Scheduled Maintenance Program Seminar - 4. Maintenance Program Establishment-Part1

7/29/2019 Scheduled Maintenance Program Seminar - 4. Maintenance Program Establishment-Part1

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1. Introduction

2. Maintenance Program (MP)

3. Scheduled Maintenance Development

4. Maintenance Program Establishment

5. Maintenance Concept

6. Maintenance Planning

7. Conclusion

1

Table of Contents

Scheduled Maintenance Seminar





4 How to Build a MP

4 General Requirements

4 Maintenance Tasks coming from MPD

• MPD Presentation

• MPD Consultation

• MPD Customization

• MPD Customization examples

4 Component Maintenance Program

4 Operator Specific Tasks

4 STC Requirements

2

Table of Contents






4 Reliability Program

4 Revision Management & Optimization Process

3

Table of Contents



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Maintenance ProgramHow to build a MP

Maintenance Program

General RequirementsMaintenance Tasks

coming from MPD

Supplemental Type

Certificate Requirements

Reliability

Program

Operator/Specific

Maintenance tasks

Component

Maintenance Program

NOTE:

Airwor th iness Author it ies provide guidance to establish the maintenance program

- EASA Part-M

- FAA in FAR part 91, 121, 125 and 135

4




4 How to Build a MP4 General Requirements


• MPD Presentation• MPD Consultation





4 STC Requirements

5

Table of Contents





4 Reliability Program4 Revision Management & Optimization Process

6

Table of Contents




Maintenance ProgramGeneral Requirements

Maintenance Program

General RequirementsComponent

Maintenance Program

Maintenance Tasks

coming from MPD

Supplemental Type


Reliability

Program

Operator/Specific

Maintenance tasks

7

M i P



The maintenance program should contain basic information that couldbe broken down in two parts:

Part 1 - Descriptive data:

- The type/model and registration number of the aircraft, enginesand, auxiliary power units.

- The name and address of the owner, operator or approvedorganisation managing the aircraft airworthiness.

- The reference, the date of issue and issue number of theapproved maintenance program.

Maintenance ProgramGeneral Requirements – Descriptive Data

Source : EASA Commission Regulation (EC) No 2042/2003 Annex I AMC to Part-M

8

M i t P




- A statement signed by the owner, operator or approvedorganisation managing the aircraft airworthiness to the effectthat the specified aircraft will be maintained to the program andthat the program will be reviewed and updated as required.

- Contents/list of effective pages and revision status of thedocument.

- Procedures for the escalation of established check periods,where applicable and acceptable to the respective authority of registry.

- Provision to record the date and reference of approvedamendments incorporated in the maintenance program.


9

M i t P




- A cross-reference to other approved documents, which containthe details of maintenance tasks related to mandatory lifelimitations, Certification Maintenance Requirements (CMR’s)and ADs.

Note: To prevent inadvertent variations to such tasks or intervals these items

should not be included in the main portion of the maintenance program document,or any planning control system, without specific identification of their mandatorystatus

- A statement that practices and procedures to satisfy theprogram should be to the standards specified in the TC holder’sMaintenance Instructions. In the case of approved practicesand procedures that differ, the statement should refer to them.

- Each maintenance task quoted should be defined in a definitionsection of the program


10

M i t P




Part 2 - Task data:

- Check periods, which reflect the anticipated utilisation of theaircraft. Such utilisation should be stated and include atolerance of not more than 25%. Where utilisation cannot beanticipated, calendar time limits should also be included.

- Details of pre-flight maintenance tasks that are accomplishedby maintenance staff.

- The tasks and the periods at which each part and systems of the aircraft, (engines, APU’s, components, accessories,equipment, …) should be inspected. This should include the

type and degree of inspection required.

Maintenance ProgramGeneral Requirements – Task Data


11

M i t P





- The periods at which components should be checked, cleaned,lubricated, replenished, adjusted and tested.

- The periods at which overhauls and/or replacements by new or overhauled components should be made.

- Details of specific structural maintenance programs where

issued by the type certificate holder including but not limited to:a. Maintenance of structural Integrity by damage Tolerance and

Supplemental Structural Inspection programs (SSID).

b. Structural maintenance programs resulting from the SB

review performed by the TC holder.

c. Corrosion prevention and control.

d. Repair Assessment.

e. Widespread Fatigue Damage


12

Maintenance Program





- Details of ageing aircraft system requirements together with anyspecified sampling programs.

- Details of, or cross-reference to, any required reliability programor statistical methods of continuous Surveillance.


13

Maintenance Program




The respective authority should assess the contents taking into account

the origins of the document i.e. the manufacturers recommendedmaintenance program, a MRB report, the operators own experience or another approved program.



Instructions issued by the respective authority can encompass all typesof instructions from a specific task to complete recommendedmaintenance schedules that can be used by the owner/operator directly.

The respective authority should verify that the maintenance program isacceptable for the continued airworthiness of the specific aircraft listedand it is appropriate for the proposed operating environment and

scheduled utilisation.

14

Maintenance Program




The respective authority may approve an incomplete maintenanceprogram:

At the start of operation of an aircraft or an operator, in order to limit

the approval of the MP to a period that does not exceed anyrequired maintenance not yet approved.



If the respective authority is no longer satisfied that a safe operation can

be maintained, the approval of a maintenance program or part of it maybe suspended or revoked. Events giving rise to such action include:

An operator changing the utilisation of an aircraft;

The approved organisation has failed to ensure that the programreflects the maintenance needs of the aircraft such that safeoperation can be assured.

15





4How to Build a MP








4 STC Requirements

16

Table of Contents






4Reliability Program


17

Table of Contents


Maintenance Program




Maintenance Program


Maintenance Program

Maintenance Tasks

coming from MPD

Supplemental Type


Reliability

Program

Operator/Specific

Maintenance tasks

Maintenance ProgramMPD Presentation

18





4How to Build a MP








4 STC Requirements

19

Table of Contents






4Reliability Program


20

Table of Contents


Maintenance Program




Maintenance Program


Maintenance Program

Maintenance Tasks

coming from MPD

Supplemental Type


Reliability

Program

Operator/Specific

Maintenance tasks

MPD Presentation

21


Maintenance Program




Single Aisle Family • A318/A319/A320/A321 MPD

Wide Bodies Family • A300 MPD

• A300-600 MPD

• A310 MPD

Long Range Family • A330 MPD

• A340 MPD

Large Aircraft Family • A380 MPD

The MPD is an envelope document valid for all A/C of a given type.It is not customized to any specific operator or f leet.

The following Maintenance Planning Documents (MPD) arepublished:

22


Maintenance Program





The main objective of this document is to provide maintenance planning

information necessary for each operator to develop a customizedscheduled maintenance program.

The MPD is an AIRBUS envelope repository document which providesdirect access to most of the repetitive maintenance tasks required bymiscellaneous source documents.

The MPD is neither a CONTROLLING document nor an APPROVEDdocument.

23

Maintenance Program




The MPD covers maintenance, which is

; scheduled, : not unscheduled maintenance.

; on aircraft level, : not on component level.

; routine maintenance, : not troubleshooting/defect correction.

; repetitive, : not one time inspections / tasks.

;already mandated or recommended

by various source documents, :not any additional stand-alone

maintenance requirements.


24

Maintenance Program




Maintenance requirements may differ in data format, layout, and information

types. Maintenance

Requirement

General visual

inspection of pump…

Interval: 6 Months

Maintenance

Requirement

Perform a detailed

inspection of piston each

500 FH

Applicabi li ty: All

… …

Maintenance requirements are issued by different parties.

MRB/ISCOther Aviation

Author it iesFAAEASA

AirbusEngineering

Ai rbusCustomer Service

…

The MPD gathers these maintenance requirements and adds supplemental

information such as zone, access, preparation, man-hours.

Original data from source

document

Supplemental data added in the MPD

25

gMPD Presentation

Maintenance Program




The MPD provides links to AMM procedures.

In addition, the MPD is updated in line with

the AMM issue cycle.

AMMMPD

• Synchronized issue dates

• connected via hyperlinksMRBR

ALS Parts

SB, AD, SIL, AD, …

AVAILABLE

IN AIRN@VNOT AVAILABLE

IN AIRN@V

MRBR, ALS Parts and other scheduled

maintenance documents do not provide

information how to carry out the

maintenance tasks.

Procedure details are explained in the AMM.

AMM[

gMPD Presentation

26

Maintenance Program




The MPD provides information about the

WHATWHEN

WHERE

WHO

of maintenance.

The AMM provides information HOW to perform maintenance in detail.

gMPD Presentation

27

Maintenance ProgramMPD P i S h d l d M i P




MSG3

AnalysesMRB

Report

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

AMM

AOT

SIL

SB

MPD

AD

/

CN

System

Safety

Analysi s(SSA) + -

ALS Part 5

FAL

Document

Damage

Tolerant

Analysis

+

Full Scale

Fatigue

Test results

OMP

EASA Certification Approved

In service experience

feedback

Airl ine Local

Authorit ies Approved

NTM

CMMVendor

ReqNational

Requirements

Manufacturer - EASA CS 25 Operator

EASA Part M

Customization

gMPD Presentation: Scheduled Maintenance Process

28

Maintenance ProgramMPD P t ti S h d l d M i t P




MSG3

AnalysesMRB

Report

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

AMM

AOT

SIL

SB

MPD

AD

/

CN

System

Safety

Analysi s(SSA) + -

ALS Part 5

FAL

Document

Damage

Tolerant

Analysis

+

Full Scale

Fatigue

Test results



feedback

Manufacturer - EASA CS 25

MPD Presentation: Scheduled Maintenance Process

29

- Consolidation over the different sources

- Revised each time the “MPD baseline” source

document is revised at the exception of Life

Limited Parts


Maintenance Program




MRB

ALI

MPD Presentation

30

Maintenance ProgramMPD P t ti




T : 12 YE

I : 6 YE

MPD Presentation

31

Maintenance ProgramMPD P t ti




T: 3200 FC I: 8000 FC

MPD Presentation

32





MPD Presentation

T : 12 YE

OR

32000 FC

I : 6 YE

OR

8000 FC

33

Maintenance ProgramMPD Presentation: Scheduled Maintenance Process




MSG3

AnalysesMRB

Report

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

AMM

MPD

System

Safety

Analysi s(SSA) + -

ALS Part 5

FAL

Document

Damage

Tolerant

Analysis

+

Full Scale

Fatigue

Test results


Manufacturer - EASA CS 25

MPD Presentation: Scheduled Maintenance Process

34


- Revised each time the “MPD baseline” source

document is revised at the exception of Life

Limited Parts

AOT

SIL

SB

AD

/

CN


feedback

Maintenance ProgramMPD Presentation In service experience




MPD Presentation – In-service experience

AD/CN, ISB, SIL, AOT is incorporated into MPD if :

Maintenance repetitive Inspection Requirement

(No « One Time » inspections)

No repetitive inspection following a repair

Affecting a significant number of aircraft

35

Maintenance ProgramMPD Presentation Sectioning




Sectioning

MPD*

Section 3

Structure

Section 2

System_APU_and_Power-Plant

Section 4

Zonal

AppendixSection 1

General Introduction

36

MPD Presentation – Sectioning

Maintenance ProgramMPD Presentation –Transmittal Letter




It provides information regarding:

- instructions

- reason for revision with revision of document sources

- highlights of changes/important notes

37

MPD Presentation –Transmittal Letter

Maintenance ProgramMPD Presentation – General Introduction




MPD Presentation General Introduction

MPD*

Section 3Structure

Section 2


Section 4

Zonal

AppendixSection 1


38

Maintenance ProgramMPD Presentation – General Introduction




This section provides information regarding :

- MPD general policy

- MPD Scope & Purpose

- Normal utilization for a given A/C type

- Revision Policy

- Overall program description

- Inspection interval policy (usage parameter concept, mixed concept)

- Abbreviations

- Effectivity_Cross_Reference_List

- Service_Bulletin_List- ….

39

MPD Presentation General Introduction

Maintenance ProgramMPD Presentation – System APU and Power-Plant




MPD Presentation System_APU_and_Power Plant

MPD*

Section 3Structure

Section 2


Section 4

Zonal

Appendix

Section 1


Cross Ref List

40

Maintenance ProgramMPD Presentation – System APU and Power-Plant




This section includes all the scheduled maintenance tasks related to theaircraft systems and components, the APU and the powerplants.

41

y _ _ _

Maintenance ProgramMPD Presentation – Structure




MPD*

Section 3Structure

Section 2


Section 4

Zonal

Appendix

Section 1


Cross Ref List

42

Maintenance ProgramMPD Presentation – Structure




This section provides the basic scheduled maintenance tasks andfrequencies applicable to the aircraft structure

43

Maintenance ProgramMPD Presentation – Zonal




MPD*

Section 3Structure

Section 2


Section 4

Zonal

Appendix

Section 1


Cross Ref List

44

Maintenance ProgramMPD Presentation – Zonal




This section provides the General Visual Inspection (GVI) requirements for eachaircraft zone to inspect system and powerplant installations for security and generalcondition, structure for general condition and Electrical wiring installation for generalcondition

45

Maintenance ProgramMPD Presentation – Layout: Revision Codes




R: Revised

N: New

D: Deleted

Revision

Code

46

Maintenance ProgramMPD Presentation - Layout: Task Number




213100-01-1

213100: ATA reference

01: Sequence number

1: Applicability index

TASK

NUMBER

47

Maintenance ProgramMPD Presentation - Layout: Zones




200: Major zone

220: Major sub-zone

221: Specif ic zone

ZONE

48

Maintenance ProgramMPD Presentation – Layout: Skill Codes




DESCRIPTION

SKILL

CODE

49

Maintenance ProgramMPD Presentation – Layout: Skill Codes




SKILL

CODE

50