4 September 2015 Aircraft Maintenance Module1 Aircraft Maintenance Management Module Maintenance & Engineering Gen Organization Structure

April 19, 2023 Aircraft Maintenance Module 1

Aircraft Maintenance Management Module

Maintenance & Engineering Gen Organization Structure

Maintenance & Repair (MRO) Organisation Structure Maintenance & Repair (MRO) Organisation efficient

Structure will vary according to the size and type of the airline(organisation) and management philosophy of the Airline.

The MRO structure must allow the airline to meet its strategic goals/objectives

The following is an example of what could be referred to an efficient Engineering and Maintenance Organisation structure(emirates case).

In the next few slides and to the rest of this chapter, will endeavour to review separately and in great detail each business unit of this structure.


However before we go into details of these units, we need to understand the hierarchy of the maintenance and Engineering structure starting from the EVP level and continue downward with designators to DSVP, VP, Managers and supervisors as appropriate. Emirates Airlines used as test case example.



Engineering Systems

Emirates Engineering operates an organisation-wide, standardised technical environment, which is managed and maintained by the Engineering Systems section. It provides information systems and enables function integration, resource optimisation and improvements in technical reliability to the Engineering department. Constant efforts of improving these information systems will continue to provide support to all engineering departments, which will produce further benefits.


Engineering Systems functions

Business user solutions to support Business Process Implementation, Integration and Information solutions to carry out assigned roles in most efficient and effective way.

Enable safe, secure and efficient management of Business Solutions, the section coordination with Emirates Group IT to deliver hardware, software & Infrastructure Support for smooth Business Operation.

Engineering Systems support team is in continuous liaison with Business Focal to ensure timely system support for on-going systems and evaluating Induction of new systems.


QUALITY ASSURANCE

The Quality Assurance section monitors all technical and technical support functions within the company to ensure that they comply with engineering procedures and remain within the scope of the Terms of Approval and requirements of the GCAA as published.

Technical Resources Centre

a) The Technical Resources Centre holds and makes available to personnel, a range of technical publications appropriate to the class of work covered by the company

approval. It makes suitable arrangements to ensure these documents are maintained at the latest state of amendment.


UAE Quality Model- Emirates

When it comes to Quality, Emirates Engineering prides itself on having the highest possible standards. Which is why the UAE GCAA, EASA 145, FAA 145 and ISO 9002 Quality Assurance is such a vital addition to Emirates engineering activities, allowing monitoring and approving of work as well as liaising between Emirates and foreign airworthiness authorities for whose aircraft Emirates Engineering undertakes maintenance. Emirates Engg is approved by three airworthiness authorities - the UAE General Civil Aviation Authority, the European Aviation Safety Agency and USA Federal Aviation Authority, to undertake aircraft maintenance.


UAE QA Cont’d

Additionally, Emirates Engineering holds ISO 9002 accreditation.

At Emirates, a wide range of intensive technical training programmes is provided covering the whole range of engineering disciplines, including courses in type training, servicing, procedures and systems - all backed up by closely supervised on-the-job-training.

The Emirates Engineering Training School holds both GCAA and EASA 147 approval. Emirates in apprentice training, carefully selected school leavers may


UAE QA Cont’d

join the Company on a three and a half year apprenticeship, approved by the General Civil Aviation Authority, which includes workshop, on-the-job and classroom training and leads to accreditation as a skilled aircraft mechanic. Fully equipped to ICAO standards, Emirates extensive training facilities include basic engineering, machine welding, composites repair, airframe, engines and avionics workshops. Graduates from the apprenticeship may then acquire an Aircraft Maintenance Engineer's Licence and subsequent type approvals.


UAE QA Cont’d

Approved aircraft type training is conducted on Airbus A330, A340-300, A340-500, A380 and Boeing 777-200/200ER/200LR/300/300ER and -200LRF variants plus the B737NG aircraft.

Courses on these aircraft are available in Airframe, Engine and Electrical/Avionics trades that meet both EASA Part 66 level l, 2 and 3 and ATA 104 Level l, 2, 3 and 4 standards.

Aircraft training utilities include advanced computer-based training systems and Ground Based Maintenance Training Devices for the A330, A340, B777 and A380 aircraft.


BASE MAINTENANCE & WORKSHOPS

a) The function of the Base Maintenance section is to carry out all routine scheduled maintenance tasks and any unscheduled major repair, replacement and modifications on company operated aircraft.

b) This will consist mainly of planned maintenance inputs extracted from the applicable Approved Maintenance Schedule including replacement of time expired equipment, component repair, modifications and any specific inspections which may be required as approved by the GCAA.

c) In support of this activity, various workshops are available and will undertake component, structural and avionic overhauls within the limits of the Terms of

Approval and Capability Lists applicable to them.April 19, 2023 Aircraft Maintenance Module 12

UAE Base Maint- Emirates Base Maintenance conducts all levels of scheduled and

unscheduled maintenance including major repairs, replacements and modifications. Our fully qualified personnel, with vast expertise in meeting critical dedicated downtimes, provide the necessary support in maintaining consistent reliability to the operation.

All Heavy Maintenance work is located within a state-of-the-art hangar complex, able to accommodate all wide-bodied aircraft through a fully computerised docking system.

Heavy Maintenance supports all levels of 'C' Checks, major modification, aircraft redeliveries, inspection programmes on Airbus/Boeing aircraft and major structural modifications on the Airbus fleet.


Line & Base Maintenance

Whether at its home base in Dubai, or at one of the many 'outstations' served by the airline, Emirates Engineering can provide line maintenance support to third party airlines. Comprehensive engineering services are provided and supported by sophisticated ground equipment, specialist vehicles and high IV qualified engineers.

Dubai The Engineering Line Maintenance Department in Dubai

provides 24 hours support for all Emirates aircraft and those of our customer airlines.


Line Maintenance cont’d

Engg teams of licensed engineers, recruited from“ around the world, hold licences issued by several authorities, including the GCAA, EASA and FAA, in airframe, engine and avionics categories. This is supplemented by full aircraft type training for all fleet types handled.

In addition to the Emirates fleet of Boeing B777, Airbus A330, A340 and A380 aircraft, we also provide services supporting more than 30 customer airlines' aircraft, including the B737NG, B747-400, A330 and A340.


Maintenance Control Centre (MCC)

MCC coordinates core departments and external handling agencies to ensure prompt aircraft turnaround times, with minimum technical delays using our state-of-the-art systems.

MCC plays a pivotal role in aircraft "on-ground situations", requiring skilled and dynamic responses. MCC is staffed 24 hours a day with dedicated senior engineers, who liaise close with operational departments and flight crew to help ensure Emirates operations run smoothly and to minimise the impact of unscheduled maintenance/technical delays.


Base Operations & Outstations

Base Operations Maintenance supports scheduled and unscheduled maintenance activity, including service, weekly and 'A' checks, to full casualty support to the Emirates fleet. At all outstations, Line Maintenance selects the most appropriate form of maintenance support from several available options to suit our own needs and that of our customers. For details on outstation capability, please refer to the insert on the last page.


Overhaul Workshops Emirates Engineering Overhaul Workshops are state of-

the-art facilities that offer an extensive range of services and support for an ever-growing variety of aircraft, including components for the A380, A330, A340-300/S00 and B777 series. The workshops are also capable of offering other support services such as Non-Destructive Testing (NDT), tool calibration and aircraft weighing. With a wide variety of support services, competitive rates and excellent turnaround times.

Safety Workshop is designed to meet all safety equipment requirements, including survival kits, life vests, stretchers and oxygen masks and offers coverage on slides/rafts. Hydrostatic Testing facility for cylinders and gas bottles.


Cabin Maint Workshop

The latest addition to the Cabin Interiors Workshop this year is a state-of-the-art cabin sidewall panel laminating machine capable of covering all current wide and narrow body aircraft sidewall panels, quickly and efficiently, in a dedicated workshop area.

Also recently installed is a fully automated aircraft carpet-cutting machine. It operates from a drawing database and cuts carpet to the required shape and quantities by simply uploading drawings into the AutoCAD system and the machine does the rest.


Cabin Maintenance cont’d


The Cabin Workshops perform testing, repair, overhaul and modifications of interior soft furnishings, seats and safety equipment installed across the Emirates fleet to ensure the highest standards of interior functionality and presentation is achieved. The Cabin workshops comprise:

Evacuation and Safety Workshop - performs repair, overhaul and modification of escape slides, slide/rafts, ramp and over-wing slides, life jackets, baby-cots, fire extinguishers, oxygen masks, cockpit seats of A310, A330, A340, A380, B777ER and ULR fleets.

Cabin General Workshop- performs repair, overhaul and modifications of passenger seats, galleys, lavatories, carpets and general furnishing items on the A330, A340,A380, B777ER and ULR fleets

Avionics Workshop

Avionics Workshop offers extensive cover for many of the avionics component fitted throughout fleet. A large dedicated Automatic Test Equipment Complex (ATEC) machines available with level two repair capability along with new ATEC Series 6 machine, which supports A380 aircraft rotable units. battery condition checks, oxygen charging, software development, customised development of Airshow system or even electrical and radio components, this dynamic workshop is more than capable of meeting all avionics maintenance requirements.


Airframe workshop Our impressive Airframe Workshops are capable of

offering Non-Destructive Testing to level three requirements with coverage for a wide variety of tests and aircraft, including:

• Magnetic Particle testing

• Penetrant, Eddy Current and Ultrasonic testing

• Wheel and brake support for various fleet of Airbus/Boeing Equipment

Coverage on Honeywell, Goodrich and Messier Bugatti wheels and brakes, electrical, pressure, torque, mass tools and equipment. Extensive coverage and support on engine Nacelle components

• Structural, metallic and composite repairsApril 19, 2023 Aircraft Maintenance Module 22

Emirates Engine Test Cell

Emirates Engine Test Cell is the largest facility of its kind in the Middle East and one of the most modern globally. This state-of-the-art facility is built on a 24,000 square metre site and includes an engine preparation area covering 3,250 square metres, dedicated to 6-engine work stations, each served by a 30-tonne crane. The system is interconnected by monorail with a bridge and turntable, which links the preparation area to the test cell chamber, making internal engine movement easier' to achieve.

The Engine Test Cell has been built to prepare and test engines with thrust levels of up to l50,000 ps of thrust, far in excess of what manufacturers produce today or are planning for or in the foreseeable future.April 19, 2023 Aircraft Maintenance Module 23

Test Cell cont’d

The Test facility is certified by GCAA, EASA and FAA to test a large spectrum of Jet Engines such as General Electric GE90-11SB (B777), Engine Alliance GP7200 (A380), Rolls-Royce Trent 500 (A340-S00), Rolls-Royce Trent 700 (A330) and Rolls-Royce Trent 800 (B777); Auxiliary Power.

Units (APU) Honeywell GTCP331-3S0 (A330/A340), GTCP331-S00 (B777) and GTCP331-600 (A340-S00).


Test Cell cont’d The APU Test Cell has been designed and built to test

different types of APU's including the APU installed on the latest A380 Aircraft.

With a capacity to test 300 engines and APU's per year - efficient test centre was designed to meet all stringent regulations for noise emissions and waste management, in addition to all safe and environmental requirements.

Emirates Engine Test Cell has set the standards of excellence in the aero engine testing industry by working in collaboration with the most Engine manufacturers, such as Rolls-Royce, General Electric, Engine Alliance and Honeywell to support Emirates ever-growing fleet and

third party requirements within the region and globally·April 19, 2023 Aircraft Maintenance Module 25

Engineering Planning

The Planning Section identifies and plans the routine maintenance program, remaining within the constraints of the applicable Approved Maintenance Schedule and any other applicable mandatory requirements.

Technical Records

a) The maintenance of a complete and comprehensive technical record of each Company operated aircraft and associated equipment in accordance with the requirements of the GCAA and the relevant sections of engineering procedures.

Reliability Support


Aircraft configuration management and control Production of long and short-term maintenance plans

Development and management of aircraft and component maintenance schedules

Reliability programme development and administration for aircraft and components Technical records administration and control


Engineering Planning

Engineering Planning provides comprehensive planning and technical records services to the highest possible standards, ensuring efficient scheduling, administration, monitoring and control of maintenance activities using fully integrated computer platforms to provide optimum support.

Engineering Planning service provides: Preparation of work scopes and the production of

Maintenance Task Operating Plans [MTOP], Maintenance task cards, Job Instruction Cards [JIC] and Works packages Aircraft and component modification planning and control


Production Planning

Production Planning provides vital planning and support services for Base Operations, Base Heavy Maintenance and Workshops to carry out smooth and effective maintenance/repair on the Emirates fleet; with an aim of ensuring minimum aircraft ground time and in-house component repair turnaround time

highlights MQs and parts which have not yet issued to the package, displays all tasks which have a status other than in progress where user action might be required. Visibility to captured man-hours and available vs. consumed resources.


Production planning cont’d

Work Package management, flow of package tasks to assign schedule date to tasks using typical resource allocation and task estimated hours, manual Package Task Scheduling is also available. Graphical visibility to task schedule, duration, status and actual man-hours. Package Monitor gives graphical visibility to the package progress.

Pre-load Monitoring and Adjustment of where quantities and due dates of MQs can be adjusted. Extensive views and reports available for package progress management and monitoring, pre-load material availability and management, non-routine management and man-hours monitoring.


Modification Planning and Control Modification Planning and Control is a primary

component of the Engineering team. IT is one of the core sections in the Maintenance Planning department and has several roles and responsibilities, but the main role is controlling and planning of all modifications decided by Emirates to be incorporated in its fleet and the component thereof in line with the established and planned maintenance activities. The primary purpose of incorporating Modification in the aircraft maintenance cycle is to improve performance, safety and reliability of aircraft, engine and components. It is accomplished either by introduction of new/enhanced component/system or by alteration of items already fitted


Modification Planning: Mods planning use mainframe Mod Control module to record all SB's (Mods) that are required to be carried out on an aircraft and or component.

Materials required for the accomplishment of the Mods are requested through Purchase requests. The forecasting, planning and control of the modifications is achieved through using the Maintenance Requirements module.

The Mod Control System is also used for reporting the mods accomplished and pending to the regulatory authorities.


Reliability Reviews

a) Emirates Technical Services Engineers evaluate data obtained through pilot reports (pireps), premature component changes, strip reports, and various other

relevant documents, and make recommendations as necessary. A Reliability Engineer produces a monthly statistics report.

A.D., S.B., SIL and any other relevant documentation is reviewed for its applicability to Emirates aircraft and equipment.

Emirates modification committee will review all ADs, SBs, and SILs for their possible incorporation into Emirates aircraft or equipment.


Modifications not covered by the above, which are derived by Emirates will be submitted to the UAE GCAA for classification and approval.

LINE MAINTENANCE

The Line Maintenance section will carry out day to day maintenance on the company aircraft and those of other operators under contractual agreements.

The section liaise with operations and responds efficiently to requirements as they arise while ensuring sufficient serviceable aircraft are made available to satisfy the companies operational requirement.


Materials Management

The materials section supports the engineering production effort by procuring such material as is necessary for that purpose. While being mindful of cost, the section identifies and utilizes sources of supply acceptable to the company and the GCAA.

The section maintains a sufficient stock level to meet the companies operational requirement and keeps a comprehensive record of all stock movement

The section accepts, stores and reissues both aircraft and commercial material.

The section segregates the aircraft and commercial stores and further provides a quarantine and a bonded aircraft stores area IAW the airworthiness requirements.April 19, 2023 Aircraft Maintenance Module 35

Materials Management cont’d

The Materials Management Department is responsible for the spares supply chain strategy, policies and processes and optimises inventory investment and operating costs for the Emirates fleet.

This includes forecasting, planning, procurement, storing, usage monitoring, repairs, stock reviews, replenishment, obsolescence and disposal of materials.


Materials Management cont’d

The Material Management section is responsible for the development of policies, processes, procedures, systems and organisation to optimise the inventory investment and operating costs. This includes forecasting, procurement planning, storing, usage, repairs, stock reviews, replenishment, obsolescence and disposal of materials.

Emirates Engineering has modern logistics facilities. Inward aircraft material and equipment are thoroughly inspected to ensure the highest quality and airworthiness standards and thereafter, stored in fully air-conditioned and environmentally controlled stock rooms. High-rise racking and semi-automatic shuttle technologies are used to ensure efficient storage and retrieval


Materials Provisioning

The Materials Provisioning teams are organised along commodity lines; Cabin, IFE, BFE, Airframe and Engines. They are supported by the Inventory Systems and Operations support group.

The section's prime responsibility is to establish optimum re-order and safety levels, raise timely purchase requests and coordinate availability of items. It is also responsible for the entire inventory, including its data accuracy and follows the highest standards of quality and safety policies as defined by aviation agencies such as CAA, EASA, FAA and ATA. One of its core functions is to provide on-site

support for the critical/AOG requirements of all aircraft maintenance activity.April 19, 2023 Aircraft Maintenance Module 38

Component Management

The Component Management section is divided into three subsections: Component Repair, Material Planning and Pooling, Loans and Borrowing, and deals with high value rotable aircraft component assets.

This includes initial-provisioning, re-provisioning and optimising the inventory, as well as managing the repair and pooling of assets. By adopting supply chain management best practice, it maintains the highest quality standards and service levels at the lowest possible cost, end-to-end for the Rotable Assets.


Component Management cont’d

Component Management (CM) section deals with Rotable parts and aircraft assets. This includes initial provisioning, re-provisioning, optimising inventory, repair, overhaul, refurbishment, pooling and purchasing of assets such that the highest quality standards and service levels are maintained at lowest possible cost by adopting supply chain management best practice, performance metrics and processes.



An accurate stock control and comprehensive records of stock flow and an update of inventory is maintained by the materials section.

In the event of spares being obtained from other airlines, either as outright purchase, exchange or loan, the airline spares transfer procedure will be used.

Only airlines nominated by the General Manager Quality Assurance will be used, unless prior consent from the General Manager Quality Assurance or his authorized

deputy is obtained.



The company approval granted by GCAA requires that a provision is made for training personnel. This training will comprise of aircraft type training, aircraft servicing, company procedures and systems update training.

Aircraft type training in all disciplines will initially be carried out by the aircraft manufacturer, terminating in an examination which meets the approval of GCAA.

Emirates subsequently undertake to have additional staff who require the same standard of course to be trained by Emirates or a company approved by GCAA for that purpose.



Aircraft servicing courses designed to provide training for contracted outstation personnel will be carried out at Emirates by the contracted company training staff.

Company procedures training requirements will be identified by the Emirate General Manager Quality Assurance and carried out within the company.

Each course to be completed will require agreement by the General Manager Quality Assurance and the UAE GCAA. The time scale of OJT will depend upon the type of course, available training facilities and content of course, and the results of a Quality Assurance audit of the training facility.


Warehousing and logistics

Emirates Engineering has modern, state-of-the-art Stores and Logistics facilities. Aircraft materials and equipment are thorough IV inspected at receipt to ensure the highest quality and airworthiness standards, then stored in fully air-conditioned and environmentally controlled stock rooms. High-rise racking and semi-automatic shuttle technologies are used to ensure efficient storage and retrieval.

A spares supply service and AOG support is provided 24 hours a day in Dubai, as well as at Emirates outstations. Being a member of the IATP, spares and equipment are pooled at most stations.


Engineering Projects

Engineering Projects are experts in the evaluation, recommendation, specification and negotiation of aircraft acquisitions. The team monitors projects from inception, through the inspection phase during aircraft assembly, right until delivery and acceptance. Qualified and experienced engineers will:

• Evaluate and recommend BFE and SFE

• Define BFE and establish budget

• Work to establish own specification

• Monitor BFE

• Ensure defined specifications are complied with


Engineering Projects cont’d

• Follow up and inspect aircraft during assembly Phase• Inspect and accept aircraft during delivery• Negotiate delivery commitments• Ensure the aircraft is service-ready for commercial use• Develop cabin layout and LOPA based on‘ specific needs

and ground rules• Design and develop configuration changes to cabin and

aircraft interior


Inflight Entertainment &Cabin Interiors Provides technical support services for the industry most

sophisticated, state-of-the-art I FE systems,

including audio/video on-demand (AVOD) systems, SMS/emails, SATCOM, telephone, air show moving map, games, connectivity /and the related software controls.

Provides technical services for passenger compartment and flight deck seats, galley/s, toilets, stowage structures, interior markings, emergency/equipment, seat controls, galley/equipment and systems.


This section also designs and implements in-house cabin reconfigurations in accordance with Emirates demanding brand standards. It also prepares and manages retrofit configuration layouts and carries out in-house modifications to bring aircrafts up to Emirates operating standards


TOTAL CABIN MAINTENANCE (TCM)

The Total Cabin Maintenance department is responsible for carrying out day to day maintenance of both Cabin and IFE systems installed on company aircraft.

The section will liaise with both Line Maintenance and MCC to ensure that serviceability of Cabin and IFE systems is maintained, so as to satisfy the company’s operational requirements.


Aircraft Maintenance Management

Introducing Aircraft Maintenance Management, adopting an efficient maintenance programs and Understanding all relevant tools and techniques will bring the following benefits to the Airline organisation:

1. Maintain Aircraft to a high standard and subsequently save money.

2. Minimize aircraft downtime while slashing maintenance and repair costs.

3. Apply systems concepts for improved integration and communication.

4. Upgrade technical and provisioning functions.


5. Improve efficiency in meeting regulatory requirements

6. Identify and monitor maintenance program problems/trends.

7. Stay on top on quality assurance, quality control, reliability standards and safety matters.

8. Adjust and tune the organisation approach towards human factors in maintenance.


Documents

4 September 2015 Aircraft Maintenance Module1 Aircraft Maintenance Management Module Maintenance & Engineering Gen Organization Structure