Scheduled Maintenance Seminar Part1 May2013

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



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.


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.

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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.


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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


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 -


Page 9Page 9


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.

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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).


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

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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•…


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


Page 14Page 14


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)

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“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


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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


The Tool: MSG3

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ATA MSG-3Operator/Manufac

turer

Scheduled Maintenance Development

Revision 2001.1


turer


Revision 2002.1


turer


Revision 2(1993)


turer


Revision 2003.1


turer


Revision 2005.1

A380

A400M


turer


Revision 2007.1

A350

XWB


The Tool: MSG3 - evolutions

Page 18Page 18

ATA MSG-3Operator/Manufacturer


Revision 2007.1

A350

Scheduled Maintenance

Policy and ProceduresHandbook

Relationship of MSG-3 Document and PPH


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

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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

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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


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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


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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


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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

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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…

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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

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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

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Maintenance analysis processes

Systems & Powerplant

StructureZonal & L/HIRF

The three processes are both complementary and concurrent

The PPH and the MSG3 analyses


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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


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System / Powerplant MSG3 analyses

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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


Data Sheet BSystem / Powerplant MSG3 analyses

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Function Functional Failure Failure Effect Failure Cause


System / Powerplant MSG3 analysesData Sheet B

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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


Level 1 AnalysisSystem / Powerplant MSG3 analyses

5, 6, 7, 8 & 9 = FEC

Failure Effect Category

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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 ?



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Level 2 AnalysisSystem / Powerplant MSG3 analyses


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.

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MSI Analysis DocumentationAdministrative PagesData Sheet AData Sheet BLevel 1 and 2 Analyses for each Functional FailureTask Summary SheetMRBR Interface SheetTask Data



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Structure MSG3 analyses

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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.


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.

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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.



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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.



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Accidental Damage…caused by contact or impact with an object or influence which isnot part of the aircraft, or by human error during maintenancepractices…



Documents

Scheduled Maintenance Seminar Part1 May2013