the area operators and inspectors for the Dents on Skins of lower pane
any.
8 Ensure during Final shakedown that no dents exist on the skins on both exterior as well as interio
attached along with the Router and attach the same along with the Traveller.
9 Ensure the protection of FOD sensitive areas during Transportation of panels or cabin from one se
10 Ensure the FOD check by both production and inspection prior to transportation and resting of t
dolleys.
11 Ensure Foams wrapped around all supports of Dolleys, skids and stands needs to be free from F
surface of the skins of Lower Tub.
12 Have the panels inspected for Dents by the inspector of next stage and take the sign off in the D
sheet in the similar manner at each stage of Transportation to other segments till final dispatch.
13 Ensure the proper care taken during clear coat painting at paint booth on the interior of Lower p
14 Ensure during clear coat inspection for the dents if any. Check on the exterior surface also.
15 Ensure Before integration 240 inspector checks for Dent check sheet from previous stages and
interior and exterior of the panels.
16 Ensure the preparation of the panel with 2 layers of protection on the panels as specified on the
protection are free from Dent causing materials. Ensure that operators are not stepping on the inte
17 Ensure after panels integration Wooden Floor boards are placed on the lower panel to protect ag
Same protection need to be followed till final shakedown.
18 Ensure the entry to FOD critical areas is restricted and no CF work from the previous stages is b
knowledge of the area manager and related Quality inspector of that area.
19 Ensure the Lower panel interior and exterior skins are free from Dents during shakedown at eac
for the same during Daily FOD checks at these segments. Ensure that FOD check happens without
trough areas needs to removed to avoid Dents.
20 Ensure Lower panels are free from Dents before offering the cabin to customer team for final bu
2. Personnel competency on surface preparation and Electrical bonding measurement. Also for pro
3. Removal of protective or decorative finishes & FOD, removal of oil, grease, epoxy and sealants fr
4. Use of approved cleaners and wiping cloth used for removal of oil, grease otherwise vapour degr
5. Cleaning of solvent wiped dry with lint free cloth before it evaporates
6. Apply Corrosion protection after bonding measurement
7. Installation or assembled in accordance with requirements of applicable installation drawings. 8.
24 hours after completion of Corrosion Protective treatment.
9. attaching hardware to achieve bonded connections specified on the applicable engineering draw
10. Protective finishes on the hardware is not removed during installation
11. Intermediary washers required in attaching hardware stack up when bonding between dissimila
12. first and second terminal lugs on a stud shall be installed with the topside up. When 3 or more
first two lugs shall be inverted. The third and subsequent lugs shall be installed top side up to prev
13. measurement of bond shall be in accordance with engineering drawing. The test shall measure
mating surfaces using milli-ohm meter. If the desired values are not met then the steps repeated
14. Environmentally exposed electrically bonded assemblies and/or installations shall be sealed to
sealed shall be slightly larger in diameter than the cleaned area. Sealing shall be completed not m
magnesium components, and not more than 7 days after installation for all other materials.
15. when protective coating is been removed from the metallic surfaces, the completed connection
a suitable protective touch-up finish , within 24 hours after inspection.
16. surface preparation, hardware installation and measurement are as per the instruction given in
by operators and inspectors.
17. Conductive coatings or finishes shall not be removed because they have suitable conductivity f
require only cleaning or degreasing to meet bonding and/or grounding requirements, (i.e. tin platin
Alodine)
18. removal of Conductive Coating from Metallic Surfaces only when defined on engineering drawin
19. If the assembly drawing does not specify a resistance limit, the requirement shall be 100 millio
20. conductive coating on connectors is not removed.
21. Sanding is prohibited on screened composite parts in which the aluminum wire mesh/copper fo
and protected by copper tape masking
22. Bonding hardware shall be 3/16 inch (#10) minimum; however, #8 may be used where clearan
with a 100 AMP current return shall be inch minimum and a 200 AMP return requires 5/16 inch m
23. Electrical components measurements shall be taken and recorded with airframe harness conne
connectors mated, due to installation location shall be taken and recorded as connectors mated.
Ensure the adherence of the PPE (Butyl Rubber or Teflon Gloves, Half face respirator equipped with
full-face respirator equipped with organic vapour cartridges) during application as specified by man
7 Viscosity Requirements after mixing
Is the max. Viscosity of the paint coatings shall be 30 Sec through #4 Ford cup, immediately after m
7?
8 Identification, Traceability and Storage of Paint components:
Are the Identification, Traceability of the Paint components, Thinners& Cleaners at Application area
Are the conditions for the storage shall be a daily ambient air temperature that is maintained at 50
9 Is the paint after mixing & storage at room temperature in a closed container consumed within it
10 Are the facilities utilized for cleaning, priming & painting provide protection from wind, rain and
11 Is there a closed room utilized which can control the dust entry, lighting to provide normal visibi
Humidity of 35 to 75%?
12 Is the Aircraft, Major component or part temperature shall be at least 60F and in equilibrium w
prior to application of any coatings?
Cleaning prior to Paint Application:
13 Cleaning General:
Is the surface to be coated clean and free of oil, dust, abrasive powder etc?
14 Is the cleaning and surface treatment of aircraft, major assemblies and parts prior to painting op
paint adhesion and finish?
15 Are non-abrasive brushes or other cleaning aids used if there is contamination or other soils tha
operations without scratching or marring the surface?
Cleaning of Metal surfaces:
16 Is there any cleaning or scuffing of anodized or chemical conversion treated metal surface?
Note: Scuffing of anodized or chemical conversion treated metal surface is not permitted.
17 Cleaning of existing exterior coatings:
Are the existing exterior coatings such as epoxy primer or aircraft paint, prior to prime or paint clea
SS8752, SS9170/560 and SS9170/681 or alkaline cleaners in accordance with SS9170/202?
18 Is 200 grit or fine sand paper or light to medium white or Red scotchbrite used for Scuffing or sa
other soils that cannot be removed with simple hand wipe operations and to provide optimal adhes
19 Is the scotchbrite abrasive pad wetted with solvent or cleaner as an aid to clean the surface and
20 Is the scuffing or sanding limited to primer glaze and not extending onto bare metal or anodized
21 Cleaning of existing Interior coatings:
4 Ensure part marking of detail level and assembly level is used for identification both by Kitting te
that it is clear and protected at different stages of Assy.
5 Ensure production, ME and Quality team are having the competency over the Sikorsky requireme
Requirements.
6 Ensure appropriate part marking method as prescribed in Engineering Dwg is called out by ME in
both production and Quality.
7 Ensure the equipment used for part marking is in line with the requirements of SS 8798, MIL-M-8
Stencil).
8 Ensure the personnel involved in part marking are aware of permanent part marking and non per
in SS8798 and relevant routers.
9 Ensure vibration peen or Dot peen markers are meeting the Radius & Diamond or Carbide Tip req
source as specified in SS 8798.
10 Ensure min part Thickness requirement of 0.025 inches are met for Part marking by Vibration pe
exceed 0.006 inches for vibration peen and 0.003 inches for dot peen.
11 Ensure usage of Alodine and clear coat after Vibration peen marking as prescribed in Visual aid
12 Ensure for Rubber stamping characters are put in a straight line and pre cut stamps are used fo
13 Ensure the characters height of 1/3 to 3/8 inches is maintained for Rubber stamping.
14 Ensure the usage of the approved ink as defined in SS 8798 and it is purchased from the source
15 Ensure the Tag and Bag method is followed where it is not possible to mark as per the Router or
bag and it is tied suitably to part with Tag clearly readable.
16 Ensure the DR no is marked and Holes where Fasteners are installed at Later stages of assy at C
as per the instructions given in DR / Router
17 Ensure the DR Repair parts are marked with appropriate no as instructed in the DR or Router us
18 Ensure the Name plates are marked with appropriate Assy no, Sl no, MFR code, Aircraft model, A
Inspector and SQAR or CQR or DQR as required by that assy. Ensure Alodine and clear coat is used
19 Ensure Engineering Assy no upon completion of it is Rubber stamped and MFG Assy no is stamp
the Dwg and router requirement. Tag method is used for small parts of size inch X 2 inch Rectan
20 Ensure the part markings by Rubber stamp are clear and readable. For rework on part marking i
cleaners.
21 Ensure the wiring harness installation parts/assemblies shall be identified with identification Tag
Num/name, Drawing /Photo book No and Aircraft effectivity.
22 Ensure Handwriting directly on the part (shall only be used when absolutely necessary). A meta
1. Personnel Competancy
2. Surface preparation
3. PPE Compliance
4. Free from FOD,chips, burrs, dust and oil.
5. Proper Cleaning : lint free cloth and wiping in single direction.
7. For NMP/Painted adhesion abrasion before application: break glaze only
8. Adhesive record
9. well ventilated area to avoid toxic vapours of the cleaners and adhesives
10. Primer or promoter Application & Curing
11. Adequate Fillet adhesive squeeze out from mating surface edges.
12. Use of Adhesive within its pot life.
13. Zero visual defects : FOD, Air bubbles, GAP, Un-even squeeze out & uncovered areas.
14. Application Time
15. Controlled temperature & time
16. Expired Adhesives handling/disposal at work centers
17. proper rolling to avoid debonding.
1 Ensure the Torque Requirements are followed as specified in SS9300.

2 Ensure ME router and Visual aid are in line with the requirements of SS9300 & Dwg requirements
3 Ensure the availability of Training to operators and Inspectors on Torqueing as per SS9300
4 Ensure the operators and inspectors are clearing the test after the Training with Qualifying marks
5 Ensure the Torque at Shop floor is performed either by Torque certified operator or Torque certifie
6 Ensure the operators and inspectors are aware of the usage of Torque wrench
7 Ensure the calibrated Torque wrenches are used for Torqueing. Ensure the operators and inspecto
any on the torque wrenches based on the calibration certificate during the Torqueing process.
8 Ensure the operators and inspectors are aware of the tolerance to be considered for the torquein
9 Ensure the self-locking nuts removed for any reason after torqueing are not reused
10 Ensure the over Torqued fasteners are not reused under any circumstances.
11 Ensure after the Torqueing instrument ID no is entered in the router or FIR with Actual Torque va
certified operator or certified inspector.
12 Ensure whenever the Nut side is not accessible operators are giving Torque at Bolt side with 10%
13 Ensure in the absence of Torque values in the B/P dwg ME is calling out the Torque values in Rou
SS9300
14 Ensure the load requirements of Tension or shear are decided by Engineering while calling the s
15 Ensure only Tightening of the fasteners are followed for the screws of size below #10 or the loa
16 Ensure the Mating threads of the fasteners are free from burrs, chips & FOD prior to Torqueing.
17 Ensure the operators are selecting the Mean Torque value for the fasteners and for the castellat
Torque.
18 Ensure during the Torqueing no over Torqueing or Under Torqueing situation arise
19 Ensure the Torque wrench is handled like a delicate instrument, always stored in a protective ca
20 Ensure the following for Series Fastener Torqueing. Diametrically torque all fasteners to minimum
21 Ensure one pitch of the threads of Bolt protrusion out of Nut after Torqueing.
22 Ensure Torque Striping carried out as per the requirements of SS9300.
23 Ensure when the adapter changes the effective length of the wrench Torque correction taken int
24 Ensure when applying the specified assembly torque, the operator shall not apply excessive axi
1 Are the production and Inspection personnel aware of the purpose of this test?
2 Are they having training, competency to perform this test?
3 Is there any detailed procedure from ME detailing the requirements? Is there any specific dwg for
captured in the procedure?
4 Is the test procedure having customer approval?
5 Is the test on First cabin (FAI) witnessed by the customer?
6 Does the temperature and humidity conditions required by the tests are maintained and recorded
7 Are the instruments, gauges used for the test are calibrated and current?
8 Is there any router from ME for this test for every cabin till 1070 and then once in every 7 to 10th
Quality?
9 Are the Emergency Door LH and RH used for this test are cleared from previous stage?
10 Are the Assy No, Cabin no, MFR code and inspection stamp are written on them?
11 Are all the parts required for this test is installed onto cabin as per B/P, TATP-007 or visual aid / R
12 Does the concerned Quality inspector witnessing all the sequence of operations as detailed in B
13 Is the surface preparation for electrical bonding carried out on cabin as well as Emergency Door
14 Are the values checked and recorded by Production and Quality inspector?
15 Are the Rubber seals (-107 & -108) of appropriate lengths are used for the test?
16 Are the gaps of 0 to 0.01 inches maintained between the ends of -107 & -108 after assembly an
17 Is the Push pull gauge located on the Handle as shown in TATP at interior as well as exterior of t
18 Is the gauge pushed normal to handle arm while the handle is rotated?
19 Is the force applied to rotate the handle is less than 50 Lbf?
20 Is the distance between corner of the hatch skin and cut skin of fuselage handles full stroke con
limit (min 1.2inches)?
21 Is the push out force at the corner of the hatch after handle is full rotated is less than 50 Lbf?
22 Are the tests performed by applying force at exterior, interior of the door handle at both LH/RH?
23 Are there any operators available at outside of the cabin near Emergency Door to hold the door
gauge?
24 Are the tests satisfactory to Production and QC inspector?
25 Are all the parts disassembled and checked for any physical damages?
26 Does the protective finishes applied at the areas of electrical bonding check?
27 Are all the relevant routers signed by Production & Quality?
28 Are the parts covered properly and handed over to CPOS area?
11 Are the production operators following the instructions given in the router for rework of scratche
12 Is the approved paint stripper used for removal of paint / Primer?
13 Are the operators aware of not using the power tools for Scuffing especially on Ti?
14 Is the sand paper used for scuffing is of grit size as indicated in the router?
15 Is the grease used along with the sand paper if specified on router only for Ti parts scuffing?
16 Is the operators scuffing till the depth of defect and spreading the area either in 1:10 or 1:20 ble
17 Are the operators and inspectors ensuring the thickness at the scuffed area at frequent interval
exceed the tolerance limits of thickness?
18 Are there any NCs raised for over scuffing beyond tolerance limits of B/P?
19 Are the production supervisors and Quality inspectors in concurrence with MRB CA team taking
of defect? Are they treating the discrepancy as the opportunity for improvement?
20 Are the operators and inspectors following the 1:10 or 1:20 or 1:30 Blending ratio requirements
through DR repair?
21 Are the inspectors ensuring the thickness after scuffing and taking appropriate action after mea
22 Are the cleaning operations post scuffing is done using approved cleaners?
23 Are the surface finish requirements as per B/P maintained post scuffing?
24 Is LPI performed at the area of scuffing as per the DR requirement?
25 Is the Post cleaning after LPI is carried out by production?
26 Are the protective finishes reapplied as per router instruction?
27 Is the Rework operations, Thickness measurements and surface finish requirements are recorde
done on the router?
28 Do the records attached to concerned router or FIR along with Crab sheet or NC/DR?
29 Is the effectiveness of CA taken being monitored by production, Quality and CA team? Is there a
CA revisited for those cases?
Only for the Cases of Dents
30 Are the inspectors using the acceptance requirements on Dents as per SS9208 on metallic parts
31 Are the inspectors raising NCs for the cases related to Dents which are exceeding the Spec req
32 Are the Dents repaired as per the Repair instructions given in DR?
33 Are the planishing tools required for repair of Dents at contoured areas are prepared by Product
34 Are the Repair Doublers, Filler coins prepared using the material as per the DR disposition?
35 Is the LPI performed if required by DR disposition?
36 Is the repair work performed after LPI as per DR disposition under the guidance of Supervisor an
37 Is any special team identified for doing such repairs and are they having required competency?
1. Personnel Competency
2. Intended Use: Alodine as per conditions defined
3. Mixing: using Qty as defined
4. Controlled Temp mixing conditions
5. MSDS Awareness
6. Shelf Life Adherence of Three months
7. Storage of conversion coating solutions in a well-sealed polyethylene, stainless steel, or acid res
preparation or expiration date, name of the solution and appropriate hazard warnings.
8. no conversion coating returning to its storage container
9. Proper Disposal of unused solutions or expired solutions as per local directive and regulations?
10. PPE Compliance
11. Use of approved chemical conversion touch up solutions
12. Ready to Use application Pens: RTU Alodine #871 and Alodine #1132 TOUCH-N-PREP Applica
with EH & S department.
13. Receiving inspection stamp with Date of Mfg and Date of Expiry
14. Use of pens within their shelf life period
15. Alodine#871 and Alodine #1132 solutions kept in same container of TOUCH-N-PREP Applica
15. Application procedure: FOD Clean
16. Use of Approved cleaner
17. Application of conversions coating solutions by brush, sponge, wipe, spray or immersion
18.Controlled temperature for application of chemical coating solution maintained
19. part surfaces are kept wet with the solution for the time period
20. Rinsing & Drying methods followed for the Alodine solutions other than #871 and #1132?
21. Reqd appearance in the form of colour witnessed
Is there any specific Dwg for the test?

Are all the requirements are captured in the procedure?
Does the latest rev controlled copies of Dwg and TATP are available at the point of use?
Is the procedure written by ME is understandable to operators and Inspectors?
8 Is the test procedure TATP-006 latest Rev is having customer approval?
10 Does the Room temperature required by the test is maintained and recorded in the relevant che
12 Does the 2.0 to 5.0 PSIG filtered dry compressed air is available for using as the test fluid?
13 APU Combustor Drain Line Leak Test:
Does the equipment set up required for the test carried out by production and witnessed by QC ins
Is the set up as per the relevant cabin requirements as specified in the TATP?
14 Does the outlet of tube installation is plugged using rubber plug as shown in Fig 1 and 1A of TAT
15 Does the Air Pressure fixture, Pressure gauge are plumbed to the Elbow on LH side upper skin u
page no 7?
16 Ensure application of Regulated Air pressure of 2 to 5 PSIG to the tube installation. Also ensure t
isolate the APU drain system from the air pressure test fixture.
17 Ensure the pressure is maintained for 5 mins. No loss of pressure is allowed during this period.
18 Ensure during test any loss of pressure is observed then apply Leak-Tec solution to the connecti
leaks as per the procedure laid down by ME. Test to be re-performed after fixing the leak for the sa
19 Does the Dismantling of the Test equipment is carried out as per the stated procedure?
20 Combined Drain Line Leak Test:
21 Does the Tee inlets on Upper Skin are plugged with 2 nos of AN929-6 Cap Assy?
Does the Tube inlet which should be connected to APU hydraulic start accumulator and one outlet o
22 Does the Air pressure fixture and pressure gauge are connected to the Union on side upper skin
23 Ensure application of Regulated Air pressure of 2 to 5 PSIG to the tube installation. Also ensure t
isolate the APU drain system from the air pressure test fixture.
12 Does the 15 PSIG filtered dry compressed air is available for using as the test fluid?
13 Engine Combustor Drain Line Leak Test:
Does the equipment set up as shown in Fig 5 page no 14 of TATP-005 required for the test carried o
inspector?
14 Does the outlet of tube installation is plugged using rubber plug as shown in Fig 5 of TATP-005 p
15 Does the Air Pressure fixture, Pressure gauge are plumbed to the Elbow on LH side upper skin u
005 page no 14?
16 Ensure application of Regulated Air pressure of 15 PSIG to the tube installation. Also ensure the
isolate the Engine drain system from the air pressure test fixture.
20 Does the above test steps repeated for the RH side Engine combustor drain line?
21 Scupper Drain Line Leak Test:
22 Does the 2 inlets on Upper Skin of the left hand tube installation are plugged with 2 nos of Rub
23 Does the Air pressure fixture and pressure gauge are connected to the left hand outlet tube on
Fig 7, page 16 of TATP-005?
24 Ensure application of Regulated Air pressure of 15 PSIG to the tube installation. Also ensure the
isolate the Engine drain system from the air pressure test fixture.
28 Does the above test steps repeated for the RH side Scupper drain line?
29 Engine Drain Leak Test:
no 17?
30 Does the outlet of the Left hand tank on Lower Skin is plugged with Rubber plug?
8 Is the test procedure TATP-004 latest Rev is having customer approval?

10 Does the Room temperature required by the test is maintained and recorded in the relevant che
12 Does the 170 & 75 PSIG filtered dry Compressed Nitrogen is available for using as the test fluid?
13 Cabin Left Hand Heating Hose Pressure Test:
Is the set up as per the relevant cabin requirements as specified in the Fig 1 page 6 of TATP-004?
14 Does the two hose ends (Which are normally connected to the Ejectors) are capped using two A
004?
15 Does the Penetration duct on side upper skin is connected with Pressurised Nitrogen Bottle, Reg
using the Adaptor and Coupling as shown in Fig 1 of TATP-004?
16 Ensure application of Regulated Nitrogen pressure of 170 PSIG to the hose installation. Also ens
completely off to isolate the heating hose system from the Nitrogen Bottle.
17 Does the pressure is maintained for 15 mins? Does the pressure gauge value at the start and en
No pressure loss is allowed during the period.
18 Ensure Pressure gauge indicates any loss of pressure.
Ensure application of Leak-Tec solution to the connecting fittings and caps to identify leakage.
After identification, fix the leak as per the procedure defined by ME and repeat above steps until no
Nitrogen pressure for 15 mins.
19 Does the equipment set up dismantled and same test repeated on RH side as shown in Fig 2 Pa
20 Cockpit Heating Hose Pressure Test:
Is the set up as per the relevant cabin requirements as specified in the Fig 3 page 8 of TATP-004?
21 Do the Hose end and Y-Fitting tube ends which are normally connected to cockpit are plugged w
TATP-004?
22 Does the Penetration duct on side upper skin is connected with Pressurised Nitrogen Bottle, Reg
using the Adaptor and Coupling as shown in Fig 3 of TATP-004?
23 Ensure application of Regulated Nitrogen pressure of 75 PSIG to the hose installation. Also ensu
off to isolate the heating hose system from the Nitrogen Bottle.
24 Does the pressure is maintained for 15 mins? Does the pressure gauge value at the start and en
No pressure loss is allowed during the period.
14 Is there any improper clearance between the cable & other parts?
Determination of Misalignment of the Cable to the pulley
15 Is a tension 15015 lbs applied to the cable by turning the hand wheel of the test fixture?
16 Is the Nut shown as P of fig 1 of TATP adjusted to maintain the quadrant stopper Assy at the neu
cable?
17 Is the cable checked for slack?
18 Is the cable sitting properly in the groove of the pulley?
19 Is the misalignment of the cable w.r.t pulley at 12 locations using the alignment tester as shown
20 Is the degree of misalignment of the cable at each pulley is less than 2 except at STA 462?
21 Is the misalignment is less than 1 at locations 11 & 12 i.e at aft of STA 462 frame?
22 Misalignment is > than Reqd value:
Is the Tension completely removed from the cable and following parameters checked
i) Position of pulley
ii) Play
iii) Path of the cable
iv) Deformation of the cable
v) Twist of the cable
Note: If any of the above factors are the cause for the misalignment fix the same and repeat the te
values.
23 Is the misalignment of the cable to the Quadrant is checked at the locations 13 & 14 as shown i
Is the measured misalignment is less than 2?
24 Are the Misalignment values are recorded by production operator and Quality inspector?
Determination of the clearance between the cable and other parts.
25 Is the tension of 150 15 lbs is applied to the cable by turning the hand wheel of test fixture?
26 Is the clearance between the cable and the airframe structure is measured with vernier caliper
Note: If the clearance is not distinct, measure the clearance at every 120.
27 Is there a clearance of 0.25 inches or greater b/w the cable and the nearest part with the excep
Is there a clearance of 0.19 inches or greater measured at the detail S, Fig 8 of page 18?
Is the clearance between the cable and the electrical wiring, tubes (hydraulic, fuel, lubrication and
greater?
28 Clearance is < than Reqd value:
Is the tension completely removed from the cable and following parameters checked?
v) Is the pot life after mixing and storage at room temperature in a closed container is 4 hours?
12 .Is the mixed primer transferred to plastic touch up kit or spray gun based on requirement?
Is the plastic container touchup kits shelf life nonrenewable?
13 Is the mixing person makes the identification on the mixed primer with Date, Time of mixing an
exterior surface of the mixed cup.
14 Are the primer mixing records maintained in the form TASL 0200 020 Primer Mixing record shee
retrievable?
Note: As per SS 8521 inspection records shall be available to the purchaser for a min of 10 years fr
15 Ensure FOD control is taken care by the operator during mixing and clean as you go is followed.
16 Ensure the post cleaning of the Equipment using the approved cleaners
17 Primer coating Test panels preparation:
Are the samples for tests selected at random from each batch a complete unopened kit?
Are the test panels prepared under lab conditions?
Are the dimensions for test panels shall be approximately 0.02 inch thk, 6 inch length and 3 inch w
Are the test panels made of Aluminum alloy 2024-T3 temper conforming to SAE-AMS-QQ-A-250/4?
Is the alloy composition & pre-treatment of test panel is in accordance with Table I of MIL-PRF-2337
Are the panels treated with conversion coating to produce coatings conforming to MIL-DTL-5541 Cl
Are the panels passing Water-Break cleanliness criteria as per ASTM F 21 before primer application
(Is the test panel (if it is deoxidized T3 Tempered SAE-AMS-QQ-A-250/5) immersed in corrosion rem
removed and rinsed with distilled water?)
Is the primer coating applied within 1 hr. after preparation of the panel as described above?
Are the primer coatings prepared and applied as follows:

i)Thoroughly mix each component separately
ii) Slowly pour component B into component A while stirring the mixture to achieve the manufactur
iii) Dilute the admixed primer coating, if necessary, with thinner conforming to MIL-T-81772, Type II
24 Ensure that the hydraulic flow and pressure is set over 4GPM at 1000100 PSIG
25 Ensure that fluid is allowed to circulate for 15mins or more.
26 Ensure that valve positions are meeting as per below position table.
TERMS FIGURE 11 VALVE NUMBER
VALVE 1 VALVE 2 VALVE 3
CLOSE OPEN CLOSE
OPEN CLOSE CLOSE
CLOSE CLOSE OPEN
27 Ensure that abandon is more than 20 cc fluid from the line.

28 RAMP ACTUATOR ( PRESS LINE )
Ensure that flushing cart line is connected to port 3T ( Ramp actuator press ) and return hose to po
32 TAIL ROTOR SERVO ( RETURN LINE)
Ensure that plugs are reconnected to outlets of flushing cart.
33 Ensure that plugs is connected as per the sketch ( Fig;3.4 )
34 Ensure that the filter units are good in condition as per the filtration requirement.
35 Ensure that valve of flushing cart is opened and pointed out as per the sketch.
37 Ensure that press line and return line is disconnected from the flushing cart.
38 Ensure that the plugs are protected from dust and contamination.
39 RAMP ACTUATOR ( RETURN LINE )
Ensure that flushing cart line is disconnected from port 4T and connected to pressure hose to port
42 Ensure that contamination test is meeting the requirement even if the test is repeated.
43 BREAKLINE
Ensure that plugs are connected as per figure 8 and figure 6
49 Ensure the filter units conditions are good.
Ensure that Pressure hose is connected to Port 10T (landing gear Extend) and return hose to port 9
27 Ensure that valve positions are meeting as per below position table.
TERMS FIGURE 11 VALVE NUMBER
VALVE 1 VALVE 2 VALVE 3
CLOSE OPEN CLOSE
OPEN CLOSE CLOSE
CLOSE CLOSE OPEN

29 RAMP ACTUATOR ( PRESS LINE )
Ensure that flushing cart line is connected to port 3T ( Ramp actuator press ) and return hose to po
33 TAIL ROTOR SERVO ( RETURN LINE)
Ensure that plugs are reconnected to outlets of flushing cart.
34 Ensure that plugs is connected as per the sketch ( Fig;3.4 )
35 Ensure that the filter units are good in condition as per the filtration requirement.
38 Ensure that press line and return line is disconnected from the flushing cart.
39 Ensure that the plugs are protected from dust and contamination.
40 RAMP ACTUATOR ( RETURN LINE )
Ensure that flushing cart line is disconnected from port 4T and connected to pressure hose to port
43 Ensure that contamination test is meeting the requirement even if the test is repeated.
49 BREAKLINE
Ensure that plugs are connected as per figure 8 and figure 6
11 DET 355 & H-Plate check after panel movement:

Is location of all DET locators w.r.t frames using tooling pins checked by segment inspector?
Is the DET355 & H-plate loaded onto panel and locking of all the pins w.r,t Frames, DET 355 & H-pla
Are the pins locking sequence is in diagonally opposite sequence?
Are all the pins entering freely and checked by segment inspector?
Is the pitch measurement between frames recorded?
Is the gap check at Sta 462 between frame and header plate recorded?
Note: 1. After witnessing above checks inspector can give clearance for performing work at FAJ2
2. If the panel work of both FAJ1 & 2 done on the same jig then above checks can be ignored and fo
12 Panel Transfer from 241 FAJ2 to PU:
Does the operators having knowledge and skill for panel transfer from 241 FAJ2 to PU as per AOS 2
13 Mandatory work completion Prior to Transfer:
Does all the AOSs work completed for 241 FAJ-2 and all the AOSs are bought by Seg Quality inspe
Does 2 nos #30 holes drilled onto Frame at Sta 462 frame are drilled as per AOS 2411-9240 with th
Does the pitch bars removed and pitch measurement between Frames measured and recorded by
Is the Gap check measured and recorded by segment inspector between Frame at Sta 462 and Hea
Does DET-355 and H-plate positioned w.r.t panel and all the pins are entering freely at 18 places?
Are the DET-355 and H-plate uninstalled after pin checking?
Is there any AOS work open due to NC/DR, Open Crabs, non-availability of fasteners or parts and fo
Quality?
Is the Traveller form filled?
Is FOD check done by Production & Quality?
Is the Final shakedown completed by segment inspector?
14 Is the role and responsibility of personnel during panel transfer discussed among the team mem
15 Outside Fitting installation:
Is the Drilling of #30 holes at 8 places on Frames at Sta 305 and 399 completed as per AOS 2411-9
Do all the holes de burred?
Are all the fasteners under Outside fitting Bracket are installed?
Are DET 23-10 at STA 305 and DET 23-19 at STA 399 removed to facilitate installation of Outside fit
Are the outside fitting Brackets installed using appropriate pins, washer and nuts?
Are the Pins and Nuts are tightened properly and is there any play in washer after tightening?
Is the orientation of washer correct?
Is the outside fitting Bracket installation checked by Inspector?
Inspection Requirements after primer application:

21 the thickness measurements performed using a conventional non-destructive measuring device
accordance with ASTM B244 or equivalent
the average dry film thickness values meeting the requirements as specified in Table I & II of SS852
22 the admixed primer coatings applied to a vertical surface are having any Sag, run or streak at a
to 0.9 mil
23 dried film have smooth, uniform surface free of grit, seeds, craters, blisters and other irregularit
24 any orange peel (wavy appearance) when viewed from at least 6ft distance
25 admixed primer coatings tack free within 5 hours and shall dry hard within 8 hours
26 any evidence of lifting or any other film irregularity after top coating the admixed primer coatin
Note: Color difference between approved primers of different vendors is not the cause for rejection
precedence over aesthetics/cosmetics.
Brush Touch up for the fasteners on Interior side of the cabin except Longeron assy LH & RH at WL
27 Dwg /Aos-Router calling for wet installation of fasteners using Primer or Touch up on Assy / Insta
28 the holes free of burrs, FOD, checked and cleared by Segment Inspector
29 the holes touched with Primer and fastener installed
30 primer Squeezing our all around the attached or inserted hardware
Note: The bulk of squeeze out material may be removed after installation; however a visible amoun
as evidence that the wet installation performed.
31 the fasteners cleaned with approved cleaners and free of FOD
32 the fasteners installation self-checked by operator and cleared by Segment inspector for prope
height, CSK flushness, Spindle break off depth in case of blind rivets, set marks on heads
33 Brush primer touch or Spray gun Touch up carried out on the head and tail side for all the interi
fasteners are installed on the skin
34 proper masking done to avoid overspray on previously primed or painted areas
35 the applied primer protected against FOD before it gets cured
36 the primer touch for the fasteners free of FOD, Runs and thickness variation and entire surface
Note: Translucent appearance is allowed as long as 0.0006 inch min thickness is met.
37 the primer touch up self-inspected for above defects and cleared by segment inspector
38 the relevant operations in the router closed by operator and inspector
39 the clean as you go followed and expired primer disposed as per the stated procedure
Mist Coat using primer prior to Glossy coat or painting at Interior or exterior of Aircraft or Major As
40 the surfaces to be mist coated, aged more than 24 hours and having glossy appearance
3 Ensure the calibration status for Laser tracker and other jigs and instruments used for ICD measu
4 Check for the laser locations position on aft side for ICD points on top deck and on ground or rigid
5 Ensure the datum points are taken with respect to Jig OPTs or MGB holes.
6 Check for the locking pins are perfectly on proper tightened conditions.
7 If MGB holes are taken as a datum then ensure that locking conditions are made except MGB plat
8 Check the appropriate method is being used for selection of the datum points. ( Either wrt to jig o
9 Ensure that selection of datum is as per the ICD plan approved by Sikorsky.
10 Ensure that the measurement surfaces are properly cleaned with cloth before taking the laser m
If Datum is Wrt to jig
11 Ensure that at least 8 to 10 accessible jig OTP points are selected for taking the measurement.
12 Ensure that minimum of best 3 fit points are considered and the points are within 0.002" variati
13 Ensure the proper alignment before the measurement is started.
If Datum is Wrt to MGB
14 Ensure that at least 8 to 10 points are selected for taking the measurement.
15 Ensure that hole no 1 and 6 is taken for establishment for datum after alignment also check for
6.
Measurement with T PROBE
16 Ensure that plane of respective surface is taken before taking the actual point.
Measurement with Adapter and SMR
17 Ensure that exact size of the adapters is checked as per the drawing before usage.
18 Ensure that SMR is used along with the adapters to check the actual location of the point.
Cross checking the Datum
19 Ensure that datum is cross verified for the all the pre-defined conditions like Breaks, External dis
laser change.
20 If deviations are observed due to above mentioned cased the ensure that measurements to be
once again.
21 Ensure that ICD measurements are as per ICD plan covering all the 14
22 Ensure all the 13 areas are covered during ICD measurement as mentioned in TOP-07-17.
23 Ensure all the 13 parameters are individually checked with respect to the appropriate method e
gauges( Pin gauge, Feeler gauge)
24 Ensure that the laser report and data sheets is recorded with all measured values and under the
Is the tape then removed in one abrupt motion and test area examined for any paint damage or re
51 Is there any removal coating exceeding 1/16th of an inch in length and width in dry or wet tape
Note: Retesting may be performed after an additional cure cycle.
52 Is the test panel retained with proper identification of batch no, date, cabin no, w.o No, inspectio
53 Are the relevant operations in the router closed by operator and inspector?
Rework of Painted Surfaces:
54 Is there any scratch or adhesion failure (peel off) or thickness variation, runs, sags, rough surfac
surfaces?
55 Are the surfaces Degreased as per SS8423 to remove oil or grease if any on the surfaces?
56 Is the approved paint stripper Turco EA6930 as per SS8786 applied at the discrepant area by ma
tape or Aluminum tape?
57 Is the person adhering to PPE during paint stripper application?
58 Is the stripper allowed to stay on the discrepant area for the reqd dwell time as specified by the
59 Is theStripping time less than 24 hours for room temperature strippers and 8 hours for hot stripp
60 Is the surface checked after 2 hours after application, for bubbling and hardness?
61 Is multiple applications ensured if no bubbling or softening is evidenced?
62 Is the bubbles scraped using plexiglass or wooden scrapers?
Note: Metallic scrapers or wire brushes not permitted for scraping.
63 Is the area thoroughly rinsed with hot or cold water until traces of stripper are removed?
64 Is the surrounding area unmasked and remasked again with new masking tape or Aluminum tap
65 Is the area dried with forced air 1 hour after water rinsing?
66 Is the area cleaned using the approved cleaners remove all the oil, grease, dirt, FOD etc.,?
67 Is the Alodine applied if the base metal is exposed?
68 Is the primer applied as per the procedure?
69 Is the paint or topcoat applied as per the B/P requirement after primer curing?
70 Is the mask removed and inspected by paint inspector?
Coating, Conductive and Anti-Static application to Fiber laminated surfaces as per SS8517:
71 Are the CHO-Shield conductive coatings Type 1 procured as per SS8517 from the approved sour
72 Are the Milli ohmmeters as specified in SS spec are available for the measurement of resistance
73 Are the fiber laminated surface lightly sanded and then cleaned using SS9170/204 or SS9170/5
74 Application of primer:
Are the surfaces primed with one coat of MIL-PRF-85582 epoxy primer?
Are the parts are related to electrical system with hardware closely spaced & in closed geometrical
Is the wire locking meant for shear applications to permit operation or actuation or emergency dev
Is the wire installed such that it can be easily broken when required in emergency situation?
Are only external snap rings locked using single wire method?
Note: No locking required for Internal snap rings.
16 Double Wire Method:
Is the hardware installed in closely spaced geometric pattern which secure hydraulic or air seals, h
areas of clutch mechanisms and superchargers has to use Double wire locking method?
17 Are the parts shall be lock wired such that it is in tension when the parts tend to loose?
Note: Safety wire should always be installed so as to make the Nut or Bolt TIGHTEN itself when th
safety wire should come around top of head of the bolt/nut and back onto the securing unit so that
direction.
18 Is the lock wire installed and twisted so that the loop around the head stays down and does not
leave a slack loop?
19 Is the care taken during installation so that lock wire is tight but not over stressed in both the m
Note: Overstressing weakens it and could cause it to break under vibration or load.
20 Is the safety wire passed through the diametrically opposite hole and then wrapped around half
case of Internal Wrenching Bolts?
21 Is a pigtail of to inch (3 to 5 twists) made at the end of wiring and it is bent back?
22 Is the safety wire new upon each application irrespective of the method?
23 Is the Castellated Nut Torqued to lowest range and wire locked if the hole in Stud or bolt or scre
Is the torque tightening continued for next 60 angle of the Nut if the hole does not aligns with low
Note: Do not over torque or under torque.
24 Is Dia 0.02 inches wire locking used on Electrical Connectors which use threaded coupling rings
fasten the individual parts of the plug together?
Are all the electrical connectors wire locked individually?
Note: Do not lock wire one connector to another unless necessary.
25 Ensure no wire locking required if the drilled head bolts or screws installed in to Self locking Nut
26 Are the wire locking carried out as shown in the pictures on Sheet 5 & 6 of TOP procedure TOP-0
Are the wire locking made opposite as shown in the pictures of sheet 5 & 6 if left handed threads a
27 Is there in any Nicks or kinks after wire locking which is the cause for rejection?
Is wire cut and re wire locking carried out in such cases?

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S.

Wet Installation of fasteners

Application of Fay Sealant

Water Tightness Demonstration process

Protection of FOD sensitive Areas

NDI-LPI, Eddy current process

Drilling/Reaming on Metals- Deburring, Score Marks,

Cold working process

Protection of Composite floor/bottom panel

Electrical Bonding Test process

Torque tightening process

Emergency Egress Hatch ATP

Nicks, Scratches, Gouges and Dents

APU Drain Leak Test

Engine-Drain Leak Test

Cabin Heating Hose Pressure Test

Flight Control Cable Alignment test process

Hydraulic System Line Flushing Process

Hydraulic Pressure Proof Test process

Movement of panels and cabin from jig to jig

Drilling/Reaming on Composites- Deburring, Score

Wire Locking process

1. Use of prescribed sealant as per the standard/procedure.

1. Approved & Proved Test equipment

1. Controlled Preservation & mixing (Temp 25 degrees).

6. FOD prevention Work instructions specific for each manufacturing area.

1. Personnel competency and awareness on Fillet sealing requirements as per SS 8640

1 Ensure the Torque Requirements are followed as specified in SS9300.

Is there any specific Dwg for the test?

8 Is the test procedure TATP-004 latest Rev is having customer approval?

Are the primer coatings prepared and applied as follows:

27 Ensure that abandon is more than 20 cc fluid from the line.

28 Ensure that abandon is more than 20 cc fluid from the line.

11 DET 355 & H-Plate check after panel movement:

Inspection Requirements after primer application:

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