Maintenance Program Overview - ICAO

1 Maintenance Program Overview 12 Learning OutcomesBytheendofthissessiondelegateswi llbeableto: DescribethebasisonwhichmodernMaintenance Programsaredeveloped Statehowto approveandmonitorMaintenancePrograms Discusstypicalproblemareasassociatedwith the processMaintenance Programs -Requirements EASA Certification Specifications( AppendixH for largeaircraft) applicableaircraft tobe maintainedin accordance withan approved Maintenance and any subsequentamendments shall be approvedbythe competentauthority ( ) Air NavigationOrder article 253 Effectiveness of theMaintenance Program4 Contents Objectives Approval of themaintenance Program Maintenance Program General Effective of the Maintenance Program Maintenance Review Board Optimization of thethemaintenance Program Operators Maintenance Program SummaryMaintenance ProgramsA MaintenanceProgramis adocument which describes the specific Maintenance tasks and theirfrequencyof completion,necessaryforthe continued safeoperationofthoseaircrafttowhich itapplies.

2 (ICAO).A MaintenanceProgram establishes compliance withinstructionsforcontinuing airworthinessissued bytype certificate, supplementary type certificate holders and organizationsthatpublish datainaccordancewith Part 21, instructionsissuedby thecompetent authority, instructionsdefined by the ownerorthe operator(MA302).5 Maintenance Programs -Requirements EASA Certification Specifications( AppendixH for largeaircraft) applicableaircraft tobe maintainedin accordance withan approved MaintenanceProgram. The MaintenanceProgram and any subsequentamendments shall be approvedbythe competentauthority ( ) Air NavigationOrder article 2567 Maintenance :AirworthinessLimitations(AWL s),CertificationMaintenanceRequirements( CMR s),MaintenanceSignificantItems,(MSI)andS tructurallySignificationItems(SSI).Thisi nformationmaybeutilisedinthemaintenanceR eviewBoard(MRB) MRBAims Toensurerealizationoftheinherentsafetyan dreliability levelsof theaircraft To restore safety and reliability to their inherent levels when deteriorationhas occurred To obtain the information necessary for design improvementof thoseitemswhoseinherentreliability proves inadequate Toaccomplishthesegoalsataminimumtotalcos t, includingmaintenancecostsandthecosts ofresultant failuresMaintenance Programs -MRB MaintenanceReviewBoard(MRB)is aregulatorybody The International Maintenance ReviewBoardPolicy Board (IMRBPB)

3 Isa charteredorganization ofregulatory authorities that recognizestheATA MSG3 process as an acceptablestandard TheMRBprocessisintendedto bea collaborative one involving airline operators,manufacturers and regulatory authorities9 Maintenance Programs -MRB Thescheduledmaintenancedevelopmentproces s,comprises representativesoftheoperators,themanufac turersoftheairframe andengine,andtheregulatingauthorities Management of the development activities is accomplished by anIndustrySteeringCommittee(ISC) MaintenanceWorkingGroups(MWG)willbeestab lisheddepending onthecomplexityoftheaircraft, systems, powerplant,zonal and structures Thedevelopedmaintenanceactivitieswillbes ubmittedforapproval, totheMaintenanceReview Board(MRB)10 MaintenancePrograms-MRB The working procedures are detailedinaPolicy andProcedures Handbook(PPH). TheMaintenanceReviewBoard (MRB)reviewsthe Maintenance proposalssubmittedby Industry SteeringCommittee(ISC) Once accepted by ISCthe Maintenance proposalbecomesthe MRBR eportProposal(MRBR(P))11 Maintenance Programs -MRBMSG-3 Analysis ProcedureAftertheMSI shave beenselectedthefollowing mustbe identifiedforeachMSI:a) Functions(s) )FunctionalFailure(s) Failureofanitemtoperformitsintended functionwithin ) FailureEffect(s) whatis theeffectofafunctionalfailured) FailureCauses(s) whythefunctionalfailureoccurs12 Maintenance Programs -MRB13 Maintenance Programs -MRB14 Maintenance Programs -MRBMSG-3 LogicAnalysisThedecisionlogichastwolevel sformeachMSI.

4 Level1requirestheevaluationofeachFunctio nal FailureforthedeterminationoftheFailureEf fect Category(FEC)Level2assessestheFailureCau sesbeforeselectinga task15 Maintenance Programs -MRB16 Maintenance Programs -MRB17 Maintenance Programs -MRB18 Maintenance Programs -MRBC opyright CAA InternationalLtd Programs -MRBS ignificantStructuralItems(SSI): SelectedatthehighestmanageablelevelStruc turalDamageResources AccidentalDamage EnvironmentalDeterioration(CalendarTime) FatigueDamage(Flight Cycles)20 Maintenance Programs -MRBF ailureEffectCategoriesFEC(FirstLevel)Onc etheanalystshaveansweredtheapplicablefir st levelquestions,theyaredirectedtooneofthe five EffectCategories; EvidentSafety (Category5) EvidentOperational (Category6) EvidentEconomic(Category7) HiddenSafety (Category 8) HiddenNon-Safety (category 9)21 Maintenance Programs -MRBZ onalProgram :corrosion,cracksandevidenceoffluidleaks /overheat/ductdamage, Programs -MRB OncompletionoftheMRBprocesstheMRBR issignedoffby the appropriateregulatoryauthority FromtheMRBR, theaircraftmanufacturerwillproducea MaintenancePlanningDocument(MPD)foruseby theoperatoroftheaircraft2324 Operators MaintenanceProgramWheredoestheoperatorfi ndtheinformation?

5 MaintenancePlanningDocument(or similar) MaintenanceReviewBoardreport AircraftMaintenanceManual(Chapter5) AirworthinessLimitationsDocumentAircraft FlightManualOperators MaintenanceProgram Preface(operatordetails,aircraft details, utilization, check cycle, etc) Inspection standards to be applied Variations procedureto taskor checkfrequencies Reviewprocedure Optimization/Evolutionprocedure Details,includingfrequencyofall scheduledmaintenancetasks2526 Operators MaintenanceProgram Specifictaskslinkedto specificoperations Lifelimited components Limitedpilotowner Maintenance Reflectapplicable regulatoryrequirements Repetitivemaintenance tasksderivedfrom modificationsandrepairs Taskcards Reliability programApprovaloftheMaintenanceProgram The authority designatedThe competent authority by the Member State of registry ..shallverify that maintenancePrograms in compliancewith Indirect approval when theaircraftis managedbyan Subpart G organizationthe MP and itsamendmentsmaybe approvedby procedure establishedby the organisation( )27 ApprovaloftheMaintenanceProgram AnaircraftcanonlybemaintainedtooneApprov edMaintenanceProgram TomoveanaircraftfromoneProgramtoanotherw ill involvesubmittinganamendment totheCAAfor approval AreviewofthedifferencesbetweentheProgram s carried outthismayresultintheneedfora'Bridging Check'to caterforanydifferences2829 ApprovaloftheMaintenanceProgram MaintenanceProgramsshouldbe developedfromTypeCertificate Holder/ SupplementalTypeCertificateHolder(TCH/ST CH) information.

6 MaintenanceProgramChecklist FormSRG1724 Thepurposeof themaintenanceProgramchecklist if toassist ownersandoperatorsin thesubmissionwitha view toensuringthat theMaintenanceProgramssubmittedtotheCAAa restandardized andincludeallitemsthatarerequiredby ,AMC andalsoany otheradditionalCAAnationally requireditems. Available onCAAW ebsite30 ApprovaloftheMaintenanceProgramThe approvalverificationshouldconsiderthe followingitems: Program rules System/powerplantrules&requirements StructuralProgram&associatedrules&requir ements ZonalProgram&associatedrules&requirement s All tasks are identifiedby their MSI/SSI STC/Modificationsinspectionrequirements3 1 ApprovaloftheMaintenanceProgram FECandCMR spositivelyidentified AirworthinessLimitations TheusageparameterswithaFECof5&8orwhichar eCMRshouldbe carefullyconsidered Buyer FurnishedEquipment(BFE) AgeingAircraft RepeatInspectionof RepairsMaintenance ProgramTaskstraceabilitytosourcedocument (MPD, MRBR, MM Chapter5, Operators Requirements)32 AircraftMTWA<2730kgs LightAircraft MaintenanceSchedule Aeroplanes/Helicopters(LAMS)publishedand approved by CAA Generic schedule applicable to piston enginedaircraft <2730kg (non EASA) LightAircraft MaintenanceProgram Aeroplanes/Helicopters(LAMP)

7 Publishedand approvedbyCAA Generic schedule applicable to piston-enginedaircraft <2730kgPart M, <2730kgsLAMS/LAMP aregenericandthereforeitis importantthat: TheOwner/Operatorcompletestheintroductor ydetails TheProgramiscustomizedfor AirworthinessLifeLimitations,Overhauland TestPeriods TheProgramiscustomizedfor AdditionalInspections CAP543orequivalentisused34 Effectiveness of the Maintenance Program Theoperator isrequiredtocontinuetomonitorthe effectiveness of the Maintenance Program (EASA (a)) Theoperatormayelectto Contract continuing airworthiness taskstoanotherappropriatelyapproved organization(EASAPartMSubpartG) Theprocessrequiredto monitorthe effectivenessis dependentuponmethodologyappliedbyTCholde r35 Effectiveness of the Maintenance Program ReliabilityProgramsaredesignedtosuppleme ntthe operatorsProgram for maintaining aircraft in a continuousstateofairworthiness(ICAO) ReliabilityProgramsshouldbedevelopedfora ircraft maintenancePrograms based upon Maintenance steeringgroup(MSG)

8 Logicorthosethatincludecondition monitored components or that do not contain overhaul timeperiodsforallsignificantsystem components(EASA) Reliability Programsneednotbedevelopedforaircraft notconsideredaslargeaircraft orthatcontainoverhaul timeperiodsforallsignificantaircraft system components36 Effectiveness of the Maintenance Program ThepurposeofareliabilityProgram istoensurethat theaircraftmaintenance Programtasksareeffective andtheirperiodicityisadequate ThereliabilityProgrammayresultintheescal ationor deletionof a maintenancetasks,as wellas thede-escalationoradditionofamaintenance task AreliabilityProgramprovidesanappropriate means ofmonitoringtheeffectiveness ofthemaintenance Program37 Effectiveness of the Maintenance ProgramThereliabilityProgramproceduremay include monitoringof: PilotsReports,TechnicalLogs AircraftMaintenanceAccessTerminal/ On-boardMaintenance Systemreadouts MaintenanceWorksheets ComponentRemovalsandWorkshopReports ReportsonFunctionalChecksAND Special Inspections StoresIssues/Reports AirSafetyReports ReportsonTechnicalDelaysandIncidents Othersources(ETOPS,RVSM, CAT II/III)38 Optimizationof the Maintenance ProgramTheoptimisationprocessshouldbeset outinthe operatorormaintenance organisationCAME/MOE/ are developedusingMSGmethodology, theoperator optimisationprocessshouldincludemethodol ogy which the Maintenance ProgramAnythingcanbeescalatedifappropria telyjustified!

9 Somethingsrequiremorejustificationthan others: CMRandanyAirworthinessLimitationsaretype certification issues,andcanonlybevariedwiththeTCholder ssupport AD sintervalscanonlybeescalatedwiththespeci fic approvalof theNAA ProceedwithextremecautionforitemssuchasC MR, FEC5&8,SSI40 Optimizationof the Maintenance ProgramA Maintenance Program approved for one Operator and onemaintenance organisationdoes not mean automatic approvalat theoperational environment, utilisation,modificationstatus, Maintenance and the Maintenance ProgramOptimisationcouldresultinthefollo wingchangestotheApproved MaintenanceProgram; Change to compliance interval category (FH, FC, Calendar,Checketc) Escalationorreductionof complianceinterval Revisionof task/process (insp,CK, FC, OPCetc) Revisionof accomplishmentinstructions DeletionofTaskor Process Revisionof workscope Additionof tasks42 Optimizationof the Maintenance Program Changes to a scheduled Maintenance Programshould be made in an incremental andcontrolledmannerwhere possible,byTrialExtensionorsamplingProgr ams Sample sizeandreviewperiod(gates)tobeagreedwith NAA(Typically10%-15%of fleet) TypeCertificate Holderssupport Incrementtobe agreedwith NAA RateofChange maybehighforanewtyperecently introduced to servicemore conservative forold types or inexperiencedoperator/ maintenanceorganizations43 Optimizationof the Maintenance ProgramJustificationcouldincludeauditof.

10 MaintenanceStandards(lineandbase) DataCollection DataProcessing Deferred/ CarryForwardDefects AircraftUtilisation NILD efects isnotinitself,justificationforescalation or deletion44 Optimizationof the Maintenance ProgramPirepsand TechnicalDelay summariesalone,donot included; ComponentStripReports ComponentReliabilityData OccurrenceandSafetyReportRates WorkpackNonRoutineCardRates Test/FlightTestReportFindings Safety ( )DefectRates Global Data-WhereObtainablefromTCHolder45 MaintenanceProgramsSummarySummary: TCHolderrecommendations shouldformthebasisofthe operatorsmaintenanceProgram TheOperatorisresponsibleformonitoringeff ectiveness ofthe maintenanceProgramandtheprocessshouldbea udited ThemaintenanceProgramprocessbringstogeth er maintenanceanddesign Themaintenancecomplianceandinspectionsta ndardsplaya significantrole in an effectiveMaintenanceProgramand shouldbeaudited Thecompetent authorityshallverifythatthemaintenance Programisincompliance46