Niche Guides & Deep Dives
Building a Part 121/135 Compliant Operation: A Guide for Small to Mid-Sized Manufacturers
Running a manufacturing business is complex enough without adding the intricacies of aviation safety and compliance. If your company operates aircraft—whether for transport, logistics, or other purposes—understanding and building a compliant operation is essential. This guide aims to lay out the fundamental steps for small to mid-sized manufacturers to develop a Part 121 or 135 compliant operation, in plain language and concrete terms.
Understanding the Basics: What Are Part 121 and Part 135?
Before diving into how to build compliance, it’s important to understand what these parts mean:
Part 121: This covers scheduled airline operations—think major airlines and carriers with frequent, regularly scheduled flights.
Part 135: This applies to on-demand and charter services—think small planes, on-demand charters, corporate flying, or air taxi operations.
Most small to mid-sized manufacturers operating aircraft for business purposes fall under Part 135. However, some may also operate larger aircraft or scheduled services falling under Part 121. The requirements differ slightly, but both are designed to ensure safety, reliability, and regulatory compliance.
Step 1: Define Your Operational Needs
Begin by clearly understanding what you need from your aircraft operation:
Type of flights: Are these scheduled flights, or on-demand charters?
Aircraft size and capacity: Small planes, corporate jets, or larger aircraft?
Frequency: How often will flights be operated?
Operational scope: Will you operate solely within the U.S., or internationally?
This initial assessment will inform the complexity of your compliance requirements and help you plan your resources.
Step 2: Understand the Regulatory Requirements
Both Part 121 and 135 specify requirements across several key areas:
1. Aircraft Maintenance and Inspection
Ensure regular inspections, repairs, and maintenance are performed according to FAA standards. Create maintenance schedules and keep detailed records.
2. Crew Training and Qualifications
Operators must ensure pilots and crew are appropriately trained, current, and qualified. This involves written tests, practical assessments, and recurrent training.
3. Operational Procedures
Develop standard operating procedures (SOPs) for safety, flight planning, emergency procedures, and more.
4. Safety Management System (SMS)
An SMS is a proactive approach to identify and mitigate safety risks. FAA encourages, and in some cases requires, implementing a formal SMS program.
5. Recordkeeping
Maintain detailed records of all maintenance, training, safety reports, and operational data for at least the periods mandated by regulations.
Step 3: Establish Your Management and Safety Structure
Designate Responsibilities
Assign qualified personnel to oversee safety, maintenance, and compliance. Even smaller operations benefit from having someone responsible for keeping documents, scheduling inspections, and liaising with FAA inspectors.
Develop Procedures
Create written procedures covering day-to-day operations, emergency response, crew training, and maintenance management. Keep these easily accessible and ensure staff understand and follow them.
Step 4: Acquire the Right Certification and Documentation
Apply for Operating Certificates
Submit your application to the FAA for an Air Carrier Certificate (Part 121) or Operating Certificate (Part 135). The process involves demonstrating your ability to safely operate the aircraft and comply with regulatory standards.
Prepare Safety and Maintenance Records
Ensure all documentation is accurate and accessible, including aircraft logs, maintenance records, pilot certificates, and operational procedures.
Step 5: Implement Training and Quality Control
Regular training keeps your team current and prepared for safe operations. Incorporate recurrent training for pilots, crew, and maintenance staff. Conduct periodic audits of operations to ensure adherence to policies and regulations.
Step 6: Monitor and Improve
Conduct Regular Safety Checks
Use your Safety Management System to identify potential hazards and address them proactively. Keep an open line of communication for crew and staff to report concerns.
Stay Updated on Regulations
Regulations change; stay informed by subscribing to FAA updates and participating in industry groups.
Summary: Build Compliance Step-by-Step
Creating a Part 121 or 135 compliant operation takes planning, discipline, and attention to detail. Start with clear definitions of your needs, understand the regulations that apply, and establish a robust safety and operational framework. Remember, compliance isn’t just about meeting minimum standards—it’s about fostering a culture of safety for your team and your business’s reputation.
Resources and Additional Information
Building a compliant operation is an ongoing process. It requires commitment but ensures your aircraft are operated safely, legally, and efficiently—saving costs in the long run and protecting your team and reputation.