Scheduled Maintenance Seminar Part5 May2013

MSG3Analyses

MRBReport

MPD

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

System Safety

Analysis(SSA)

ALS Part 5

FALDocument

Damage TolerantAnalysis

+Full Scale Fatigue

Test results

EASA Certification Approved

Maintenance Schedule Development

OMP

Approved by local AA

Airlinetasks

National Requirements

Manufacturer Operator

A/C configuration

Customization

Planning Mtce Checks

Page 162

MaintenanceProgram

Operational parameters (FH/YE, FH/FC)

Maintenance concept : block (basic)

semi equalized fully equalized

Check intervals

Maintenance Program

Customization

MPDVendor requirements

National requirements Specific A/L requirements

Scheduled maintenance engineering process

MPD: Maintenance Planning Document

MIS: Maintenance Information System Work-package, Task / Job Cards

Production

Do

Maintenance

Do Maintenance

Part 145 organisation

Maintenance Schedule developmentSchedule maintenance process

PrepareMaintenance

Part M organisation

Packaging

definition

Page 163

From Block

To Equalized


Page 164

Maintenance Concept Definition

Work Packages

Aircraft utilization

- Seasonality/Charter- Low Aircraft Utilization- Long or Short Haul- Scheduled- Freighter

Fleet Age

- Structural Items Threshold- Additional ageing program- Fatigue Structural findings

Aircraft Ground Time -Airlines Policies

- Return to main base - Night stop- Outstation capability

Manpower Skills and availability- Task Man-hour - Access Man-hour - Preparation Man-hour

Fleet Size- Facilities- Manpower- Materials- Maintenance Planning


Page 165

Block concept Tasks grouped by interval families and performed close to their deadline.

Maintenance workload and ground time per event could vary significantly

Several concepts could be possible :

Equalized concept Tasks grouped in order to fit with predefined maintenance ground times.

Event manpower load and maintenance ground time are balanced

On Demand concept Tasks not grouped in order to optimize predefined maintenance interval. Next due

managed task by task.

Event manpower load and maintenance ground time are flexible according to the Work Package selected

Maintenance Schedule DevelopmentMaintenance Programme Packaging Concepts

Page 166

1A Package2A Package4A Package

1C Package2C Package4C Package

Number of M/H

Maintenance

Events

Block concept principles: Block checks clearly identified at fixed intervals + 100% interval use The workload of each block check varies maintenance is done

during the block checks as it becomes due

Maintenance Schedule DevelopmentBlock Concept

0

100

200

300

400

500

600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

2A 50%

4A 25%

A and OOP tasks equalized on A events, C and Structure tasks stay as Block

Maintenance Schedule DevelopmentSemi-Equalized Concept (A & Multiples Equalized)

A and OOP tasks equalized on A events, C and Structure tasks stay as Block

Maintenance Schedule DevelopmentSemi-Equalized Concept (A & Multiples Equalized)

0

100

200

300

400

500

600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

2C 50%

A and OOP tasks equalized on A events, C tasks equalized on C events and Structure tasks stay as Block

Maintenance Schedule DevelopmentSemi-Equalized Concept (A, C & Multiples Equalized)

A and OOP tasks equalized on A events, C tasks equalized on C events and Structure tasks stay as Block

Maintenance Schedule DevelopmentSemi-Equalized Concept (A, C & Multiples Equalized)

0

100

200

300

400

500

600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1C 12.5%

2C 6.25% +

A, OOP and C tasks equalized on a A events except Structure tasks (stay as Block)

Maintenance Schedule DevelopmentFully-Equalized Concept (A, C & Multiples Equalized)

A, OOP and C tasks equalized on a A events except Structure tasks (stay as Block)

Maintenance Schedule DevelopmentFully-Equalized Concept (A, C & Multiples Equalized)

On Demand concept principles Tasks managed on a case by case basis in order to optimise the

maintenance program according to various operator parameters .

0

100

200

300

400

500

600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Maintenance Schedule DevelopmentOn Demand Concept

Pros

Less investments as fewer maintenance stations (spares / tools / consumables / Accessing / Docking / Tooling)

Maintenance task interval utilization optimized

Lower risk for additional ground times (AD, Mods, Repairs, )

More time for defects rectifications

Cons

Unbalanced manpower load over the checks

Premature planning of Out of Phase and Time Controlled Items

Maintenance Schedule DevelopmentBlock Concept Pros & Cons

Pros

Better Aircraft availability & better operational flexibility

Even Maintenance Ground Time

Even Manpower load

Better interval utilization for Out of Phase and Time Controlled Items

Cons

More investments as more maintenance Stations (spares / tools / consumables / Accessing / Docking / Tooling)

Repetitive access opening/closing

Increase of non-routine items on ageing aircraft affect expected maintenance ground time

More stringent monitoring and correction of arising defects

Maintenance Schedule DevelopmentEqualized Concept Pros & Cons

Pros

Better operational flexibility due to less down time

Better A/C availability

Optimized to fit operator needs

Better interval utilization for Out of Phase and Time Controlled Items

Takes real benefits of Interval Evolutions (coming from MPD or from Airline)

Cons

High Planning complexity

Accurate A/C utilization & routes known in advance

MIS availability mandatory

Large line maintenance capacities

More investments as more maintenance Stations (spares / tools / consumables / Accessing / Docking / Tooling)

Maintenance Schedule DevelopmentOn Demand Concept Pros & Cons

Page 177

1932 FH/YE 2.5 FH/FCA320 LOW UTILIZATION:

A320 HIGH UTILIZATION: 4500 FH/YE - 2 FH/FC

Maintenance Schedule DevelopmentPlanning Example 1 : Effect of A/C utilization

Page 178

Maintenance Schedule DevelopmentPlanning Example: Effect of A/C utilization

7500FH Maintenance

Check45%drop outs 22%drop outs

6000FH Maintenance

CheckOR

30Mo Maintenance Check

54%drop outs

2%drop outs

24Mo Maintenance Check

Maintenance Schedule DevelopmentCommunication on Maintenance Checks: Special Attention !

A

I

R

B

U

S

2

0

0

5

S

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Maintenance Programs 9 Approved by local Airworthiness Authorities9 Contains customized approved and non-approved

maintenance requirement sources

9 Contains as well Customer specific tasks, Vendor requirements and local Airworthiness requirements

Maintenance Schedule9 Based on Operator Maintenance concept 9 Flexible to cope with Operator policy and operational

constraints

Maintenance Schedule DevelopmentConclusions

Initial Maintenance Program Development


Maintenance Program Customization

In Service Experience Feedback

Data Collection and analysis

Maintenance Program Revision


In Service experience collection and analysis is required in the frame of Continued Airworthiness (EASA Part M AMC 302 & FAA AC N120-17A)


Safety First

At operators level

Keep OMP up to date according to fleet in service experience feedback

Optimize maintenance costs and aircraft availability

At Manufacturers level

Keep ICAs up to date according to fleet in service experience feedback

Reliability Control program :

Is used to monitor the effectiveness of the Maintenance Program

Is an essential Quality System process

Contribute to the optimization of maintenance costs (scheduled / unscheduled)

Reliability program is imposed by the Regulatory Authorities, which require an Operator to establish a program for continuing analysis & surveillance of its operations.


Reliability Control Program


Reliability Control Program

Fulfill the authorities requirementsReliability reports

Contribute to the Maintenance & Engineering missionInvestigate deficiencies affecting aircraft operationsDefine & implement required improvementsEnsure continuous airworthiness through the monitoring

of the effectiveness of the maintenance program

Minimize operating costsSchedule disruptionsScheduled Maintenance task interval adjustmentSound evaluations for implementation of modifications

Provide the Airline Management with a performance measurement tool


Performance Measurement & Reporting

$

Analysis

Corrective Actions &

Decision Making

Actions&

Follow-Up

Data Collection

Supplier Manufacturer


Data Collection

Data collected from different sources:

Aircraft log book & On-Board Maintenance System

Operational interruptions

Technical incidents

MaintenanceMaintenance complaintsRemoval dataDeferred defectsCheck findings

Workshops Shop findings

Efficient data collection means reduced workloadBetter quality of informationInformation easier to use (standards, coded data)


Collected data usually computed into rates to help assessmentPerformance measurement compared to:

trends

Targets

alerts levels

Performance Measurement & Reporting

$

Analysis


Analysis triggered when:

Alert level is reached

Trend is not as expected

Objectives are not met

Objective:

identify & confirm root causes of the issue

Propose recovery actions


Corrective Actions &

Decision Making

Proposed corrective actions: technical, process or organization

TechnicalModificationsMaintenance program changes

ProcessesMaintenance practicesTraining

OrganizationalProvisioning reviewEquipment and tools management

Quality assurance / control

Engineering / technical services

Maintenance (line, hangar, shop) Material

Planning

Fleet Management

Proposals documented in detailed reports used forReliability Control Board meetings

Actions&

Follow-Up

Follow up to Validate solutions or re adjust as soon as possibleLearn from experience


The MRB Report represents the initial maintenance program

Maintenance Checks

Initial MRBR intervals are often conservative

Operator can adjust tasks and intervals according to their own experience

Analysis of maintenance check results is associated to the Reliability Control Program

Data shared in real time

MRBR

Updates

Unique Airbus Data collection Template

(with CPCP)

XML Format, No volume limitations

Customized studies -

Benchmarking

Data Collection on an On-Going Basis

[email protected]

DatabaseAirlines



Maintenance Checks Data Collection

MPD task reference

Nber of Months

(ONLY NUMBER)

Nber of FH(ONLY

NUMBER)

Nber of FC(ONLY

NUMBER)

Date at inspection(ONLY DATE

FORMAT)

FH(ONLY

NUMBER)

FC(ONLY

NUMBER)

Previous inspection(Aircraft Status at previous inspection)

Actual interval(interval since the previous inspection)

Mandatory

Actual interval

information

Finding?(Y/N)

Details of finding(e.g corrosion Level, component/element which failed and how

did it fail, possible reasons for defect)

Type of Findings Associated Corrective Action

Task Result(to be filled if finding found during the task accomplishment)

Task findings / nil findings and

corrective actions

Assistance: [email protected]

Operator A300 A300-600 A310 A320 fam. A330 A340XXX >> >> >>


Benchmark my finding rates with IDOLS for Scheduled Maintenance


Operator A300 A300-600 A310 A320 fam. A330 A340XXX >> >> >>

Benchmark my finding rates with IDOLS for Scheduled Maintenance

Examples of benchmarking queries: Benchmarking Finding Rates, Operator vs. Fleet for a list of tasks selected.

Benchmarking Finding Rates, 3 groups based on A/C age (e.g. 0-10, 10-15 and >15) for a list of tasks.


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Documents

Scheduled Maintenance Seminar Part5 May2013