1. Production Planning and Control
Embry-Riddle Aeronautical University
Production Planning and Control
Chapter 9

2. Development of Maintenance Programs
Introduction
Forecasting
Production Planning
Production Control
Feedback for Planning
Organization of PP&C
Summary

3. Introduction PP&C is the heart of the maintenance organization
Three primary functions:
Forecasting
Planning
Control
“Plan your work and work your plan”

4. Goals of PP&C To maximize the M & E contribution to the airline
To plan and organize work prior to execution
To adjust plans and schedules to meet changing requirements

5. Forecasting
Includes the estimated maintenance workload for the long and short term based on existing fleet and business plans and on any known changes in these for the forecast period.
Fleet size and make up
Route structure
Facilities
Manpower and skill requirements
Aging and replacement of equipment
New equipment
Incorporation of ADs and SBs

6. Long term (5-10 years) changes impact:
Forecasting
Long term (5-10 years) changes impact:
Scheduling
Budgeting
Training
Manpower
Facilities
Adjustments are made to meet goals and objectives of airline
Growing or shrinking
Long Term is general and subject to yearly revisions

7. Short term (1-2 years) more detailed:
Forecasting
Short term (1-2 years) more detailed:
Definitive plans with actual numbers:
Scheduling
Budgeting
Training
Manpower
Facilities
Schedules for checks and modifications finalized
Large Airlines develop intermediate (2-5 years)
Key to keep up with changes in the operating climate

8. Deals with day-to-day activities of M&E
Production Planning
Deals with day-to-day activities of M&E
Goal to provide airworthy vehicles to flight department (OPs) to meet flight schedule
Planning of the work with the goals in mind
Planning includes:
Daily, 48-hr, transit checks, letter checks (A –D), modifications due to ADs, SBs, SLs, and EOs.
Planning and scheduling of manpower, parts, supplies, and facilities to accomplish above
Coordinate with Ops, ground handling and support activities

9. Production Planning
Daily, 48-hour, and transit checks are standardized and require little effort for PP&C.
“A” checks and higher are planned, scheduled, and coordinated
“A” checks planning begins 1 to 2 weeks prior
“C” checks about 4 weeks
Incorporation of ADs or SBs may require longer based on parts availability

10. Aircraft Maintenance Check Schedule
Pg. 115
Certain items that are less in time or cycles than the “A” check may be slid to next “A”
Airlines defer items due to pressing schedules – may back selves in corner
Take aircraft out of service
Delays cost $$$$

11. Aircraft Maintenance Check Schedule
SBs, ADs, or SLs, that don’t require excessive time may be incorporated in “A” checks
Careful planning is KEY
Time is MONEY

12. Aircraft Maintenance Check Schedule
“C” check is once a year
Takes 4 to 7 days to complete
Typical PP&C tasks:
Locate and secure hangar space for the duration of the check
Obtain release from Ops for maintenance
Arrange and schedule plane washing
Secure tow vehicles and manpower to move A/C to the wash rack and then to hangar (wingwalkers, brake rider etc..) and PP&E
Ensure all parts and supplies are on hand to complete check
Identify manpower (skills, quals and certs, QA) needed for the check
Conduct meeting to cover tasks and issue MRCs (Maintenance Requirement Cards)

13. This data will help shape the time constraints on the next check
Production Control
The plan by PP&C allows for certain time to perform the work based on past knowledge
Also parts, supplies, manpower, GSE and facilities available
Key is the estimate is cast in jello
Because time is MONEY…feedback from maintenance on the performance/status of the checks is critical
This data will help shape the time constraints on the next check
Tracking time is not disciplinary but used for practical planning purposes

14. Organization of PP&C Centralized all functions:
Forecasting, planning and control in one location with liaison made with work centers
Partially decentralized:
Forecasting and planning by PP&C
Control by work centers with feedback and coordination between the two
Decentralized:
Planning and control done by each work center
Problem is little or no coordination among the centers…NOT RECOMMENDED

15. Development of Maintenance Programs
Introduction
Forecasting
Production Planning
Production Control
Feedback for Planning
Organization of PP&C
Summary

16. Questions?