Requirements for a Maintenance Program Embry-Riddle Aeronautical University Requirements for a Maintenance Program Chapter 6

Development of Maintenance Programs Introduction Aviation Maintenance Program Outlined (AC 120-16E with Chg 1) Summary of the Maintenance Program Objectives (1 – 5) Additional Maintenance Program Requirements Engineering, Materiel, Planning, Maintenance Control, Training, Computing, and Publications Summary

Introduction Regulatory and additional maintenance requirements need to be adhered to in order to achieve the objectives of a sound maintenance program (the 5 maintenance objective covered in Ch. 3)

Maintenance Program Objectives To ensure the realization of the inherent safety and reliability levels of equipment. To restore safety and reliability to their inherent levels when deterioration has occurred.

Maintenance Program Objectives To obtain the information necessary for adjustment and optimization of the maintenance program when these inherent levels are not met. To obtain the information necessary for design improvement of those items whose inherent reliability proves inadequate.

Maintenance Program Objectives To accomplish these objectives at a minimum total cost, including the costs of maintenance and the cost of residual failures.

Aviation Maintenance Program Outlined (AC 120-16E with Chg 1) FAA requires OPSpecs and for maintenance the requirements are identified in the FAA Advisory Circular, AC 120-16E with chg 1 “Air Carrier Maintenance Programs” Airworthiness Responsibility Maintenance manual Maintenance organization Maintenance schedule Maintenance record keeping system Accomplishment and approval of maintenance and alterations Contract maintenance Personnel training Hazardous materials and dangerous goods

Aviation Maintenance Program Outlined (AC 120-16E with Chg 1) FAR 121.373 requires each operator to have a “continuing analysis and surveillance” (CASS) effort to ensure the maintenance and inspection programs are effective FAR 121.380 – record keeping – maintenance recording requirements FAR 121.380a – txfr of maintenance records FAR 43.2 – records of overhaul and rebuilding FAR 43.9 and 43.11 – content, form, and disposition of records All have been incorporated in the AMP

Airworthiness responsibility The airline must adhere to the FAA approved maintenance program the Ops Specs identifies. Can be modified with appropriate justification and approval of the FAA The airline is “ULTIMATELY” responsible for maintaining its own aircraft in an airworthy condition regardless of who actually performs the maintenance.

Maintenance Manual A system of manuals and an expansion of the manufacturer’s manuals The maintenance manual is the primary, all-inclusive, expression of how maintenance will be conducted and how the program will be monitored and improved.

Maintenance Organization The FAA states: “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 direction necessary to achieve your maintenance program objectives.” AC 120-16E with chg 1

Maintenance Organization Essential elements: An organization that is capable of doing the required work. A director of maintenance responsible for the overall activity – must be FAA licensed mechanic. For part 121 operators, a chief inspector. An organization or process to develop and upgrade a maintenance manual that describes all aspects of the maintenance program. Oversight and supervision activities to ensure that maintenance is accomplished in accordance with the airline’s manual.

Maintenance Organization Essential elements: An inspection function for required inspection items (RIIs) that is separate from other routine inspection and maintenance functions. Competent personnel and adequate facilities available for the maintenance to be performed. Procedures to ensure that each aircraft released for service after maintenance is airworthy and properly maintained. Efforts to ensure that the maintenance program remains effective as conditions change. Management personnel who are qualified and have sufficient experience and expertise to effectively organize, manage, and control the maintenance program.

Maintenance Schedule FAA requires a schedule which identifies what, who, when or how often maintenance is to be performed. Tasks are found in the Maint Review Board, Maint Planning Data Intervals – flt hrs, cycles, calendar time, daily, every flt, or flt hrs – 200, 300 etc. It is an airline’s responsibility to adjust the initial MRB schedule to comply with individual airline needs.

Maintenance Record-keeping FAA requires an airline to keep accurate records of maintenance and alteration activities. Two types required: Summary information and airworthiness status information Maintenance logbook – in aircraft and “home” activity Includes flt time, fuel, crew data, and flt crew maintenance related problems and corrective action Mechanical reliability report (MRR) and Mechanical Interruption Summary (MIS)

Accomplishment & Approval of Maintenance & Alterations Program must include instructions for conducting maintenance on the aircraft as well as specific maintenance for engines, propellers, parts, and appliances Scheduled, unscheduled, on aircraft and off. Must address aging and corrosion problems Required Inspection Items (RIIs) – FAA defined as “those items that could result in unsafe operation of the aircraft if maintenance is not performed correctly or if improper parts are used.” FAA doesn’t specify but requires airline to identify its own, in writing, the mechanics qualified and authorized to perform those inspections.

Contract Maintenance Airline “ULTIMATELY” responsible for ALL maintenance Airline is responsible for providing outside units with proper training on your procedures and for assuring that these outside units have the personnel, skills, and facilities to accommodate the work required.

Continuing Analysis & Surveillance System (CASS) Fed Aviation Reg. (FAR) requires that a monitoring program exists and ensures maintenance and inspection programs outlined in the Ops Specs are effective. CASS is a program to detect and correct deficiencies in maintenance program effectiveness and performance. Looks at problem areas, determines corrective action, tracks the activity to determine effectiveness of the correction. Data collection and analysis, daily monitoring of all activities of maintenance, suppliers, and its contractors.

Personnel Training FAR states, “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 the duties.” Many require an airframe and power plant license (A&P) – just means qualified for the job Must have orientation, trained on policies, procedures, and equipment configuration

Hazardous materials & dangerous goods Caustic substances dangerous to eyes, skin, lungs and as well to metal, fabric, and other materials. Storage, handling and environmental concerns and the regulatory requirements Safety issues, fatigue, and other human conditions Airlines required to provide employees with the necessary equipment and training on protection, storage, handling etc.. OSHA mandates most elements

Summary of FAA Requirements To ensure the realization of the inherent safety and reliability levels of the equipment. To restore safety and reliability to their inherent levels when deterioration has occurred. To obtain the information necessary for adjustment and optimization of the maintenance program when these inherent levels are not met. To obtain the information necessary for design improvement of those items whose inherent reliability proves inadequate. To accomplish these objectives at a minimum total cost, including the cost of maintenance and the cost of residual failures.

Homework Assignment - Define the purpose of the following additional Maintenance Program Requirements

Additional Maintenance Program Requirements Engineering Materiel Planning Maintenance Control Center Training Computing Publications

Summary Introduction Aviation Maintenance Program Outlined (AC 120-16E with chg 1) Summary of the Maintenance Program Objectives (1 – 5) Additional Maintenance Program Requirements Engineering, Materiel, Planning, Maintenance Control, Training, Computing, and Publication

Questions?

Engineering Primary purpose is to establish the initial maintenance program from the manufacturer’s maintenance manual and other documents and to upgrade the program over time. Provide technical assistance, review manufacturers service bulletins, changes, and provide engineering expertise to the company or hired consultants in the design of facilities or modification.

Materiel (Supply) Provide maintenance with parts and supplies to carry out maintenance activities. Includes purchasing and warehousing of the parts, supplies and tools. Handle warranty claims and pass on the repairable components to the appropriate workshop or vendor for repair.

Planning Responsible for planning all of the scheduled maintenance including manpower, facilities, and supplies needed Also to collect data on the time, manpower, facilities actually used to subsequently plan for future maintenance actions/requirements.

Maintenance Control Center The nerve center of line maintenance Responsible for keeping track of all vehicles and service and status Coordinates the numerous activities between operations, engineering and maintenance and within the various maintenance work centers. Coordinates the personnel for troubleshooting, repair or parts assistance required.

Training Responsible for follow on training and upgraded skills as required. May even coordinate initial training. Maintains records of all training, qualifications, and certifications of all personnel assigned. Trains engineers, supervisors, managers, inspectors not only maintenance specific but managerial/supervisory roles.

Computing Provides the equipment, software, training and support for all computing activities. Includes: Data collection on malfunctions Parts tracking and control Collection and manipulating reliability data (MTBF) Failure rates, removal rates Tracking of serial numbered items

Publications Responsible for keeping all technical publications up to date Paper, microfilm, or electronic media Distributes to appropriate work centers Provides revisions and additions Inspects periodically for completeness Maintains Master Library