Transcript Lecture 4 Development of Maintenance Programs

393SYS
Airport Engineering Practice
Lecture 4
Development of
Maintenance
Programs
1
4.0
Documentation for
Maintenance
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4.0 Documentation For Maintenance
Types of Documentation
Main types of documentation –
1.
Manufacturer’s Documentation 
2.
Regulatory Documentation
3.
Airline Generated Documentation
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4.0 Documentation For Maintenance
Regulatory Documentation
In the United States, the FAA (Federal Aviation
Administration) issues many documents on aircraft
maintenance. The most significant ones are –
●
Federal Aviation Regulations (FARs)
●
Advisory Circulars (ACs)
●
Airworthiness Directives (ADs)
●
Notice Of Proposed Rule Making (NPRM)
This last one is issued by the FAA whenever the
FAA intends to change a FAR. It is issued in
advance of the change to give aviation industry
plenty of time to study and comment on the
proposed change.
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4.0 Documentation For Maintenance
The following figure shows the process from initial Notice of Proposed Rulemaking
(NPRM), consultation and comment period, to the publishing of the Final Rule in
the Federal Register and finally in the Code of Federal Regulations (CFR
14).
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4.0 Documentation For Maintenance
Federal Aviation Regulations (FARs)
These are the laws of the United States which relate to all aspects of
aviation including private, commercial and experimental aircraft;
airports; navigational aids; air traffic control; training of pilots, air
traffic controllers, mechanics etc.
Example FAR
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4.0 Documentation For Maintenance
Advisory Circulars (ACs)
Designed to help airline operators meet the requirements of
FARs.
An AC often states that something is “a means, but not the
only means” of complying with a regulation.
Airworthiness Directives (ADs)
The airworthiness directives are very important regulations
issued by the FAA to correct an unsafe condition that exists in
an –
●
aircraft
●
aircraft engine
●
propeller,
●
aircraft appliance
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Example AC
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4.0 Documentation For Maintenance
Aircraft owners or operators are required to maintain aircraft
in compliance with all ADs.
Typically an AD will include –
a)
a description of the unsafe condition
b)
the item to which the AD applies
c)
the corrective action required
d)
date of compliance
e)
where to get additional information
f)
information on alternative methods of compliance (if
applicable)
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Effective, November 12, 2002
Airworthiness Directives;
Boeing Model 737 Series Airplanes
Applicability: All Model 737 series
airplanes; certificated in any
category.
To prevent an uncommanded rudder
hardover event and consequent loss
of control of the airplane due to
inherent failure modes, including
single-jam modes, and certain latent
failure or jams combined with a
second failure or jam; accomplish
the following: ….
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4.0 Documentation For Maintenance
Airline Generated Documentation
Operations Specification (“Ops Spec”)
•
Written by the airline in accordance with strict FAA
requirements.
•
The Ops Spec is required for each aircraft type flown by the
airline.
•
It details the airline’s maintenance, inspection, and operations
programs.
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4.0 Documentation For Maintenance
Technical Policies and Procedures Manual (TPPM)
The airline’s Maintenance & Engineering (M&E) operations
manual.
Defines exactly how all M&E functions and activities will be
carried out.
A detailed document – may be several volumes.
Personnel in M&E must be trained on the TPPM.
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4.0 Documentation For Maintenance
Inspection Manual (IM)
Usually a chapter in the TPPM.
Contents relate to a) mechanic inspection tasks
b) QC inspector tasks
c) special inspections (hard landings, bird strikes, etc.)
d) airlines required inspection item (RII) program
e) paperwork and forms to carry out these functions
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4.0 Documentation For Maintenance
Quality Assurance Manual (QAM)
This could be either

a special manual for QA auditors only, or

a separate chapter in the TPPM.
Defines procedures used in the annual QA audits conducted
on the M&E units, suppliers and outside contractors.
Includes formats for forms and reports to be used in the QA
procedures.
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4.0 Documentation For Maintenance
Minimum Equipment List (MEL)
The aircraft manufacturer produces the Master Minimum Equipment
List (MMEL).
This includes all aircraft configurations available for a particular model
of aircraft (e.g. Boeing 747-100, 747-200, … etc.).
For some models of aircraft, customers can choose –

engines from three different manufacturers

various auxiliary systems as buyer options
.. much of this is not applicable to some operators.
The airline operator is therefore required to customize the MMEL for
their aircraft engine / airframe configurations.
The customized MMEL becomes the MEL.
Copies of this MEL must be carried in each aircraft for flight crew
reference.
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4.0 Documentation For Maintenance
Task Cards
Certain tasks defined in the AMM for - removal/installation, testing,
servicing and similar maintenance - are reproduced on separate cards
or sheets so that the mechanic can perform a particular maintenance
task without having to carry the entire maintenance manual around
with them.
These tasks may call for the mechanic to open panels, set certain
circuit breakers “in’ or “out”, turn other equipment “on” or “off”, etc.,
before they can do the maintenance task, and then they must reverse
these steps when they have completed the maintenance task.
However, much of the work done during an aircraft check involves a
combination of several tasks applied in the same area of the aircraft.
To avoid repeating the same tasks and unnecessary opening and
closing of the same panels, most airlines write their own task cards to
combine these maintenance activities.
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4.0 Documentation For Maintenance
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5.0
Requirements for a
Maintenance
Program
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5.0 Requirements For A Maintenance Program
Objectives Of A Maintenance Program
These are as follows :
1. To ensure the inherent (i.e. designed-in) safety and reliability levels of
the equipment.
2. To restore safety and reliability to their inherent (designed-in) levels
when deterioration has occurred.
3. To obtain the information necessary for the adjustment and optimization
of the maintenance program when these inherent levels are not met.
4. To obtain the information necessary for design improvement of those
items whose inherent reliability proves inadequate.
5. To accomplish these objectives at a minimum total cost, including the
cost of maintenance and the cost of residual failure.
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5.0 Requirements For A Maintenance Program
This section outlines the main ingredients of a maintenance program
for achieving these five objectives.
Airworthiness Responsibility
Under aviation regulations such as those issued by the FAA,
an airline operator is responsible for all maintenance on it’s
fleet of aircraft.
The airline must have operating specifications for each model
of aircraft flown.
It must adhere to the approved maintenance program
identified in the Ops Spec.
The airline must follow both its own policies and those of the
regulatory authority in carrying out maintenance and
inspection.
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5.0 Requirements For A Maintenance Program
In some cases, an airline may have another airline or a third
party maintenance organization do some or all of its
maintenance under contract.
However, the airline is responsible for ensuring that any work
done for them by these outside contractors is done to their
own maintenance schedule, standards and requirements, and
is in accordance with the airline’s regulatory authority
requirements.
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5.0 Requirements For A Maintenance Program
Maintenance Manual
Earlier, we identified the manuals provided by manufacturers and
other vendors of aircraft parts and systems.
These manuals provide of the equipment to be maintained and the
procedures to be used to achieve this maintenance.
This section, however, refers to other areas of concern such as –

the management and administration of maintenance,

the procedures for work performance, and

the procedures for inspection, audit, and analysis of the
maintenance work.
The maintenance manual referred to here is therefore the primary,
all-inclusive document of how the maintenance program will be
conducted, monitored and improved.
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5.0 Requirements For A Maintenance Program
Maintenance Organization
The FAA states that an airline must have a maintenance
organization “that is able to perform, supervise, manage, and amend your
program, manage and guide your maintenance personnel, and
provide the necessary direction to achieve your maintenance
program objectives.”
The essential elements of this organization are as follows :
1.
An organization that is capable of doing the work.
2.
A Director of Maintenance (or similar title)
responsible for the overall activity (must be suitably
licensed).
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5.0 Requirements For A Maintenance Program
3.
For certain categories of operators, a Chief Inspector (or
similar title).
4.
An organization or process to develop and upgrade a
maintenance manual that describes all aspects of the
maintenance program.
5.
Supervisory activities to ensure that maintenance is
accomplished in accordance with the airline’s manual.
6.
An inspection function for required inspection items (RII)
that is separate from other routine inspection and maintenance
functions.
7.
Competent personnel and adequate facilities available for
maintenance to be performed.
8.
Procedures to ensure that each aircraft released for service
after maintenance is airworthy and properly maintained.
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5.0 Requirements For A Maintenance Program
9.
Efforts to ensure that the maintenance program remains
effective as conditions change.
10.
Management personnel who are qualified and have sufficient
experience and expertise to effectively organize, manage, and
control the maintenance program.
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5.0 Requirements For A Maintenance Program
Maintenance Schedule
The FAA (for example) requires an airline to have a
maintenance schedule which identifies –

what maintenance will be done

how it will be done, and

when or how often it will be done.
This maintenance schedule is derived from data supplied by
the aircraft manufacturer in various documents delivered with
the aircraft.
In the USA, they are identified in the Maintenance Review
Board (MRB) report which is an FAA approved document.
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5.0 Requirements For A Maintenance Program
In the USA, they are identified in the Maintenance Review
Board (MRB) report which is an FAA approved document.
tasks are divided into groups based on the suggested interval
– flight hours, flight cycles, or calendar time.
These manufacturer’s documents, however, are only
guidelines.
Each operator is different – different airplane configurations,
operational and environmental conditions.
Therefore, it is an airline responsibility to adjust the initial
MRB schedules to comply with the individual airline needs.
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5.0 Requirements For A Maintenance Program
Maintenance and Record Keeping
Commercial aircraft are delivered to the airline operator with
a standard airworthiness certificate.
It is the airline’s responsibility to keep that aircraft in
airworthy condition.
To ensure that this happens, the airline is required to keep
accurate records of maintenance.
Failure to keep accurate records can result in substantial fines
or imprisonment for the airline operator.
Two types of record are required – “summary information”
and “airworthiness information.”
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5.0 Requirements For A Maintenance Program
Contract Maintenance
Although an airline has responsibility for all maintenance on
its aircraft, very often, some, or all, of the maintenance may
be performed under contract with some other airline or some
third party maintenance organization.
Under these circumstances, the airline maintenance program
must include procedures for making sure the work is done
properly.
This means an airline is responsible for providing the outside
maintenance organizations with proper training on its
maintenance procedures.
Also, the airline must make sure that the outside organization
has the personnel, skills, and facilities to do the work required.
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5.0 Requirements For A Maintenance Program
Continuing Analysis and Surveillance System (CASS)
Airlines need to be able to demonstrate to the relevant
authorities that the maintenance and inspection programs
outlined in the Ops Spec are effective.
This is done by adopting suitable QA programs.
Essentially, CASS is a program to detect and correct
deficiencies in maintenance program effectiveness and
performance.
It looks at possible problem areas, determines the corrective
action required, and tracks the activity afterward to determine
the effectiveness of the correction.
This accomplished through data collection and analysis.
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5.0 Requirements For A Maintenance Program
Personnel Training
The USA FARs are very brief in stating the training
requirements for aviation maintenance –
airlines should “have a training program to ensure that each
person (including inspection personnel) who determines the
adequacy of work done is fully informed about procedures
and techniques and new equipment in use and is competent to
perform his duties.”
Another part of the FARs provides further elaboration by
discussing the requirements for Aviation Maintenance
Technician Schools.
In these schools, you can earn an airframe and power plant
(A&P) license, but this license does not fully qualify you to
work on the aircraft of a particular airline.
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5.0 Requirements For A Maintenance Program
The A&P license simply means that the person having the
license is qualified for the job of maintenance mechanic.
In order to be qualified to do the airline’s work, a mechanic
must receive orientation training on the airline’s policy,
procedures, and its equipment configuration.
The airline must validate the mechanic’s skills using the
appropriate testing methods, and must ensure that the
mechanic is up to date in all aspects of the job.
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5.0 Requirements For A Maintenance Program
Hazardous Materials and Dangerous Goods
Examples include –

caustic substances dangerous to eyes, skin and lungs,
as well as to metal, fabric, and other materials

radioactive substances,

flammable materials,
Safety issues including heavy and unstable loads, set up and
use of scaffolding and stands, working in high places, even
fatigue and other human conditions fall into this area of
concern.
The airline is required to identify these and to provide
employees with the necessary equipment and training on
protection, storage, handling, etc.
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Summary
Summary
Documentation For Maintenance

Regulatory Documentation

Airline Generated Documentation
Requirements of a Maintenance Program

Objectives of a Maintenance Program

Airworthiness Responsibility

Maintenance Manual

Maintenance Organization

Maintenance Schedule

Maintenance and Record Keeping

Contract Maintenance

Continuing Analysis and Surveillance System

Personnel Training

Hazardous Materials and Dangerous Goods
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What you need to know for the exam !

Can you identify the four main types of regulatory documentation
issued by the FAA in the United States ?

Explain, briefly, the purpose of the following : Federal Aviation
Regulations (FARs), Advisor Circulars, Airworthiness Directives
and Notices Of Proposed Rule Making (NPRMs).

Provide a brief description of the different types of
documentation generated by airlines.

What are the five objectives of an aviation maintenance
programme ?

Explain, briefly, the nature of the different areas relating to
aviation maintenance which contribute to the five objectives of
an aviation maintenance programme.
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