1、Designation: F 2279 06Standard Practice forQuality Assurance in the Manufacture of Fixed Wing LightSport Aircraft1This standard is issued under the fixed designation F 2279; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year
2、of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This practice establishes the minimum requirements forthe development of a Quality Assurance and ProductionAccepta
3、nce Program, to be used for the manufacture of LSAsor LSA kits.1.2 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applic
4、a-bility of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:2F 2245 Specification for Design and Performance of a LightSport AirplaneF 2564 Specification for Design and Performance of a LightSport Glider3. Terminology3.1 Definitions:3.1.1 design and performance specific
5、ationused herein torefer to Specifications F 2245 and F 2564.3.1.2 LSA (light sport aircraft)used herein to refer to bothLSA airplanes and LSA gliders, including kits.3.1.3 LSA airplane (light sport aircraft airplane)poweredaircraft designed in accordance with Specification F 2245 thatis manufacture
6、d and delivered ready to fly.3.1.4 LSA glider (light sport aircraft glider)aircraft de-signed in accordance with Specification F 2564 that is manu-factured and delivered ready to fly.3.1.5 LSA kit (light sport aircraft kit)aircraft designed inaccordance with Specifications F 2245 or F 2564 that is m
7、anu-factured and delivered as a kit.3.1.6 manufacturerany entity engaged in the productionof a LSA.3.1.7 permanent recordwhere specified herein, applicablequality assurance records shall be kept for each LSA producedfor as long as the relative airworthiness certificate remains ineffect.3.1.8 reserve
8、d holding areafor rejected parts, materials,and assemblies, shall mean an area for the containment ofrejected non-airworthy items awaiting proper disposition,where such rejected items shall not be distributed for use on aLSA.3.1.9 satellite manufacturing, assembly, and distributionfacilitiesrefers t
9、o facilities being operated by commercial orprivate entities that, though authorized by the original manu-facturer, are not directly associated with or controlled by theoriginal manufacturer.3.1.10 secure storage areafor accepted parts, materials,and assemblies, shall mean an area of storage where t
10、hepreservation of the contents to required design specifications isreasonably assured until distributed for use on a LSA.3.2 Acronyms:3.2.1 AOIaircraft operating instructions3.2.2 QAMquality assurance manual; the documentationof the Quality Assurance Program1This practice is under the jurisdiction o
11、f ASTM Committee F37 on Light SportAircraft and is the direct responsibility of Subcommittee F37.20 on Airplane.Current edition approved Aug. 15, 2006. Published August 2006. Originallyapproved in 2003. Last previous edition approved in 2003 as F 2279 03.2For referenced ASTM standards, visit the AST
12、M website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, Unite
13、d States.3.2.3 QAPquality assurance program; the method of in-spections used by the manufacturer of a LSA to verify andensure the proper production thereof3.2.4 QARquality assurance record; the record of QualityAssurance associated with each LSA produced4. Significance and Use4.1 The purpose of this
14、 practice is to provide the minimumrequirements necessary for the establishment of a qualityassurance and production acceptance program for a manufac-turer of light sport aircraft.5. Quality Assurance Program (QAP)5.1 Manufacturers of LSA shall develop a Quality Assur-ance Program (QAP) in accordanc
15、e with the criteria estab-lished within this practice.5.2 Quality Assurance Manual (QAM)Each manufacturershall document their QAP in the form of a Quality AssuranceManual (QAM).5.3 Quality Assurance AdministrationThe manufacturersadministration that is charged with the implementation of theQAP may c
16、onsist of one or more: company employees,company officials, or manufacturers agents or assigns. Theindividual(s) that make up the quality assurance administrationshall be identified within the QAM.5.4 Quality Assurance Record (QAR)A record shall bemaintained of the date of acceptance, the origin, an
17、d thecertifications of materials used in the production of airframecomponents considered by the manufacturer to be critical to thestructural integrity of a LSA (see Note 1).NOTE 1The intent of this record is to provide a means for themanufacturer to identify and reduce the number of LSA within a fle
18、et thatmay be affected by a materials anomaly that would require correctiveaction, thereby reducing the economic impact of such corrective action.This paragraph should not be construed as a requirement for specific partstraceability.5.4.1 Manufacturer shall maintain a Quality AssuranceRecord (QAR) f
19、or each LSA produced. Each QAR shallconsist of the following:5.4.1.1 Applicable final inspection records, check, and testdocumentation from the production acceptance procedures (seeSection 8),5.4.1.2 A copy of the Manufacturers Statement of Compli-ance, and5.4.1.3 The configuration of each aircraft
20、at its point ofdelivery (for continued operational safety monitoring pur-poses), including associated parts lists and installed equipmentlists.NOTE 2Each item listed in 5.4.1 shall include the LSA serial numberand date of manufacture.5.5 Quality Assurance RevisionsA system shall be imple-mented to e
21、nsure that only the latest revisions to the QAM arein use.5.6 Quality Assurance AuditsManufacturer shall conductan annual audit of their QAP. Manufacturer shall maintain arecord of all such audits.Any determination of non-complianceshall be resolved and a revision to the QAM shall be made ifnecessar
22、y to address any anomalies found.6. Engineering and Manufacture6.1 Record of ComplianceThe manufacturer shall keep apermanent record of the design documentation used to showcompliance of a particular configuration to the version of thedesign and performance specification in effect at the time ofmanu
23、facture.6.2 Configuration ControlAll LSA configurations in pro-duction shall have Records of Compliance to the latest releasedrevision of the design and performance specification.6.3 Production DocumentationThe manufacturer shallmaintain a record of all production documentation, includingrevisions.
24、Production documentation may include, but is notlimited to, the following:6.3.1 Parts lists,6.3.2 Process routings,6.3.3 Component and assembly drawings,6.3.4 Manufacturing instructions and specifications,6.3.5 Tooling and gauge drawings,6.3.6 The AOI,6.3.7 The maintenance manual, and6.3.8 The QAM.6
25、.4 Special ProcessesA system shall be implemented tocontrol all special processes and services related to the pro-duction of airframe components considered by the manufac-turer to be critical to the structural integrity of the LSA, suchas welding, brazing, heat treatment, plating, structural compos-
26、ites, adhesive bonding, and so forth, that ensures that eachprocess and service is performed in accordance with approvedspecifications containing definitive standards of quality, andthat periodic inspection of gauges, solutions, or any criticalequipment is controlled and documented.7. Quality Assura
27、nce Inspections7.1 Manufacturers shall implement and document a systemof inspections to verify conformity of product to all applicableengineering requirements and production specifications.7.1.1 Conforming, non-conforming, and items awaiting in-spection must be separated or clearly distinguishable.
28、Itemsfound to be nonconforming shall either be evaluated by aMaterials Review Board (MRB) in accordance with 7.4 orrejected in accordance with 7.5.7.2 Receiving InspectionManufacturer shall implement apurchasing procedure that shall ensure all items ordered areclearly specified. Incoming items provi
29、ded by outside vendorsshall be inspected for conformity to applicable specifications.7.3 Acceptance of Conforming ItemsConforming itemsshall be distributed as required or placed in a secure storagearea for future use.7.4 Evaluation of Non-Conforming Items by a MaterialsReview BoardA Materials Review
30、 Board (MRB) may beestablished to determine the disposition of non-conformingitems, and shall consist of one or more manufacturer desig-nated technical representatives. MRB representatives shall beidentified within the QAM. If analysis, additional inspection,functional checks, repair, rework, and so
31、 forth assures that anitem meets all of the relevant design requirements, the MRBmay authorize its use in the production of a LSA. Otherwise,F2279062the item must be rejected in accordance with 7.5. The manu-facturer shall keep a permanent record showing the dispositionof non-conforming items that h
32、ave been evaluated and ac-cepted by the MRB.7.5 Rejection of Non-Conforming ItemsA process fordisposing of items found to be unusable due to damage, shelflife limits, or other variations must be defined and imple-mented. A rejected item must be mutilated, disposed of, orsufficiently marked as reject
33、ed to ensure that it is not used inthe production of a LSA. A rejected component may be placedin a reserved holding area for future disposition or disposal.8. Production AcceptanceNOTE 3The following criteria should not be construed as require-ments for specific features to be included on a LSA. Whe
34、n a requirementspecifies a feature that does not exist on a LSA, the requirement does notapply.8.1 Final InspectionsManufacturer shall verify andrecord that a shop order for each LSA produced has beencompleted prior to conducting the following Production Ac-ceptance procedures.8.1.1 LSA KitManufactu
35、rer shall verify and document theproper completion of the production process prior to the furtherdistribution of any LSA kit or subsystem kit. Manufacturershall provide the builder of a LSA kit with appropriateProduction Acceptance Ground Check and Flight Test Proce-dures, as described below.8.1.2 L
36、SA Airplane and LSA GliderManufacturer shallverify the proper completion of the production process prior tothe further distribution of any ready-to-fly LSA. The followingground check and flight test procedures shall be conducted anddocumented for each ready to fly LSA.8.1.2.1 Ground CheckPrior to fl
37、ight testing, the manufac-turer shall conduct a thorough ground inspection of each LSAproduced to verify at least the following:(1) Weight and BalanceEmpty weight and proper centerof gravity location has been calculated and verified to be withinlimits, and that a weight and balance report has been c
38、ompletedfor the airplane;(2) Systems CheckThe proper function of all switchesand circuits, instrumentation, brakes, and any other appropriatesystems shall be verified.(3) Flight Controls CheckAll flight controls shall bechecked for smooth and proper function and proper maximumdeflections. Control sy
39、stem connections and safeties shall bechecked and verified intact.(4) Seats and Safety BeltsSeats and pilot restraint systemshall be checked for security and visual defects.(5) Engine CheckEngine checks and procedures shall beperformed to verify:(a) Proper engine installation,(b) Proper servicing of
40、 all engine fluids,(c) No apparent fuel, oil, or coolant leaks, as appropriate,(d) Propeller installation and pitch adjustment, as appli-cable,(e) Performance of an engine “run-in” with adjustments, asrequired,(f) Tachometer indicates engine idle RPM and maximumstatic RPM is within manufacturers pub
41、lished limits,(g) Proper function of engine instrumentation,(h) Proper function of ignition system(s),(i) Proper function of induction heating system, and(j) For powered LSA gliders, proper retraction and exten-sion of the engine.(6) Placards CheckThe aircraft shall be checked toverify that all requ
42、ired placards, switch, and instrument mark-ings are in place.(7) Preflight InspectionThe following shall be verified:(a) All required documentation is on board,(b) All visible surfaces are free of deformation, distortion,or other evidence of failure or damage,(c) Inspection of all visible fittings a
43、nd connections fordefective or insecure attachment, and(d) Complete walk-around inspection in accordance withthe AOI.8.1.2.2 Taxi TestAfter completion of the Ground Check, aTaxi Test shall be conducted to verify:(1) Brake function,(2) Landing gear tracking and steering, and(3) Proper compass reading
44、s, to be verified by a reference,and corrected with compass card if needed.8.1.2.3 Flight Test for LSA AirplanesAfter completion ofthe Taxi Test, a flight test shall be conducted.(1) Safe flight operation of each completed LSA airplaneshall be verified to include acceptable handling and controlchara
45、cteristics, stall characteristics, engine operation, airspeedindications, and overall suitability for normal flight in accor-dance with the AOI. The flight test procedure, at a minimum,shall include recorded verification of the following:(a) Takeoff runway wind, outside air temperature, andpressure
46、altitude,(b) Verification that takeoff distance meets manufacturerspublished specification,(c) Verification that the climb rate meets or exceeds themanufacturers published specification,(d) Appropriate response to flight controls in all configu-rations,(e) Wings-level idle-power stall speed in all c
47、onfigurations,including verification of appropriate stall warning and stallrecovery characteristics,(f) Verification of no unusual performance or handlingcharacteristics, and(g) Proper engine operating temperatures.8.1.2.4 Flight Test for LSA GlidersAfter completion ofthe taxi test, a flight test sh
48、all be conducted. Safe flightoperation of each completed LSA glider shall be verified toinclude acceptable handling and control characteristics, stallcharacteristics, airspeed indications, and overall suitability fornormal flight in accordance with the AOI. The flight testprocedure, at a minimum, sh
49、all include recorded verification ofthe following:(1) Wings-level stall speed in all configurations, includingverification of appropriate stall warning and stall recoverycharacteristics,(2) Appropriate response to flight controls in all configu-rations, including, if allowed, which launching and aerotowing,andF2279063(3) Verification of no unusual performance or handlingcharacteristics.8.1.2.5 In addition, for powered LSA gliders, the flight testprocedure shall also include the recorded verification of thefollowing:(1) Takeoff runway
