Key Responsibilities and Required Skills for Aircraft Inspector

🎯 Role Definition

An Aircraft Inspector is a certified aviation maintenance professional responsible for ensuring aircraft airworthiness, regulatory compliance, structural integrity, and safety. Working closely with maintenance teams, engineers, and quality departments, the Inspector performs scheduled and unscheduled inspections, non-destructive testing (NDT), technical documentation reviews, and certifies corrective actions and releases-to-service in accordance with FAA/EASA and company procedures. This role requires deep knowledge of aircraft systems, maintenance manuals (AMM/IPC/SRM), airworthiness directives (ADs), service bulletins (SBs), and strong attention to detail to identify discrepancies and drive corrective action that maintains safety and operational readiness.

📈 Career Progression

Typical Career Path

Entry Point From:

Licensed Aviation Mechanic (A&P Technician) with 1–3 years line maintenance experience
Avionics Technician transitioning into structural and systems inspection
Quality Control Technician or Maintenance Planner with inspection exposure

Advancement To:

Lead Inspector / Senior Aircraft Inspector
Quality Assurance Manager or Maintenance Control Manager
Regulatory Compliance Specialist / Certification Engineer
Airworthiness & Continued Airworthiness Manager

Lateral Moves:

Maintenance Planner / Reliability Engineer
NDT Specialist / NDT Supervisor
Production Support Engineer / Technical Records Specialist

Core Responsibilities

Primary Functions

Perform comprehensive scheduled and unscheduled inspections on airframes, engines, landing gear, flight controls, avionics systems, nacelles, pylons and auxiliary power units (APUs) in accordance with the Aircraft Maintenance Manual (AMM), Illustrated Parts Catalog (IPC) and Structural Repair Manual (SRM); identify and document all discrepancies and non-conformances.
Conduct detailed non-destructive testing (NDT) such as eddy current, ultrasonic, magnetic particle and dye penetrant inspections to detect cracks, corrosion, delamination and hidden defects in metallic and composite structures; generate NDT reports and recommend repair or replacement actions.
Execute pre- and post-flight inspections, daily checks, periodic maintenance checks (A, B, C, D checks) and engine borescope inspections; validate completion of maintenance tasks and evaluate airworthiness for return-to-service.
Review and interpret engineering drawings, schematics, wiring diagrams and service bulletins to determine inspection scope, allowable damage limits and necessary repair procedures; correlate findings against OEM tolerances and company repair schemes.
Carry out corrosion control assessments, including surface preparation evaluation, removal of corrosion, application of treatments and verification of corrosion prevention measures; document corrosion reports and lifecycle recommendations.
Verify compliance with regulatory requirements including FAA/EASA airworthiness directives (ADs), manufacturer service bulletins (SBs), minimum equipment list (MEL) deferrals and operational limitations; apply regulatory judgment and update maintenance actions as required.
Perform functional checks and ground runs on aircraft systems (hydraulics, flight controls, landing gear retraction/extension cycles, environmental control systems, fuel systems and avionics) and log functional test results in maintenance records.
Author and sign maintenance release documentation (e.g., FAA 8130 forms, logbook entries, EASA Form 1 equivalents) to certify that maintenance actions meet regulatory and company standards for return-to-service.
Troubleshoot complex system anomalies using fault isolation procedures, test equipment, software diagnostic tools and wiring harness inspections; collaborate with engineering to develop corrective repair plans.
Evaluate and approve repairs performed by in-house technicians, contractors or foreign repair stations; oversee repair quality, tool usage, calibration status, and adherence to approved repair schemes.
Conduct structural inspections after hard landings, bird strikes, lightning strikes or storm damage; coordinate emergency inspections and expedite structural repair approvals with engineering and regulatory authorities.
Inspect and verify the condition and expiration of life-limited parts, safety-critical components, loose hardware and critical fasteners; ensure torque sequences and fastening specifications are followed and documented.
Maintain and update technical records, digital logbooks and CMMS entries (e.g., AMOS, TRAX, OASES) with inspection results, deferred defects, corrective actions and parts used to ensure traceability and regulatory compliance.
Perform fuel tank and fuel system inspections, including access panel removals, leak checks, fuel filter inspections and verification of fuel quantity measurement systems per fuel system safety protocols.
Inspect and test emergency equipment, escape slides, oxygen systems, life rafts, ELTs and crew safety equipment to ensure serviceability and compliance with regulatory shelf-life and maintenance intervals.
Lead and participate in quality audits, safety surveys and internal compliance inspections; develop corrective action plans, track findings and close audit reports with measurable outcomes.
Provide technical guidance and training to maintenance technicians, apprentices and contractors on inspection techniques, tooling, NDT methods, and company inspection standards to raise quality and workmanship levels.
Coordinate parts procurement and spares availability with materials management to ensure timely completion of inspection-related repairs; verify part conformity and traceability certificates.
Support pre-buy, pre-lease and teardown inspections, provide condition reports, and advise on airframe condition, projected maintenance costs and remaining life-limited components.
Participate in incident/accident investigations, collect inspection evidence, create factual inspection reports, and recommend preventive measures to reduce recurrence and improve safety management systems.
Ensure correct calibration and certification of inspection tooling, test equipment, torque wrenches and NDT devices; coordinate equipment calibration schedules and maintain calibration logs.
Monitor and assess reliability data, trend recurring defects, and contribute to continuous improvement initiatives to reduce recurring inspection findings and unscheduled removal rates.
Support software and avionics upgrades validation by performing post-modification inspections, compatibility checks and documentation of configuration control changes.
Ensure adherence to company safety policies including proper use of personal protective equipment (PPE), confined space entry procedures, fall protection and hazardous materials handling during inspections.

Secondary Functions

Assist maintenance planning and reliability teams by providing detailed inspection scopes, man-hour estimates and special tooling requirements for scheduled checks and major inspections.
Support engineering and certification teams by supplying inspection data, photos, and measurement records necessary for Supplemental Type Certificates (STCs), repairs and design changes.
Participate in cross-functional lean initiatives and 5S projects to improve shop flow, reduce inspection cycle time and improve turnaround times (TAT).
Provide input to training programs and assessment checklists; mentor junior inspectors and facilitate on-the-job training to develop inspection capability across the team.
Liaise with suppliers, OEM representatives and repair stations to coordinate complex repairs, obtain technical support, and verify subcontractor compliance with approved repair schemes.
Prepare aircraft for export/import or ferry flights by completing technical records reviews, airworthiness certificates and release documentation required by regulatory authorities.
Contribute to the development and review of inspection procedures, checklists, and standard operating procedures (SOPs) to align workplace practices with regulatory and OEM guidance.
Participate in tooling and equipment procurement evaluations by recommending inspection fixtures, borescope upgrades and specialized test instruments to improve inspection accuracy.
Support sustainability and parts recovery initiatives by identifying reusable serviceable components and advising on repair vs replacement decisions that reduce lifecycle costs.
Serve as a subject matter expert during internal investigations into recurring defects and reliability hotspots, helping translate inspection findings into engineering corrective actions.

Required Skills & Competencies

Hard Skills (Technical)

FAA Airframe & Powerplant (A&P) Certificate or EASA Part-66 Category B1/B2 licence (or country-equivalent aircraft maintenance licence) — required.
Authorized Inspector experience (e.g., DER, DAR, CAA/Authority-accepted inspector) and proven ability to sign for return-to-service documentation.
Proficient in non-destructive testing methods (NDT Level I/II or equivalent: eddy current, ultrasonic, magnetic particle, dye penetrant) and borescope inspection techniques.
Deep knowledge of Aircraft Maintenance Manual (AMM), Structural Repair Manual (SRM), Illustrated Parts Catalogue (IPC), Wiring Diagram Manuals (WDM) and Service Bulletins (SBs).
Strong understanding of Airworthiness Directives (ADs), Certification Maintenance Requirements (CMR), Minimum Equipment List (MEL) and continuing airworthiness processes.
Experience with Computerized Maintenance Management Systems (CMMS) such as AMOS, TRAX, OASES or equivalent; digital logbook and technical records management.
Ability to interpret engineering drawings, structural repair schemes, fastener schedules, tolerance tables and damage tolerance assessments.
Competence in avionics/avionic system inspections, software updates, LRUs, and functional testing procedures.
Familiarity with composite materials inspection and approved composite repair techniques, including bond testing and delamination assessment.
Skilled in use and calibration of inspection tools (micrometers, borescopes, torque wrenches, eddy current probes, ultrasonic flaw detectors) and maintaining calibration records.
Proven ability to complete detailed technical reports, defect documentation, work orders and maintenance release paperwork with clear, audit-ready records.
Knowledge of safety management systems (SMS), hazardous materials handling (HAZMAT) and confined space/height safety protocols.
Experience supporting heavy maintenance checks (C/D) and capability to scope, estimate and supervise large structural repairs and teardown inspections.

Soft Skills

Exceptional attention to detail and methodical inspection approach to detect subtle defects and ensure regulatory compliance.
Sound judgment and decisive problem-solving skills when assessing airworthiness and recommending corrective action.
Strong written and verbal communication skills for clear report writing, cross-team coordination and regulatory liaison.
Collaborative team player who can work closely with engineers, planners, technicians and external vendors.
Time management and organizational skills to prioritize inspection tasks under tight maintenance windows and AOG scenarios.
Integrity, accountability and commitment to safety and ethical maintenance practices.
Adaptability to changing regulations, new aircraft types, and evolving maintenance technologies.
Coaching and mentoring ability to transfer inspection skills and standards to junior staff and maintenance teams.
Customer-focused mindset to balance operational demands with safety and compliance obligations.
Analytical mindset for trend analysis, reliability improvement and continuous process optimization.

Education & Experience

Educational Background

Minimum Education:

High School diploma or GED plus FAA A&P certificate or equivalent national aircraft maintenance licence.

Preferred Education:

Associate degree or diploma in Aviation Maintenance Technology, Aeronautical Engineering Technology or related technical field.
Bachelor’s degree in Aerospace Engineering, Aviation Management or related field (preferred for positions with engineering liaison or certification responsibilities).

Relevant Fields of Study:

Aviation Maintenance Technology
Aeronautical/Aerospace Engineering
Avionics Technology
Aircraft Structures and Materials
Mechanical or Electrical Engineering (technical foundation)

Experience Requirements

Typical Experience Range:

3 to 7 years of aircraft maintenance experience with at least 2 years performing formal inspections or approved inspector duties.

Preferred:

5+ years of experience as an Aircraft Inspector or Senior Maintenance Technician with heavy maintenance, line maintenance, or OEM experience.
Demonstrated inspection experience on specific fleet types (e.g., Boeing 737/747/777 family, Airbus A320/A330/A350 family, regional jets, turboprops) and experience with major checks (C/D).
Prior experience working within an FAA/EASA-regulated environment, including completing AD compliance, SB incorporation and certification paperwork.
NDT Level II certification and formal training in borescope inspection, composite repairs and structural damage tolerance assessment.