Preparing for DAR Visit

Preparing for a DAR's Conformity Inspection

There are two types of conformity inspections, parts conformity and installation conformity.

Part (s) conformity  DAR will review all design data and production records used to build the parts and assemblies and any inspection (s) to verify part (s) meet the design criteria.

Installation conformity  DAR will review all design data and production records used to install the part (s) and assembly (ies) on an aircraft and any inspection (s) to verify installation (s) meet the design criteria..

In both cases, the parts and assemblies and the installation of those same parts and assemblies must be in 100% conformance with the design data. No deviations from the design data are permitted, nor are any Material Review Board action(s) allowed.

**NOTE: The conformity for any given part must be completed prior to it being installed on or in the aircraft.

A DAR's conformity inspection involves the review of all design data and production documents that are generated as part of the manufactures design approval program with the Federal Aviation Administration (FAA). Also, the manufacturer will also have to have full traceability of all parts used in the article/installation.

The DAR will need the following signed forms before starting the conformity inspection:

  1. FAA Form 8120-10¹, Request For Conformity (RFC) from the MIDO delegating the inspection to applicable DAR.
    1. The Statement of Conformity requires that the applicant comply with Section 21.33(a) of Title 14 CFR Part 21.
    2. The 8120-10 (and the TIA) generally originates from the Aircraft Certification Office (ACO) in which the project resides. In some cases, a Designated Engineering Representative (DER) will be granted authority by the FAA to issue the 8120-10 directly to the DAR.
  2. Form 8130-9, Statement of Conformity from the applicant².
    1. This is the document the company uses to show conformity to the design data and the parts/assemblies have been inspected and found that they are in compliance with the design data.
    2. For first article parts and assemblies that are part of a design approval project, the following must be accomplished:
      1. The applicant has performed a 100% inspection.
      2. No deviations from the design data are allowed, however it is possible that the design data can be changed to take into account certain deviations found during the inspection.
      3. Items that are found to be unsatisfactory may have to be remade or reworked in order to bring them into conformance and these items will have to be re-inspected.
  3. The DAR will examine some or all of the following documents and records, ensure they are available prior to DAR's arrival:
    1. Design Data (Drawings, Process Instructions, Test Specifications)
    2. Production records (Travelers, Inspection reports, Test reports)
    3. Vendor Certificate of Compliance
    4. Purchase Orders
    5. Material Certifications

¹ NOTE:  If your company is not the program applicant with the FAA, the DAR will need a letter authorizing you to act as an agent on their behalf.  This letter must be signed by the program applicant.  Please note that the inspection cannot begin until the DAR has received authorization to do so in the form of the above referenced documents.

² NOTE: A conformity inspection is not to be used in place of a final inspection. By the time the conformity inspection takes place, the applicant should have performed all necessary tests and inspections and found 100% conformance to the design data. The DAR will perform no tests or measurements themselves; rather they will examine all production records and request that certain random inspections be conducted again as a spot check to verify that the parts, assemblies, and installations are in compliance with the design data. The DAR does not perform the responsibilities of the applicant; they verify that the applicant has performed their responsibilities.

Post inspection activities include the filling out the following forms and paperwork:

  1. FAA Form 8100-1, Conformity Inspection Record
  2. FAA Form 8110-6, Type Inspection Report, Engines
  3. FAA Form 8110-7, Type Inspection Report, Propellers
  4. FAA Form(s) 8130-3, Authorized Release Certificate as required
  5. Other documents as requested or required by the program office

The required forms for any given inspection are listed on the Request for Conformity and the original signed documents are sent to the program office. Except for the Original FAA Form 8130-3(s) which must remain attached to the part and/or assembly, a copy of the 8130-3 will be sent to the program office.