Key Responsibilities and Required Skills for Jet Repair Inspector

🎯 Role Definition

As a Jet Repair Inspector you will be the authoritative quality gate for structural and systems repairs on commercial and business jets. You will evaluate repair proposals, perform in-depth inspections (including borescope and NDT), verify conformity with technical data (AMM, SRM, IPC), record and sign-off airworthiness documentation, and champion safety and regulatory compliance (FAA / EASA). This role requires strong technical judgement, meticulous documentation habits, and clear communication with maintenance teams, engineering, and customers.

📈 Career Progression

Typical Career Path

Entry Point From:

A&P Mechanic / Licensed Aircraft Technician with progressive experience in jet airframes and engines
Non-Destructive Testing (NDT) Technician (Level II / Level III) transitioning into inspection roles
Structural Repair Technician or Sheet Metal Specialist with inspection responsibilities

Advancement To:

Lead/Principal Inspector
Quality Assurance Manager / Maintenance Control Manager
Certification Engineer or Regulatory Compliance Lead

Lateral Moves:

Maintenance Program Manager (MPM)
Supplier Quality Engineer / Vendor Inspector

Core Responsibilities

Primary Functions

Conduct comprehensive post-repair and post-modification inspections of jet airframes, engines, landing gear, flight controls, and avionics installations to ensure conformity with applicable maintenance manuals, engineering data, and airworthiness directives.
Perform and interpret non-destructive testing (NDT) techniques—eddy current, ultrasonic, magnetic particle, and liquid penetrant—to detect cracks, corrosion, and material discontinuities on structural components and critical engine parts.
Execute borescope inspections of turbine engines, auxiliary power units (APUs), and other hard-to-access areas; document findings with high-resolution imagery and provide actionable disposition recommendations.
Review and approve repair schemes, structural repair drawings, and engineering disposition reports; verify that proposed repairs meet AMM, SRM, IPC, and manufacturer service bulletin requirements prior to work release.
Sign off maintenance release documents, logbooks, and electronic maintenance records in accordance with FAA 14 CFR, EASA Part-145/Part-M, or relevant national authority requirements, maintaining traceability of all certifications.
Investigate and root-cause analyze recurring defects and in-service failures, coordinating corrective actions with engineering, maintenance, and procurement to prevent recurrence and improve fleet reliability.
Perform dimensional inspections, hardness testing, and functional checks on repaired components and assemblies, using calibrated gauges and test equipment to verify torque, clearances, and tolerances.
Validate vendor-supplied repair work and incoming parts through supplier inspection, certificate of conformity review, and lot traceability checks to ensure compliance with purchase orders and quality standards.
Maintain and calibrate inspection tools and NDT equipment, ensure calibration records are current, and submit discrepancies for corrective action when tools fall outside tolerances.
Lead on-wing and in-shop inspections during scheduled maintenance checks (A, B, C, D checks) and unscheduled events, coordinating access, tooling, and safety protocols to minimize aircraft downtime.
Prepare detailed inspection reports, non-conformance reports (NCRs), and engineering evaluation packages with clear findings, photographs, measurements, and disposition recommendations for internal and customer review.
Collaborate with design engineering to evaluate structural repairs, temporary repairs, and repair alternatives; provide practical field feedback to improve repair procedures and maintenance instructions.
Ensure compliance with hazardous materials handling, safety data sheets, and environmental regulations during inspections and repair oversight, reporting any incidents per company safety management system (SMS).
Mentor and train mechanics and junior inspectors on inspection criteria, NDT basics, technical data interpretation, and company quality standards to raise overall maintenance capability.
Represent the maintenance organization during internal and external audits, including regulatory, airline customer, and OEM inspections; prepare evidence packages and lead corrective action implementation.
Manage configuration control and part eligibility decisions for repaired components, ensuring that serviceable part numbers and life-limited items are correctly tracked and documented.
Coordinate ferry and test flight readiness for aircraft released after structural repairs, ensuring all MEL/dispatch items, deferred defects, and signing authority requirements are satisfied prior to release.
Review and implement airworthiness directives (ADs), service bulletins, and site-specific procedures; determine applicability to aircraft and coordinate incorporation into maintenance plans.
Evaluate and disposition permanent and temporary repairs following accident/incident or damage events, liaising with safety investigators, insurance representatives, and regulatory authorities when required.
Provide on-site technical support during complex removal/installation tasks, ensuring that fastener configurations, bonding processes, and structural integrations meet OEM and engineering specifications.
Maintain up-to-date knowledge of manufacturer repair approvals, Structural Repair Manuals, and damage tolerance criteria; proactively recommend process or tooling upgrades to improve inspection accuracy and throughput.
Drive continuous improvement by analyzing inspection data trends, proposing process changes, and participating in cross-functional Lean/Six Sigma initiatives to reduce rework and improve first-pass acceptance rates.
Ensure all inspection records are entered and maintained in the enterprise maintenance management system (CMMS/AMOS/MX) with correct tagging, attachments, and approval workflows to support regulatory compliance.

Secondary Functions

Provide technical input to procurement for approved vendors, tooling, and NDT supplies to ensure inspection readiness and quality outcomes.
Support warranty claims and customer liaison activities by supplying documented inspection evidence and technical justification for corrective actions.
Participate in change control boards and procedure review cycles to keep inspection instructions aligned with latest regulatory and OEM guidance.
Support emergency response and on-call inspection coverage for AOG events, coordinating rapid assessments and repair prioritization.
Contribute to safety stand-downs, lessons-learned briefings, and SMS reporting to enhance organizational safety culture and reduce repeat findings.

Required Skills & Competencies

Hard Skills (Technical)

FAA Airframe & Powerplant (A&P) license or EASA Part-66 Category B1/B2 (preferred) with demonstrated aircraft inspection authority.
Extensive experience with structural repair standards, AMM, SRM, IPC, and OEM structural repair procedures for commercial/business jets.
Certified NDT skills: proficiency in eddy current, ultrasonic, magnetic particle (MPI), and liquid penetrant (LPI) testing; NDT Level II or equivalent preferred.
Advanced borescope inspection skills with ability to capture technical imagery, identify engine/HP/IP/LP anomalies, and produce findings reports.
Strong familiarity with airworthiness regulations (FAA 14 CFR, EASA Part-145/Part-M, or equivalent national authority requirements).
Proficiency using inspection tools and measurement systems: calibrated micrometers, vernier calipers, bore gauges, torque wrenches, and CMM basics.
Experience with maintenance documentation systems (e.g., AMOS, Ramco, TRAX, CAMP, or equivalent) and electronic logbook sign-off procedures.
Ability to read, interpret, and apply technical drawings, wiring diagrams, structural drawings, and repair schemes.
Knowledge of materials, metallurgy, corrosion control, and composite repair techniques applicable to jet aircraft structures.
Competence in preparing engineering disposition packages, non-conformance reports, and corrective action requests with clear technical justification.
Familiarity with quality management systems (ISO 9001, AS9100) and audit processes; able to support supplier audits and corrective action workflows.
Basic competency with Microsoft Office (Excel for data analysis), image editing for inspection photos, and digital reporting tools.

Soft Skills

Exceptional attention to detail and meticulous documentation habits to support regulatory sign-off and traceability.
Strong analytical and problem-solving skills with the ability to make sound airworthiness decisions under time pressure.
Clear and professional verbal and written communication; capable of explaining technical findings to maintenance crews, engineers, and customers.
Good organizational and time-management skills to prioritize multiple inspections during maintenance checks and AOG events.
Teamwork orientation with experience collaborating across engineering, maintenance, procurement, and quality departments.
Customer-focused mindset, maintaining professionalism during customer-facing inspections and status briefings.
Integrity and accountability in signing maintenance releases and ensuring compliance with regulatory responsibilities.
Adaptable and resilient in rotating shifts, travel assignments, and on-call situations for rapid mobilization to support aircraft recovery.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED plus FAA A&P certification or equivalent licensing (EASA Part-66 preferred).

Preferred Education:

Associate or Bachelor’s degree in Aviation Maintenance Technology, Aeronautical/Aerospace Engineering, Mechanical Engineering, or related technical field.
Additional certificate or coursework in NDT, composites repair, or aviation quality systems is advantageous.

Relevant Fields of Study:

Aviation Maintenance Technology
Aeronautical or Aerospace Engineering
Mechanical Engineering
Materials Science / Nondestructive Testing

Experience Requirements

Typical Experience Range:

3 to 10+ years of hands-on aircraft maintenance and inspection experience on regional, narrow-body, or wide-body jets.

Preferred:

5+ years in a dedicated inspection role or as a senior A&P mechanic with frequent structural repair and NDT responsibilities.
Prior experience in a Part-145 maintenance organization, OEM MRO environment, or airline maintenance control preferred.
Demonstrated history of regulatory sign-off, audit participation, and technical liaison with engineering functions.