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COSCAP Seminar details
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COSCAP SeminarScheduled Maintenance
Dubai-29th May 2013
Presented byChristian DELMAS – Director Maintenance Programmes Engineering – Airbus Customer Services
Page 2
Introduction
Maintenance Schedule Development
Initial Maintenance Program Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 3
Who are we?
Engineering & Maintenance
SEEngineering &
Maintenance Projects
Engineering SupportSEE
Upgrade ServicesSEU
A/C Embodiment
OperationsSEO
Maintenance Programs &
Services
SEM
Technical Data
SED
Customer Services
S
SEMSMaintenance
ProgrammesSupportLuc COUSIN
SEMEMaintenance Programmes Engineering
Christian DELMAS
SEMB
Service
Bulletins
SEM
Advanced Airline Operations
Page 4
Maintenance Program Development
Initial Maintenance Program Development
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 5
& &
Airworthiness standards are not only set for the design of the aircraft but also for operation and maintenance while in service.
Maintenance Program Development
Regulation Frame Work
Regulation(s) :CS/FAR 25.1529 Instructions for continued airworthiness
“Instructions for Continued Airworthiness in accordance with Appendix H must be prepared.”
Economics :Airline operation needs maintenance instructions to keep level of safety, reliability and availability at minimum cost.
Page 6
Scheduled Maintenance Requirements
A group of scheduled tasks to be accomplished at specified intervals. The objective of these tasks is to prevent deterioration of the inherent safety and reliability levels of the aircraft.
Maintenance Program Development
Page 7
Fatigue Analysis
Safe Life Airworthiness
Limitation Items
Safe Life
Damage Tolerant Airworthiness
Limitation Items (ALI)
Fail safe - Damage Tolerance Analysis
SystemSafety Assessment
(pre DSG)+
MSG3 Analysis
Certification Maintenance
Requirements (CMR)
Aging System Maintenance
(ASM)
SystemSafety Analysis
(Post DSG)+
MSG3 Analysis+
System Life Limits
Fuel Airworthiness
Limitations(FAL)
Fuel Tank Safety Analysis
FuelStructureEASA/FAR 25-571 EASA/FAR 25-981
SystemsEASA/FAR 25-1309 (mainly)Regulations
Maintenance Program Development
Page 8
MaintenanceFAA AC121-22
EASA MRB Work Instructions / IO11 Maintenance Review Board Team
Maintenance Analysis(MSG3)
Maintenance Review Board Report
Data / SoftwareJAR 25-1301
Aircraft Information System Security
(AISS)- A380 -
Maintenance Program Development
Page 9Page 9
Maintenance Program Development
The MRBR ProcessThe European Aviation Safety Agency (EASA)
Federal Aviation Administration (FAA)
Transport Canada (TCCA )
regulations
require the A/C Type Certificate holder
to prepare, revise as necessary and submit for approval to the relevant Airworthiness Authorities
the Initial Minimum Scheduled Maintenance Requirements
that are applicable to a dedicated Aircraft family.
Page 10
Maintenance Program Development
The MRBR Process
EASA FAA
EC Regul 2042/2003 – Annex I = Part M
Regulationsmandate establishment of maintenance tasks / requirements
Advisory Materialspropose MRB process / Organization as Means of Compliance
AC 121-22MRB Work instructions
Ref: IO11 Maintenance Review Board Team
Part 121
Page 11
The final aim is to compile a Maintenance Review Board (MRB) Report proposal
that is acceptable to the Maintenance Review Board (MRB).
Maintenance Program Development
The Initial scheduled maintenance requirements establishment requires a collaborative work, in order to combine knowledge and experience, between :
• Customer airlines• Aircraft manufacturer • Regulatory advisors
MRB Report
Once approved by the MRB, this proposal becomes the
Page 12
MPP MRBMWG 1 MWG 3 MWG 2
MWG 6 MWG 5 MWG 4 ISC: Industry Steering Committee
MWG: Maintenance Working GroupMPP: Maintenance Program ProposalMRB: Maintenance Review Board
•Policies•Procedures•Evolutions for new MRBR rev•…
Maintenance Program Development
The MRBR Process
ISC
The ISC - owns the MRBR process (policies, targets…) - validates the content of the MRBR and submits to MRB
Page 13
M12
Type Certificate
M13
1st MSN EIS
1st MSN operational
A/C Production
Last MSN operational lifeLast MSN EIS
A/C Devlpt
(5, 6 years)
A/C IN SERVICE > 50 yearsMAINTENANCE
MRB Process …
Safety + availability & reliability at minimum cost
Maintenance Program Development
Page 14Page 14
Maintenance Program Development
The Method: MSG-3 “Maintenance Steering Group - 3
Written by the Maintenance Steering Group - 3 Task Forceorganized under the leadership of the A4A (former ATA).
The MPIG: Maintenance Program Industry Group
4 Major sections
• Systems / Powerplant, including components and APU’s
• Aircraft structure• Zonal inspections• Lightning / High Intensity Radiated Field
(L / HIRF)
Page 15Page 15
“Airline and manufacturer experience in developingscheduled maintenance for new aircraft has shown thatmore efficient programs can be developed through the useof logical decision process”
Objective of the MSG-3 DocumentTo present a means for developing the scheduled
maintenance tasks and intervals which will be acceptable to the regulatory authorities, the operators,
and the manufacturers.
MSG-3 is a method to develop maintenance tasks
The Method: MSG-3
Maintenance Program Development
Page 16
Development of the MSG Methodology
Maintenance Evaluation and
ProgramDevelopment
MSG-1
Prepared by:747 Maintenance
Steering Group
Date: July 10, 1968Aug. 1, 1968June 1, 1969
Airline / Manufacturer Maintenance ProgramPlanning Document
MSG-2
Prepared by:R&M Subcommittee
Air Transport Association
Date: March 25, 1970
Boeing 747Douglas DC-10
Lockheed L-1011
Airbus A300B2/B4AS/BAe Concorde
VFW 614
A310/A300-600A318/A319/320/A321
A330/A340B757/767/777
European Maintenance System
Guide
EMSG
Prepared by:Association of European
Airlines
Date: July 1972 August 1972Sept. 1972February 1973
Airline / Manufacturer Maintenance Program
Development Document
MSG-3
Prepared by:MSG-3 Task Force
Air Transport Association
Date: September 30, 1980March 31, 1988 - Rev.1 Sept. 12, 1993 - Rev.2
Maintenance Program Development
The Tool: MSG3
Page 17
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2001.1
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2002.1
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2(1993)
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2003.1
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2005.1
A380
A400M
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2007.1
A350
XWB
Maintenance Program Development
The Tool: MSG3 - evolutions
Page 18Page 18
ATA MSG-3Operator/Manufacturer
Scheduled Maintenance Development
Revision 2007.1
A350
Scheduled Maintenance
Policy and ProceduresHandbook
Relationship of MSG-3 Document and PPH
Maintenance Program Development
The Tool: MSG3 – Policy & Procedures Handbook (PPH)
The ATA MSG-3 document no procedures/details necessary for analysis. Additional guidance on details of analysis procedures required
• Interpretation of rules, interval selection, etc.
• Form sheets
• Detailed work steps, responsibilities and scheduling
Page 19
Maintenance Program Development
The Tool: MSG3 – Policy & Procedures Handbook (PPH)Table of contents
Cover pageAcceptance letterRecord of revisionsHistory of changesTable of contents
Section 1 - IntroductionSection 2 - Organization and administration Section 3 - Analysis procedure - GeneralSection 4 - Systems and Powerplant analysis procedureSection 5 - Structure analysis procedureSection 6 - Zonal and L/HIRF analysis procedureSection 7 - Type certification interface
Appendix A : reference documentationAppendix B : A380 MSG3 Analysis form sheetsAppendix C : Corrosion Rating TablesAppendix D : Glossary, acronyms and abbreviationsAppendix E : Meeting scheduleAppendix F : OrganizationAppendix G : Required data for MWG Report to ISC
SCHEDULED MAINTENANCE DEVELOPMENT
AA338800PPOOLLIICCYY AANNDD PPRROOCCEEDDUURREESS
HHAANNDDBBOOOOKKFor further information about this handbook, please contact:
AIRBUS S.A.S.Customer Services Directorate
Maintenance Engineering DepartmentB.P. No. 33, 31707 Blagnac Cedex, FRANCE
REFERENCE: 95A.1689/02ORIGINAL ISSUE: December 2002
Page 20
Applicability (e.g A380)A380-800
Aircraft Utilisation Assumptions (e.g A380)2000 to 6000 FH per year360 to 1100 FC per year
A380-840
A380-860
1000 2000 3000 600050004000 7000 8000 9000
200
400
600
800
1000
1200
A380 PPHAircraft utilisation
assumptions
FH/year
FC/year
Routine use of A380 on short haul routes (higher FC
per year) not covered
These figures are used as a reference but not as a limit
of validity
Medium / Long Haul routes
Maintenance Program Development
Page 21
Interval Frame (example A380)Usage parameters versus letter intervals
Flexible concept planning can be optimised according to actual aircraft operationTask interval not influenced by planning concerns
A380 Design Objectiveno scheduled maintenance requirement below 750FH at EISStructure Inspections
design compatible with no scheduled maintenance
requirement below 1000FH
Exception may be granted for
corrosion sensitive areas
EnvironmentalDeterioration
Fatigue Damage
Initial Inspection /Threshold
Repetitive Interval
12 years 6 years
7600 FC 56000FH
3800 FC28000 FH
Maintenance Program Development
Page 22
Before launching the MRB process with the customers, the TC Holder can call for MRB kick off meetings to:
• Present the project
• Present the major content of the PPH
• Identify any show stopper
• Set up an acceptable PPH quality level before presentation to the customers
The PPH must be approved by the ISC and accepted by the MRBs before starting the technical activities
Maintenance Program Development
Page 23
Maintenance Program Development
The MRBR Process: implementation
The Type Certification Holder calls for the 1st ISC meeting:• Presentation of the project
Major descriptions of Aircraft design & novelties
Validation of the MWGs
• Introduction of the manufacturer teamISC Co Chair assistantMWG Chairs
• Presentation of the MRB team
• Presentation the major contents of the PPH
• Election of the ISC Chair
• Presentation of the macro planning up to 1st MRBR submission for approval
Page 24
Maintenance Program Development
The MRBR Process: implementation
•Before the start of the MWG activities, all the participants must be trained on
• General aircraft features
• The MRB Process, the PPH and MSG3 method
•The objective is also• Ensure efficient discussions during MWG and ISC meetings
• Ensure common understanding of the process and the objectives by operators, authorities, suppliers…
Page 25
Maintenance Program Development
Once the training is completed, the PPH may need to be revised according to feedback from the Q&A sessions and validated by the ISC
The detailed MWG activities can start
44 45 46 47 48 49 50 51 52 53week
A350 Planning - 2009
Training sessions
Page 26
Maintenance Program Development
Based on ISC instructions / PPH and aircraft design maturity the detailed technical MWG activities can start in the different MWGs
MWG 1: Hydraulics & Flight Controls
MWG 2 : Environmental
MWG 3 : Power Plant APU
MWG 4 : Avionics
MWG 5 : Structures
MWG 6 : Zonal
MWG 7: Fuel
MWG 8: Landing Gears
MWG 9: Interior
Page 27
Maintenance analysis processes
Systems & Powerplant
StructureZonal & L/HIRF
The three processes are both complementary and concurrent
The PPH and the MSG3 analyses
Maintenance Program Development
Page 28
The MWGs / ISC first proceed in selecting the MSIs and SSIs and Zones on which the detailed analyses will later be performed. This approach remains very conservative
Maintenance Program Development
Page 30
Function 2Function 1 Function 3
Failure Cause 2
Failure Cause 1
Failure Cause 3
Functional Failure B
Functional Failure A
Functional Failure C
Functional Failure D
Failure Effect
Maintenance Program Development
Data Sheet BSystem / Powerplant MSG3 analyses
Page 31
Function Functional Failure Failure Effect Failure Cause
Maintenance Program Development
System / Powerplant MSG3 analysesData Sheet B
Page 32
Economic effectsNo
7
Non-safety effectsNo
9
1) failure evident or hidden ?
Yes
2) Safety effect ?No
3) add second failure -->
safety effect ?
Safety effectsYes
8
No
4) operational or economic effect ?
YesOperational effects
6Safety effects
Yes
5
Maintenance Program Development
Level 1 AnalysisSystem / Powerplant MSG3 analyses
5, 6, 7, 8 & 9 = FEC
Failure Effect Category
Page 33
Level 2 Analysis
Task Selection Question 8ALUBRICATION/SERVICING
INSPECTION/FUNCTIONAL CHECK
RESTORATION
DISCARD
Task Selection Question 8C
Task Selection Question 8D
Task Selection Question 8E
LUBRICATION or SERVICING TASK ?
NOYES
YESNO
NOYES
YESNO
OPERATIONAL/VISUAL CHECKTask Selection Question 8B
FAILURE FINDING CHECK ?
YESNO
CHECK FOR DEGRADATION ?
RESTORATION ?
DISCARD ?
TASK/COMBINATION MOSTEFFECTIVE MUST BE DONE
REDESIGN IS MANDATORY
Task Selection Question 8F
NO
YES
TASK or TASK COMBINATION ?
System / Powerplant MSG3 analyses
Maintenance Program Development
Page 34
Level 2 AnalysisSystem / Powerplant MSG3 analyses
Maintenance Program Development
Initial Task Interval Selection
Letter interval (e.g. A or C):•former concept (A # FH, C # calendar)
•Planning considerations in interval selection
•Misleading and conservative
Usage Parameter:•Technically correct
•Unit=f(function degradation or failure mode)
•Several parameters possible:FH, FC, Calendar…
Interval Figure:Shall answer the question:
How long can I stand with the failure unfixed or before detecting degradation?
Answer based ontests and technical analysis,Vendor RecommendationsCustomer or other similar inservice experience
Engineering Judgment.
Page 35
MSI Analysis DocumentationAdministrative PagesData Sheet AData Sheet BLevel 1 and 2 Analyses for each Functional FailureTask Summary SheetMRBR Interface SheetTask Data
System / Powerplant MSG3 analyses
Maintenance Program Development
Page 37
The actuating portions of items such as landing gear, flight controls, doors, etc. will be treated as systems components and will be analysed following the Systems/ Power Plant Analysis Procedure.
Maintenance Program Development
Attachment of the actuators to the airframe will be treated as structure.
Structure MSG3 analyses Definitions
AIRCRAFT STRUCTURE
All load carrying structures wings, fuselage, empennage, engine mountings, landing gear, flight control surfaces, and related points of attachment.
Page 38
Primary Structure Element (PSE)
element that contributes significantly to carrying of flight, ground, or pressurisation loads, and whose integrity is essential in maintaining the overall structural integrity of the airplane.
Structural Significant Item (SSI)any structural detail, element or assembly whose failure could affect the structural integrity necessary for the safety of the aircraft.
Other Structurejudged not to be a Structural Significant Item.
Maintenance Program Development
Structure MSG3 analyses Definitions
Page 39
Non-metallic structure…graphite epoxy (CFRP), boron epoxy, fibreglass (GFRP), aramidefiber (AFRP – such as kevlar epoxy), acrylics,…
GLARE…hybrid material…Al Alloy 2024T3 + glass fibre/adhesiveFor MSG-3 analysis purposes, it will be treated as Metal.
Maintenance Program Development
Structure MSG3 analyses Definitions
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