SIASA project This project is funded by the European … 140923... · 1st MSN EIS 1st MSN operational A/C Production Last MSN operational life Last MSN EIS ... - A320-210 with CFM

SIASA project

This project is funded by the European Union and implemented by EASA.

TE.GEN.00409-001

Maintenance Program ImplementationChristian DELMAS Director‐Maintenance Programs EngineeringAirbus Customer Services

Technology Evolution – Impact on Airworthiness23‐24 September 2014, Windhoek, Namibia

Introduction

Maintenance Program process implementation at Type Certification Holder and Operator level

• A standard process

• Consistent with new technologies and regulations

Complete, Available and Accessible documentation

Easy access to Airbus support & services

Objective of the Presentation:

Page 2

Maintenance Schedule Development

Initial Maintenance Program Development

Maintenance Program Customization

In Service Experience Feedback

Data Collection and analysis

Maintenance Program Revision

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Maintenance Program Development

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 5

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 6

MWG 1 MWG 3 MWG 2

MWG 6 MWG 5MWG 4

MPP

ISC: Industry Steering CommitteeMWG: 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

MRB

ISC


Page 7

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 years MAINTENANCE

MRB Process …

Safety + availability & reliability at minimum cost


Page 8

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 9

ATA MSG-3Operator/Manufacturer


Revision 2007.1

A350Scheduled

Maintenance

Policy and ProceduresHandbook

Relationship of MSG-3 Document and PPHThe 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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Applicability (e.g A320Fam)- A320-110 with CFM 56 Series engines,- A320-210 with CFM 56 Series engines,- A320-230 with IAE V2500 Series engines,- A320-250 with CFM LEAP-X Series engines,- A320-270 with PW 1100G Series engines,- A321-110 with CFM 56 Series engines,- A321-130 with IAE V2500 Series engines,- A321-210 with CFM56 Series engines,- A321-230 with IAE V2500 Series engines,- A321-250 with CFM LEAP-X Series engines,- A321-270 with PW 1100G Series engines,- A319-110 with CFM56 Series engines,- A319-130 with IAE V2500 Series engines,- A319-150 with CFM LEAP-X Series engines,- A319-170 with PW 1100G Series engines,- A318-110 with CFM 56 Series engines,- A318-120 with PW 6000A engines.

Aircraft Utilisation Assumptions 1800 to 4400 FH per year1000 to 2500 FC per year


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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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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 53DocumentsMRB AI MeetingISC 2 3CMCCTraining SessionsWG 1 Hydraulics & F/CWG 2 EnvironmentalWG 3 Powerplant & APUWG 4 Avionics - GeneralWG 5 StructureWG 6 Zonal & L/HIRFWG 7 FuelWG 8 Landing GearsWG 9 Interior

4

E1 E2 E3 E4

111

1

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 33 34 35 36 37 38 39 40 41 42 43week

A350 Planning - 2009

Training sessions


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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


Page 14

The MRB Report


StructureZonal & L/HIRF


Page 15


Page 16


Structure


Page 17


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Zonal & L/HIRF*

(*) L/HIRF_Lightning / High Intensity Radiiated Fields

Even before the start of the MRBR process Maintenance Engineers get involved in Aircraft design development


Page 19

Information is available on line and/or on physical media (DVD)

On Line access available via AirbusWorld


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“Maintenance & Engineering” Page

Access to MRBR or ALS


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“Prepare MaintenancePrepare Maintenance Program”


Access to MRBR or ALS

Page 22

Easy access to scheduled maintenance data per aircraft program and document


Page 23

New MRB Report or ALS document revision notification by dedicated communication


Real time information

Page 24Page 24

Page 25

MPD

The Maintenance Planning Document

AMM

Non approved repository of repetitive scheduled maintenance requirements

Link between requirements and procedures (AMM)

Additional information (access, m.h, skill…)

MSG3Analyses

MRBReport

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

System Safety

Assessment(SSA)

ALS Part 5

FALDocument

Test results

Damage TolerantAnalysis

+Full Scale Fatigue

Test results

EASA Certification Approved

ETOPSCMP


Source for maintenance program & planning operators to develop a customized scheduled maintenance program.

The AIRBUS MPD Envelope repository document Tasks from other source documents

MPD: neither a CONTROLLING document nor an APPROVED document.


Page 26

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.

MPD Presentation

Page 27


MSG3

AnalysesMRB

Report

D

ALS Part 4

ASMDocument

Document

ALS Part 2

DT-ALIDocument

Document

ALS Part 3

CMRDocument

AMM

MPD

System Safety

Analysis

(SSA)

+ -

D

ALS Part 5

FALDocument

Fatigue Test

Damage Tolerant

Analysis

+

Full Scale Fatigue Test

results

AOT

SIL

SB

AD

/

CN

In service experience feedback

Manufacturer - EASA CS 25

- Consolidation over the different sources

- Revised each time the “MPD baseline” source document is revised at the exception of Life Limited

Parts

- Consolidation over the different sources


ETOPSCMP


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MRBALI

Page 29


T : 12 YEI : 6 YE

Page 30


T: 3200 FC I: 8000 FC

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T : 12 YEOR

32000 FCI : 6 YE

OR8000 FC

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

MPD Presentation: System, APU & Power Plant

Page 33


MRB 9=

MRBR FEC 9(hidden / non safety)

FEC=Failure Effect Category (from MSG3)

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

MPD Presentation: Structure

Page 34


CPCP

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

MPD Presentation: Zonal

Page 35


MPD

AirN@v / PlanningCommon AirN@v layoutInteractivity with AirN@v / Maintenance

EXCEL

PDF

TSDF SGML

Easy Data Manipulation Filtering, Sorting, Calculation

“Digital Paper” Printing capability

Specific ASCII for MIS and Database uploadProvided with data specification

MPD Presentation: MPD Deliverables

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Why MPD customization is needed ?• MPD = envelope document• Different aircraft configurations some MPD tasks

are not relevant to a given fleet, sub fleet or MSN

How to select MPD tasks ?

Select tasks according to Applicability column using the above listed documents

What are the information needed to customize MPD ?- Aircraft type - Weight variant

- Engine type - APU type

- Mod Status - SB status

- Cabin Layout - Emergency equipment list

Work Scope


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OMP

Approved by local AA

Airlinetasks

National Requirements

MSG3Analyses

MRBReport

MPD

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

System Safety

Analysis(SSA)

ALS Part 5

FALDocument

Test results


+Full Scale Fatigue

Test results


Manufacturer Operator

A/C configuration

Customization

ETOPSCMP









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MSG3Analyses

MRBReport

MPD

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

System Safety

Analysis(SSA)

ALS Part 5

FALDocument

Test results


+Full Scale Fatigue

Test results


OMP


Airlinetasks



A/C configuration

Customization

Planning Mtce Checks

ETOPSCMP


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

Number of M/HOr

Number of Tasks

Maintenance Events

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Equalised maintenance Concept

Block-like maintenance Concept

Maintenance concept

development

Maintenance concept

development

Perform tasks as they become due

One flexible maintenance program Numerous maintenance concepts

etc.

Flexible Maintenance Program

Usage parameter task intervals

Flight hours

Flight cycles

Calendar time


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7500FH Maintenance

Check22%drop outs

6000FH Maintenance

CheckOR

45%drop outs

30Mo Maintenance Check

54%drop outs

2%drop outs

24Mo Maintenance Check

Communication on Maintenance Checks: Special Attention !


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30 Month C check communication correct but:

• About 50% drop out tasks

• Only if aircraft utilization < 3000FH/year







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In Service experience collection and analysis is required in the frame of “Continued Airworthiness” (EASA Part M AMC 302 & FAA AC N°120-17A)


At operator’s level

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

Optimize maintenance costs and aircraft availability

At Manufacturer’s level

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

Page 46

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


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Actions & Follow-Up

AnalysisAnalysis

Performance Measurement & Reporting

Performance Measurement & Reporting

Corrective Actions &

Decision Making

Corrective Actions &

Decision Making

SupplierManufacturer


Page 48

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


Page 49

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


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Maintenance Checks – Data Collection

TASKNUMBER

100%INT

Date at inspection(ONLY DATE

FORMAT)

FH(ONLY

NUMBER)

FC(ONLY

NUMBER)

531101-01-1 10 YE

531102-01-1 6 YE

531104-01-1 10 YE

IS CORRESPONDING TASK APPLICABLE

TO MSN AND PERFORMED DURING

CHECK?(Y/N)

Reported inspection(Aircraft Status at inspection) Check

Package Type

Approved Interval

(Interval actually approved by the local

Authorities)

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]


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

Benchmark my finding rates with IDOLS for Scheduled Maintenance


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MSG3Analyses

MRBReport

MPD

ALS Part 4

ASMDocument

ALS Part 2

DT-ALIDocument

ALS Part 3

CMRDocument

System Safety

Analysis(SSA)

ALS Part 5

FALDocument

Test results


+Full Scale Fatigue

Test results

OMP


Airlinetasks



A/C configuration

Customization

Planning Mtce Checks

ETOPSCMP









Page 56

1st A/C operational life # 30 years

A/C Production # 20 years

Last A/C operational life # 30 years

Last EIS

A/C IN SERVICE MAINTENANCE # 50 years

1st EIS

A/C Devlpt

(5-6 years)

Type

Certificate

Program Launch

Maintenance Program Process

Page 57


2 possibilities for maintenance program evolution

OPERATOR

Operator Fleet

In‐service experience

Local AirworthinessAuthorities

MANUFACTURER / ISC (MRBR)

World Fleet

In‐service experience

FAA/EASA/TCCA

MRB ProcessCustomized

WHO INITIATES?

TARGET

JUSTIFICATION

APPROVAL BY

Manufacturer Maintenance Program (MRBR, ALS, MPD) evolution exercise

Customized maintenance program evolution


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Customized/Operator Maintenance Program Evolution exerciseOperator’s Maintenance Programme must be kept up to date according to

Evolution of Aircraft configuration (e.g modification / SB)

In service experience feedback (e.g AD, Reliability Control Program, feedback from maintenance events)

Evolution of Maintenance Program Source Documents (e.gALS, MRBR)


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3 main reasons for MP (MRBR, ALS, MPD) evolution

Regulation Change (CPCP, EWIS, FTS, TLOD…)

Design Change

In service experience feedback (fleet survey, DSG/ESG, reliability, findings/nil findings…)

Manufacturer Maintenance Program Evolution exercise


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Scope:

Ensure that the MRB Report remains efficient according to in service experience feedback

Review the MRB Report initial conservative figures

The evolution process can be extended to the Maintenance Planning Document (MPD) tasks (Limitations excluded)

Interval adjustment means optimisation and not necessarily escalation!

MRBR evolution- In Service Experience Feedback:

Pre Requisite: In service experience feedbackReports from previous maintenance visits (findings and nil findings)Representative sample of the worldwide fleet:

aircraft agedifferent operations, different environmentsVolume, amount of data

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Guidance

Up to end 2007: different approaches from manufacturers

From 2008: MRBs have set up a “common approach” applicable to future evolution exercises IMRBPB Issue Paper 44 (IP44)

Principle: Justify the evolution exercise on a task by task basis thanks to a suitable statistical analysis of in service data supported and validated by engineering judgement

Effectivity: all evolution exercicesto be finalized after April 2009

MRBR evolution- In Service Experience Feedback:


Applicable to customized or fleet wise revision

Maintenance Program Revision - Summary

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Revision:• Adaptation to aircraft configuration• Adaptation to regulations• In Service Experience Feedback / Reliability Control Program• Task by task basis approach

Maintenance Program Optimization

Maintenance Programtask interval Escalation only

Maintenance Program Optimization

Maintenance Programtask interval Escalation only

=

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Airbus Assistance

Airbus Assistance

Page 66

Training Service:ScheduledMaintenance Program Seminar

Maintenance Engineering Services: Exceptional one time deviations Maintenance program optimization Corporate Jet Operations

Airbus Assistance

Page 67

Airbus Assistance

The aim of the seminar is:to familiarize you to Scheduled Maintenance Requirements development and evolution,to give basic guidance on maintenance concept to develop the appropriate maintenance program and planning

Airbus maintenance engineering offers a dedicated Scheduled Maintenance Program (SMP) seminar.

If you are interested please contact us or your CSD or

Sched‐[email protected]

Scheduled Maintenance Program Seminar

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Due to unforeseen exceptional circumstances it happens that amaintenance task cannot be performed at the due date.

Refer to MPD introduction for guidance for exceptional variations

Exceptional one time extensions (1/3)

NOTE: Exceptional Variations should not be used to compensateplanning shortcomings!

What can you do

STEP 1

STEP 2 Beyond MPD allowance contact us for Airbus Statement of Airworthiness Compliance:

ASAC

MPD

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Airbus Assistance

MPD

STEP 1


Page 70

Airbus Assistance

ASAC

An Airbus Statement of Airworthiness Compliance ASACcould be issued by Airbus on demand

STEP 2


An ASAC is not an approved document

An ASAC is an official document issued by Airbus to support operators demand for exceptional deviation in front of the NAA

Page 71

Airbus Assistance

Airbus can support operators in their efforts to optimize maintenance program efficiency

Customized Maintenance Program Optimization

Availability of supporting data is essential

Different levels of support can be offered depending on operators’ priorities

Page 72

Airbus Assistance

We can help operators to manage their maintenance program & planning!

First contact: the Airbus Representatives: FSR, FSM, CSD

[email protected] scheduled maintenance questionsManage Special situations e.g. deviations, return to service, storage…Manage Task interval evolution

[email protected] task [email protected] Special trainings (SMP Seminar)[email protected] customized programDevelop Maintenance Schedule

Technical support and assistance

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Airbus Assistance








Conclusion

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Different StepsDifferent Actors

To control the ScheduledMaintenance process

Page 75

Airbus Scheduled maintenanceprocess and documents

adapted support + customized services=

safe operationsoptimized aircraft availability at reduced cost

Page 76

Compliant with latest regulations and Industrial Standards Adapted to technology evolutions Revised according to in service experience Updated all along aircraft life

Easily accessible on Line

Flexible to adapt to any operation or maintenance strategy

Adapted to operators’ needs

Compliant to Instructions for Continued Airworthiness (CS25.1529 app.H)







Page 77

© AIRBUS S.A.S. [2014] All rights reserved. Confidential and proprietary document.

This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by the delivery of this

document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS

S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied.

The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to

explain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M, ACJ are registered trademarks