Chapter 6 Requirements for a Maintenance Program

AC E Aviation Maintenance Program Outlined FAA Advisory Circular Requires Ops Specs Authorizes maintenance program Required maintenance manuals Operational equipment as commercial airliner Describes airline responsibility for performing approved maintenance/alterations Accomplished by airliner or contractor Applies to any individual employed/engaged Air carrier maintenance Preventative maintenance Alteration of its aircraft

Maintenance AC E Scope/Content Background of programs FAA regulatory requirements Airworthiness responsibility Air carrier maintenance manual/organization Maintenance record keeping system Accomplishment/approval of maintenance and alterations Maintenance schedule Required inspection items (RII) Contract maintenance Personnel training Continuous analysis surveillance system (CASS)

Airworthiness Responsibility Air carrier/operator Responsible Maintenance/alterations of aircraft Ops specs for each model aircraft Adhere to FAA approved maintenance program Must follow their policies/procedures/regulatory Changes Approved by FAA Maintenance completed by Carrier Another carrier Third party maintenance organization

Airworthiness Responsibility Operating airline Responsible for Ensuring work completed to their Maintenance schedule Standards Requirements Airline’s regulatory authority requirements

Air Carrier Maintenance Manual Expansion of manufacturer’s manuals All-inclusive expression of maintenance plan Manuals guide maintenance program Administrative policies and procedures Administration management and accomplishment Audit/inspection Flight/ground events Severe turbulence Hard landings Overweight landings Manual identifies Types of inspections Maintenance processes

Maintenance Organization FAA requires organization Perform Supervise Manage Amend Manage/guide personnel Provide direction necessary to achieve program objectives

Maintenance Organization Essential elements Director of Maintenance (DOM) Responsible for overall maintenance Have current FAA A&P rating Chief inspector Maintenance duties/responsibilities Current functions at site Names Aircraft Ensure after maintenance service Airworthy Properly maintained Highest degree of safety

Maintenance Organization Essential elements Maintenance personnel Current/qualified Sufficient experience Delegate Manage Control Highest degree of safety RII inspections Separate from routine/daily inspections Management activities All functions are being accomplished Program remains effective

Manufacturer Record Keeping Manufacturer Aircraft built to type certificate Airworthy condition at delivery

Manufacturer Record Keeping Airline Keep aircraft in airworthy condition Accurate records of maintenance/alterations Summary/airworthiness status information Logbook Maintained in aircraft Flight information Flight times, fuel/oil uplift, crew data Crew can identify maintenance related problems Corrective action/aircraft release Mechanical reliability report (MRR) Mechanical interruption summary (MIS) Reports of major alterations/repairs

Maintenance Program Instructions Conducting maintenance on aircraft Specific maintenance Engines Propellers Parts Appliances Scheduled maintenance Tasks according to time limitations Unscheduled maintenance Follow Procedures Instructions Maintenance standards

Maintenance Program Instructions RII “Those items which could result in unsafe operation of the aircraft “If maintenance is not performed correctly or if improper parts are used” Propellers Parts Appliances FAA does not specify Airline required to identify their own unique items Identify names of qualified/authorized personnel

Manufacturer Schedule Maintenance Task Schedules What maintenance to be accomplished Time limitations How to accomplish When/how often to accomplish Airlines Organize individual tasks into scheduled work packages Comply with their needs Input from MRB report Tasks divided into groups Flight hours/cycles Calendar items Programs vary from airline to airline

RII Related to flight safety/airworthiness Must be identified in manuals Identify RII procedures RII authorization Requirement on Job cards Work forms Engineering orders

Contract Maintenance Complies with Part 121/135 Airline responsible for Providing proper training to contractors Airline policies/procedures Clear authority Responsibility Direction Contractor maintenance personnel Skills Facilities Knowledge of airline’s manuals On-site audit Inspection of facilities/equipment Competent personnel

Contract Maintenance Maintenance options Other airline Repair station Third-party maintenance organization

Personnel Training Initial training Indoctrination Company orientation Policies/procedures Courses Aircraft systems Ground equipment Hazardous materials training Airlines Validate AMT’s skills through testing Provide recurrent training Specialized training Changes to equipment, procedures,regulations

CASS Quality Assurance Program Detect/correct program deficiencies Surveillance Analysis Data collection Corrective action Problem areas Tracks effectiveness Disconnect power Tie up loose cables for removed equipment

CASS System requires Audits Trends analysis Self-reporting Analysis of effectiveness Identifying deficiencies Safety management Risk management Investigation analysis Corrective action/follow-ups

Additional Documentation Engineering Establish initial maintenance program Continually upgrade Technical assistance Troubleshooting Workable maintenance processes/procedures Review manufacturer’s service bulletins Other maintenance tips, changes, suggestions Engineering expertise

Additional Documentation Materials Part and supplies Purchase/warehousing Tools Issuance of parts Handling of warranty claims Planning Scheduled maintenance activities Manpower Facilities Supplies Collects data on time, manpower, facilities used

Additional Documentation Maintenance Control Center Keep track of all vehicles in operation Location Maintenance/servicing needs Other requirements Minimize delays/down time Dispatches personnel for support

Additional Documentation Training Records of all training Engineers Supervisors Managers Inspectors Type of training Initial Recurrent New skills Processes/procedures

Additional Documentation Computing Provides equipment Software Support Programs Parts tracking/control Collecting/manipulating reliability data Data collection on malfunctions

Additional Documentation Publications All technical publications Up-to-date Paper Microfilm Electronic media Distribution