It should come as no surprise that in a world where there is a thriving and burgeoning market for counterfeit automotive parts, that the commercial airline industry has also been the target for the manufacture of counterfeit parts. One of the most publicised instances was when, back in December 2023, the UK’s Serious Fraud Office (SFO) began an investigation onto AOG Technics regarding the supply of counterfeit aircraft parts and the falsification of the necessary documentation that, by law, has to accompany such parts. As a result of this investigation, in May this year, the company owner, Jose Alejandro Zamora Yrala, was charged with fraudulent trading, the indictment alleging that AOG Technics sold uncertified parts for passenger and cargo aircraft engines.
In 2023, Aircraft in the UK and across the world were grounded after the CAA, FAA and European Union Air Safety Agency (EASA) each issued safety alerts to all carriers who may have bought or used parts from Technics. The alerts were sent out after a TAP Air Portugal technician discovering an aircraft engine part that appeared to be used when they believed a brand-new part had been ordered.
The above highlights just how important it is to adopt a rigorous inspection policy for all incoming aircraft parts through a highly controlled and structured incoming inspection process. Beyond that, there is also the obvious implications of using aircraft parts which are not fit for purpose, these counterfeit parts directly affect flight safety and operational performance. Regulatory oversight and rigorous quality requirements demand a highly controlled and structured incoming inspection process, and below we have listed ten individual elements we see as essential and necessary.
1. Regulatory and Airworthiness Compliance
Aircraft parts must comply with stringent aviation standards and airworthiness directives. Incoming inspection processes must align with:
- Civil Aviation Authorities (CAA, FAA, EASA) regulations for approved parts.
- AS9100 and ISO 9001 aerospace quality management standards.
- OEM and Part Manufacturer Approval (PMA) guidelines. All received parts must be traceable to approved suppliers and accompanied by appropriate airworthiness documentation.
2. Mandatory Supplier Documentation Verification
Every shipment must include and be checked against:
- Certificate of Conformity (C of C) or Authorised Release Certificates (e.g., FAA 8130-3 or EASA Form 1).
- Purchase order and packing list.
- Material Safety Data Sheets (MSDS) when applicable.
- Batch/lot traceability records and shelf-life information (for time- or life-limited parts). Inspectors must validate that part numbers, serial numbers, and modification status match the procurement specification.
3. Visual and Physical Condition Checks
All aircraft parts must undergo detailed visual inspection to detect:
- Physical damage such as dents, cracks, or corrosion.
- Signs of improper storage or handling, including contamination or moisture ingress.
- Correct labelling, barcoding, and packaging integrity to maintain part protection and traceability. Special attention is required for delicate parts like avionics, seals, or composite materials, which are susceptible to handling damage.
4. Dimensional and Functional Verification
Critical parts may require dimensional checks against OEM specifications using calibrated measurement tools such as micrometres, callipers, or CMMs. Functional verification, including connector fit checks or resistance testing for electronic components, may also be required depending on part type and criticality.
5. Life-Limited and Shelf-Life Items
Many aircraft components, such as O-rings, lubricants, fire extinguishers, and life-limited engine parts, have expiration dates or operational cycle limits. Incoming inspections must:
- Verify shelf-life expiry dates and remaining life.
- Record cycle- and time-tracked components in maintenance systems for monitoring. Parts that are expired or insufficiently documented must be quarantined immediately.
6. Sampling and Acceptance Criteria
For bulk consumables, sampling may follow industry statistical standards (e.g., ANSI/ASQ Z1.4), but critical parts typically require 100% inspection due to their safety significance. Acceptance criteria must be clearly defined and documented in the quality manual, with immediate escalation procedures for any non-conformity.
7. Traceability and Digital Records
Each part must be uniquely identifiable, often by serial number or lot number, and entered into the warehouse management or enterprise resource planning (ERP) system. This ensures full traceability for future maintenance actions, regulatory audits, or potential recalls. Digital copies of airworthiness certificates must be linked to part records.
8. Handling and Storage of Non-Conforming Parts
Parts failing inspection must be clearly labelled, segregated in a quarantine area, and processed according to a documented non-conformance procedure. This includes raising a Non-Conformance Report (NCR), informing quality assurance, and initiating supplier corrective actions or part returns.
9. Personnel Qualifications and Training
Personnel performing incoming inspections must be trained in aircraft parts identification, regulatory compliance, handling requirements, and inspection techniques. Continuous training ensures compliance with changing regulations and evolving OEM specifications.
10. Integration with Aviation Maintenance Information Systems
To support fleet management and regulatory compliance, incoming inspection results must integrate with aviation maintenance and engineering systems (e.g., AMOS, TRAX). This enables real-time inventory updates, automated airworthiness recordkeeping, and streamlined supplier performance analysis.
Conclusion
Incoming inspection of aircraft parts needs to be a highly controlled process and consequently it must strictly adhere to regulatory standards, OEM specifications, and quality management frameworks. By ensuring robust documentation verification, physical inspection, traceability, and skilled personnel, warehouses and the operational procedures adopted within them play a critical role in safeguarding flight safety and operational readiness. Effective processes not only reduce the risk of installing non-conforming parts but also strengthen supplier relationships and enhance overall compliance with aviation regulations.
