1. Maintenance Optimization Made Simple Brian McLoughlin – Boeing Richard Lewis - Ryanair

2. Most Airlines Are Not Operating at Previous 737NG Maintenance Planning Data (MPD) Document
Example: 737NG Operators
13% of At / Beyond
Previous MPD
87% Below

3. Why Do Operators Remain Below MPD Limits?
Unique Data Requirements
Guidelines require Operators perform analysis of their own operational experience and data
Utilization Factors
Unique Customer operating profiles can result in FH, FC and calendar based tasks not aligning for packaging purposes
Maintenance Packaging Fall-Out Tasks
Many Operators package check visits to meet the least common denominator of the individual tasks within the package
An optimization allows Operators to realize the full potential value of the maintenance program through customized analysis of their maintenance data

4. Requirements for Implementing MRB/MPD Updates
Once an MRBR/MPD has been incorporated into an operator’s program, the Airline Maintenance Program must be adjusted based on the airline’s actual in-service experience
Excerpt from FAA AC C Implementing the MRBR/MPD Changes once an airline has operating experience
…Do not confuse the MRBR (MPD) requirements with an operator maintenance program. After FAA
approval, the requirements become a base or framework around which each operator can develop its own individual aircraft maintenance program
Excerpt from FAA AC F on Aircraft Maintenance Programs
… regulations (§§ and ) that require you to establish and maintain a system for the CASS of the performance and effectiveness of your maintenance program.
Excerpt from FAA AC A on Continuing Analysis and Surveillance System (CASS)
… The maintenance schedule should be task-based and appropriately modified in accordance with the CASS data collection and analysis findings.
Excerpt from EASA Annex I – Part M - Subpart C - M.A. 302 Aircraft Maintenance Programme - (g)
… The aircraft maintenance programme shall be subject to periodic reviews and amended accordingly when necessary. These reviews shall ensure that the programme continues to be valid in light of the operating experience …
Excerpt from IATA Operator Task Interval Adjustment/Optimization Guidelines
… As service experience is accumulated, scheduled maintenance requirement intervals should be adjusted / optimized to reflect the results of actual in-service experience.

5. Boeing Optimized Maintenance Program
Optimization at individual task level
Customized analysis of each individual task interval
Based on operator’s maintenance data and operational goals
Based on operator’s unique environment and utilization
Benefits of the Optimized Maintenance Program
Efficient and effective maintenance program
Creates additional revenue operation days
Reduces labor and material requirements
Supports safety and reliability through establishing effective intervals for each maintenance task
Boeing has the tools and capability to maximize maintenance program effectiveness

6. Statistical Application Probability Assessment
Comprehensive Data Driven Results
Statistical Application
Probability Assessment
OEM Engineering
Severity Assessment
Operator Data + +
Airline Operational Data
Task Intent / Mapping
OEM Design/Cert.
MSG-3 Failure effect
Current Task Procedure
Scheduled Maintenance
Log Book
Component Removal
Delay & Cancellation
Shop records
Maintenance Cost
Data
Processing
Mining
Categorization
Customized Results
Statistical Analysis Engine
OEM Backed OMP
Optimized intervals
Regulatory Support

7. Optimal Scheduled Maintenance Intervals
System Degradation
Effective Interval
Significant Finding
Reduction in functionality or unacceptable operational / economic penalties
Significant Finding (System Failure)
Opportunity For
Preventative Maintenance
Minor Finding
No immediate functional, operational, or economic impact
Minor Defect (Latent Failure)
TMF
TSF
High probability of Unscheduled Maintenance
Early inspection - NFF
Time
Minimize looking too early (NFF) and too late (In-service failures, unscheduled maintenance)

8. Boeing OMP Customers
OMPs for Cathay Pacific, Ryanair, Virgin Atlantic and Virgin Australia and most reapat requst for additional support. GOL, Ethiopian and Volotea are engaged with maintenance operations consulting services.. All within the last 18 months

9. OMP: Strong Track Record of Delivering Value
Customer
Achieved Savings ($/yr)
Reg. Appr.
Customer A (737NG)
$8.5M total
Yes
Customer B (777)
$50.6M
Customer C ( )
$2.4M
Customer D (737NG)
$27.5M
Customer E (737NG)
$11.2M
Customer F (737NG)
$4.6M
Customer G (777)
$24.3M
In Work
Customer H (777)
Customer I (737NG)
$5.4M
Customer J (737NG)

10. For more information Please contact: Brian McLoughlin
Optimized Maintenance Programs
Boeing Professional Services