Presentation on theme: "MAINTENANCE ERROR ACCIDENTS"— Presentation transcript:
1 MAINTENANCE ERROR ACCIDENTS ByWg Cdr (Retd) M U Khan, VSMDeputy General Manager (Flight Testing)Hindustan Aeronautics Ltd
2 Maintenance Error Accidents Maintenance is :Essential & Integral part of aviation industry.ThusMaintenance errors are likely to occur just like the flight crew related errors.Aim is to:Minimise the risk of maintenance related accidents / incidents
3 ContentStatistics of Indian Civil Helicopter Accidents due to Maintenance reasonsContributory factors towards maintenance errorsManMachineEnvironmentNew Safety RequirementsPreventive and Predictive MaintenanceFuture Trends
4 Year Wise Statistics of Accidents (1990-2005) Total Maintenance
5 Statistics of Accidents (1990-2005) PILOT ERROR57%MAINTENANCE28%GROUND ACCIDENT10%OTHERS5%
6 Breakdown of Maintenance Related Accidents (1990-2005) Improper Maintenance40%Technical Defects60%Fatal : 2Injury : 1Substantial Damage : 8Total Loss : 3
9 Maintenance Errors ERRORS Oversight Attention lapses VIOLATIONS Non-compliance of laid down instructions or regulations- Someone in most maintenance departments make life or death decisions everyday.- They determine if an aircraft is safe for flight or not.- Most component technical issues in helicopters fall into shades of gray categorythus
10 THE INDIVIDUAL WHO MAKES SAFETY OF FLIGHT DECISION CAN’T MAKE MISTAKES The maintenance personnel have a tough task to perform to keep the fleet airborne.Their decision is easy if it’s a major safety of flight issue – ‘The aircraft is down’.It is more difficult if it’s a minor discrepancy like metal chips in a transmission, a leaky actuator or minor cracks in secondary / tertiary structures.All military & commercial aircraft fly with minor discrepancies.THE INDIVIDUAL WHO MAKES SAFETY OFFLIGHT DECISION CAN’T MAKE MISTAKES
11 Individuals usually realise their mistakes and rectify them. However,Not all errors lead to incidents / accidents.Individuals usually realise their mistakes and rectify them.Research has shown that people involved in critical professions routinely make small mistakes, which they detect and correct themselves.
12 Other Human Factors Lack of Communication Complacency Distraction Lack of KnowledgeLack of TeamworkFatigueLack of AssertivenessStressLack of ResourcesPressure
13 Environmental Aspects Mostly all maintenance activities take place by night in artificial lighting conditions.Hangars & Tarmac may not be always available at all times for maintenance operations.Heat, Dust, Rain etc can be source of initiation of maintenance related incidents / accidents.
14 Errors due to the Machine The helicopter is a very complex machine as compared to its fixed wing counterpart.It operates in adverse environment such as dusty and salt laden atmosphere as well as close to ground. Thus making it maintenance intensive.Present concept is to make the design for near Zero routine maintenance for short terms and ‘inspect & replace’ for the longer term maintenance cycles.
15 Avoid Maintenance Errors thru Design Design features known to be a source of human errors are eliminatedSoftware logic to prevent errorsH U M S (Health & Usage Monitoring system)I E T M S (Interactive Electronic Technical Manuals)Onboard Diagnostics
17 Preventive Vs Predictive Maintenance Maintenance professionals emphasize prevention as an inexpensive method of controlling maintenance costs and ensuring safety.Technology has now advanced to such a point that a new trend has emerged – Predictive Maintenance.But the two are not mutually exclusive.An operator who has adopted both approaches is unlikely to get an unwelcome surprise from maintenance problems.However the future is towards predictive maintenance.
18 Future Trends in Maintenance Onboard diagnostic systems to not only record but also to analyse the data during the flight.Possibly relay the same to the maintenance agency to ensure ‘just in time’ deliveries of replacement parts rather than stockpiling them.Nanotechnology.Smart materials.Virtual Retinal Display.
19 ConclusionThe human aspect of the maintenance personnel is the most important area and needs careful attention by both – the operator and the regulator.The environment plays a major role in ensuring proper maintenance of our helicopters and thus requires careful attention.Modern technologies can aid reduction in maintenance error accidents.