1. MGMT 203 Aircraft Systems and Maintenance – Importance to Management Module 4

2.  September 28  1920 — American pilot Howard Rinehart, flying a Dayton-Wright R.B Racer, becomes the first person to fly an airplane fitted with retractable landing gear. THIS DAY IN AVIATION

3.  September 28  1921 — United States Ordnance Bureau tests 4,300 pound aerial bomb at Aberdeen, Maryland. THIS DAY IN AVIATION

4.  September 28  1924 — Two Army Douglas World Cruisers complete Air Service's 175 day circumnavigation of the world. THIS DAY IN AVIATION

5.  September 28  1934 — Lufthansa (Deutsche Lufthansa), Germany's national airline flies its millionth customer. THIS DAY IN AVIATION

6. Questions / Comments

7. Learning Objectives – Module 4 (9/26/16 – 10/9/16) Aircraft Systems and Maintenance – Importance to Management Upon successful completion of this module, you will be able to: –1. For a typical aircraft, describe the functions of the flight controls. –2. Examine the components of a typical airframe system such as fuel, landing gear and brakes, oxygen systems, air conditioning systems, pressurization systems, hydraulic systems, deice and anti-ice systems, electrical, and autopilot systems. –3. Explain the formation of shock waves on an aircraft wing. –4. Describe fly by wire primary flight controls and the advantages of this technology. Management of Aeronautical Science Monday

8. Learning Objectives – Module 4 (9/26/16 – 10/9/16) Aircraft Systems and Maintenance – Importance to Management Upon successful completion of this module, you will be able to: –5. Describe the three areas that most maintenance procedures are based upon. –6. Examine the scope and detail of the 100 hour and annual inspection. –7. Describe the recording and approval of Major Repairs and Alterations. –8. Differentiate between the four options to the inspection program for large turbine powered multi-engine aircraft. –9. Discuss the Continuing Analysis and Surveillance System (CASS) of an air carrier maintenance program. –10. Critique the make or buy decision and outsourcing maintenance. –11. Explain the three primary airline maintenance processes. –12. Examine quality requirements for an airline maintenance program. Management of Aeronautical Science Tuesday Wednesday

9. Questions / Comments

11. Discussion: Aircraft Systems: Wed Oct 5 Your post should be a minimum of 300 words with at least, two sources cited. Respond to at least two of your classmates. Your responses to classmates should be at least 100 words and contribute to the continuing conversation.

12. Discussion: Aviation Maintenance: Wed Oct 5

13. Module 4 Review Questions (Due Fri Oct 7) Spend quality time responding to the following questions in your own words. 1. Describe the primary flight controls, their movement about each axis, and location. 2. Explain the formation of the wing airfoil normal shock wave during high-speed flight. 3. Examine the scope and detail of the 100 hour and annual inspection. Who has the authority to sign off on each inspection? 4. Differentiate between the four options of the inspection program for large turbine powered, multi- engine aircraft. 5. What is the make or buy decision? Critique both sides for aviation maintenance. 13

14. Assignments Due – Module 4 (9/26/16 – 10/9/16) Review Module 4 Instructions for the following assignments: Discussion Board Due (Aircraft Systems) –(Due - Wed Oct 5) – 2 part (Post and Respond) Discussion Board Due (Aviation Maintenance) –(Due - Wed Oct 5) – 2 part (Post and Respond) Review Questions – Aircraft Systems and Maintenance – Importance to Management –(Due - Fri Oct 7) – 5 Questions Management of Aeronautical Science

15. SUNDAYMONDAYTUESDAYWEDNESDAYTHURSDAYFRIDAYSATURDAY 2526 Module 4 Intro Aircraft Systems / Maintenance 27 Module 4 Aircraft Systems / Maintenance 28 Module 4 Aircraft Systems / Maintenance 29 (ILT) Ridgeland Airport 30 Flightline Friday 1 23 Module 4 Aircraft Systems / Maintenance 4 Module 4 Aircraft Systems / Maintenance 5 Module 4 Aircraft Systems / Maintenance Discussion Due 6 Beaufort County Airport (ILT) 7 Review Questions Due Flightline Friday 8 910 Module 5 Intro Aviation Safety and Security 11 Module 5 Aviation Safety and Security 12 Module 5 Aviation Safety and Security 1 st Quarter Grades Due 13 Beaufort County Airport (ILT) 14 Flightline Friday Report Cards Sent Home 15 1617 Module 5 Aviation Safety and Security 18 Module 5 Aviation Safety and Security 19 Module 5 Aviation Safety and Security Discussion Due 20 Beaufort County Airport (ILT) 21 Flightline Friday Review Questions Due 22 September/October 2016

16. Questions / Comments

17. MGMT 203 Aircraft Systems and Maintenance – Importance to Management Module 4

18. Deice and Anti-Ice Systems There are many types of systems available – Deicer boots or pneumatic deice system Boots normally installed at leading edge of wings and/or stabilizers. – Weeping wing uses small holes in leading edge that allow antifreeze solution to weep out the holes. – Anti-ice using exhaust heaters – Thermal anti-icing and deicing systems Uses jet engines bleed air Operates whenever icing conditions are first encountered or expected to occur. – Windshield Ice Control Systems Most common is electrically heated element window windshield panels. 18

19. Wing Deicer Boots 19 FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 15-13

20. Wing Anti-icing 20 Turbine compressor bleed air Wing Anti-Icing FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 15-5

21. Deice and Anti-Ice Systems There are many types of systems available – Pitot Tube Heat System – Rain Elimination System Wipe it off (Wiper system) Blow it off (Blast system) Windshield Rain Repellent (chemical removal) system – Not common due to issues with hazards and corrosion 21

22. Pitot Tube and Static Ports 22FAA. (2008). FAA-H-8083-25 Pilot's Handbook of Aeronautical Knowledge. p. 7-2

23. Deice and Anti-Ice Systems There are many types of systems available – Jet Engine Anti-icing System Anti-ice of inlet guide vanes, nose dome, and nose cowl – Bleed air from compressor is used mostly. Fuel Deicer – Operates as a heat exchanger – Uses bleed air – Prop Anti-icing System Ice causes a loss of blade efficiency and vibration May use fluid system Electric deicing/anti-icing system Reciprocating engines and turboprop 23

24. Ice and Rain Protection 24 FAA. (2012). FAA-H-8083-31 Aviation Maintenance Technician Handbook – Airframe. Volume 2. p. 15-3

25. High Speed Flight 4 areas of flight – Below 0.75 Mach = Subsonic – 0.75 to 1.2 Mach = Transonic – 1.2 to 5 Mach = Supersonic – Above 5 Mach = Hypersonic Speed of sound varies with changes in temperature of the air as speed of sound is a function of temperature. 25

26. High Speed Flight Shock Wave Formation (Fixed wing aircraft) – Depends upon airfoil design and wind tunnel testing at different parameters. – Always forms on the top of the wing first because air stream is accelerated here first. Called Critical Mach Number At flight speed of Mach 0.77, a normal shock wave develops on top of wing. Drag results aft of the shock wave Boundary layer separation – At flight speed Mach 0.82, top of wing shock wave moves toward trailing edge and a normal shock wave develops on bottom of wing. 26

27. High Speed Flight Shock Wave Formation (Fixed wing aircraft) – At flight speed Mach 0.95, normal shock waves move to trailing edge. – At flight speed Mach 1.05, a shock wave is formed at the leading edge and is called a bow wave. 27

28. Airfoil Shock Waves M =.77 Normal Shock Wave forms turbulence or possible separation

29. Airfoil Shock Waves M =.82 Normal Shock Wave turbulence or possible separation Normal Shock Wave forms

30. Airfoil Shock Waves Normal Shock Wave M =.95 Supersonic airflow turbulence

31. Airfoil Shock Waves Normal Shock Wave M = 1.05 Supersonic airflow Bow Wave starts to form turbulence

32. Airfoil Shock Waves Normal Shock Wave M = above 1.05 Supersonic airflow Bow Wave compresses turbulence

33. Maintenance Understand management perspective of aviation maintenance 33

34. Maintenance Maintenance is a must when considering aircraft designs or modifications. – Modifications to existing aircraft are being accomplished in lieu of aircraft redesign and development. – Avionics modification – Aging fleet problems – High cycle aircraft can result in initial fatigue cracking of the complete airline fleet. Most aircraft designs include redundancy – Backup systems – Prevents effects of failure on safety 34

35. Maintenance Practices Good and reliable maintenance assures an item stays as reliable as initially designed. Reliability = safety Good maintenance practices provide – Reliability and safety – Insure customer satisfaction – Insures equipment utilization – Increases confidence in the public's eyes 35

36. Maintenance Procedures Most maintenance procedures are based on – Hours or Time – Cycles Landing gear retractions and extensions Engine starts and operation – Chronological time/calendar Accomplished in accordance with Title 14 CFR(s) and manufacturers’ procedures. Adequate inspection is a must 36

37. Title 14 CFR Requirements Aircraft, rotorcraft, engine, and propeller Airworthiness Regulations and 14 CFR Part 39: Airworthiness Directives (AD) (previously discussed) 14 CFR Part 21 Certification Procedures for Product and Parts – Provides requirements for replacement parts and approvals Part 21.303 replacement and modification parts require all replacement parts used on an aircraft must be produced under a Parts Manufacturer Approval (PMA). 4 exceptions – Parts approved under a type or production certificate. – Parts produced by an owner or operator for maintaining or altering his own product. – Parts produced under a Technical Standard Order (TSO). – Standard parts such as fasteners, safety wire, etc. 37

38. Title 14 CFR Part 43 Title: Maintenance, Preventive Maintenance, Rebuilding, and Alteration. – Aircraft having a U.S. Airworthiness Certificate – Includes airframe, engines, and propellers – Logbook Entries for inspections and repairs – Appendix A: Lists Major repairs Major alterations Preventive maintenance 38

39. Title 14 CFR Part 43 Appendix B Recording of Major Repairs and Major Alterations – FAA Form 337 – Person performing repair completes form Form completed by the A&P Approved by person with an Inspection Authorization (IA) Appendix D Scope and Detail of Annual and 100 hour – Describes the inspection requirements 39

40. Title 14 CFR Part 43 Appendix E Altimeter System Test and Inspection Appendix F ATC Transponder Tests and Inspections Note – Aircraft manufacturer may perform alterations, maintenance, and inspections. – If special tools or testers are required by aircraft manufacturer you must use them. 40

41. Title 14 CFR Part 91 Title: General Operations and Flight Rules Has maintenance requirements – Includes the requirements for maintenance, inspection, and record keeping. – General Aviation Inspections Each aircraft must undergo an annual inspection once during each 12 calendar months. – Inspector Authorization (IA) – Scope and detail in Part 43 In addition to above requirement aircraft that are used for hire must be inspected each 100 hours of operation. – A&P – Scope and detail in Part 43 41

42. Title 14 CFR Part 91 Progressive Inspection – An alternative to the 100 hour/annual inspection – Breaks up and change the 100 hour/annual inspection into smaller/shorter inspections for compliance at a different hourly or calendar time basis. – Complete inspection must be accomplished in 12 calendar months. – Supervisory requirement IA Certified repair station Aircraft manufacturer 42

43. Title 14 CFR Part 91.409 Large Turbine Powered Multi-engine Aircraft – Provides 4 options to the inspection program Continuous Airworthiness Program Part 121 (airlines or air carrier) Air Taxi Operator Program (Part 135) Aircraft with more than 10 passenger seats. Manufacturer's Inspection Program Owner-Operator Developed Inspection Program approved by FAA. 43

44. Preflight Inspections Requirements can be found in – Approved Flight Manual – Pilot's Operating Handbook – Maintenance Manual – Additional inspection requirements Mandatory inspections – 14 CFR Part 91 - Pilot is responsible for deter­mining the airworthiness of the aircraft before flight – Pilot must conduct inspection 14 CFR Part 135 and Part 121 have requirements for inspection – Check company procedures – For an example maintenance personnel may perform an in- depth preflight – Flight crew may perform a preflight walk around visual and check of equipment 44

45. Special Inspections Detailed in aircraft maintenance manuals 3 common types – Hard or overweight landing inspection – Severe turbulence inspection – Lightning strike inspection 45

46. 14 CFR Part 121 Airlines Maintenance Title: Certification and Operations: Domestic, Flag, and Supplemental Air Carriers and Commercial Operators of Large Aircraft. Continuous Airworthiness Program (airlines or air carrier) FAA approves the air carrier's maintenance program and any changes to the program – Time limitations – Inspections – Overhauls – Effectiveness of preventive maintenance 46

47. 14 CFR Parts 121 Airlines Maintenance Part 121.131 Manual Requirements – Often called Air Carrier Manual. – For use and guidance of flight and ground operations personnel. – Both operational specification and manual are laws to follow after accepted by FAA. – Part 121.135 Provides detailed requirements for manual contents. Part 135 also has a manual requirement 47

48. 14 CFR Part 121 Operator's Maintenance Manual Part of the air carrier manual or may be a separate manual. Define the continuous airworthiness maintenance program. Prescribes the authorizations, methods, standards, and procedures of maintenance. Has 3 general categories – Policies and Procedures. – Detailed Instructions for accomplishment of the scheduled inspection program. – Technical manuals for maintenance standards and methods. Part 121 and 119 specifies the time limitations for overhaul, inspections, and checks set forth in the operations specifications. 48

49. 14 CFR Part 119 Operations Specification (OpSpec) Issued to air carriers Lists authorizations and specifications Legally binding and has 8 broad categories 1.General 2.Enroute authorizations and limitations 3.Airport authorizations and limitations 4.Maintenance 5.Weight and Balance 6.Schedules 7.Equipment interchange 8.Aircraft leasing 49

50. Airlines Maintenance 3 Primary Maintenance Processes – Hard Time (HT) (Time Changes) Overhaul time limits or part life limit. Dates back to the origin of aviation. – On-Condition Maintenance (OC) Repetitive inspections or tests must be accomplished, at specific intervals. Requires periodic inspected for serviceability. – Condition Monitoring (CM) Depends upon data collection and analysis. Analysis of failures to improve performance. 50

51. 5 Types of Maintenance Inspection – Scheduled Maintenance – Tasks performed at specific intervals – Routine and non-routine Unscheduled Maintenance – Basically a discrepancy and corrective action process – Maintenance or flight crew discrepancies Major Repair and Overhaul – Sometimes called Depot Repair – Shop operations Preventive Maintenance – Directed to the prevention of failure – Proactive in nature Required Item Inspection (RII) – 2 A&Ps must sign maintenance documents 51

52. AC 120-16F Air Carrier Maintenance Program Explains the meaning, scope, and content of the maintenance program. 10 Elements of the air carrier program – Airworthiness responsibility – Air carrier maintenance manual – Air carrier maintenance organization – Accomplishment and approval of maintenance and alterations – Maintenance schedule – Required Item Inspection (RII) Usually 2 A&Ps will sign off the maintenance task – Maintenance recordkeeping system – Contract maintenance – Personnel training – Continuing Analysis And Surveillance System (CASS) 52

53. Airline Maintenance Checks Airlines undergo periodic checks from simple, routine examinations to detailed inspections. Specifically stated by airline in their procedures. The information below is an example only A Check – The shortest and simplest work – Performed every 300 hours of operation 53

54. Airline Maintenance Checks B- Check – Incorporates "A" check requirements – Often is 600-hour intervals or every 6 months – More detailed examinations – May require some disassembly of airframe over the one-to two-day process C- Check – Performed every two to three years – Includes all elements of “A" and "B" checks – Some disassembly – Detailed aircraft & engine examinations – Often lasts a week or longer 54

55. Airline Maintenance Checks D-Check – Every 6 years – Requires complete structural and systems examination and testing including engine removals. – Several weeks to months depending upon aircraft condition. – Equivalent to Military Depot level maintenance. 55

56. Make or Buy Decision Make is company does their own maintenance Buy is company outsources or contracts out – Called 3 rd party maintenance – Maintenance, Repair, and Operations facilities Consider 4 key areas for make or buy decisions – Comparative costs – Labor relations – Quality of work – Flexibility 56

57. 3 rd Party Maintenance Contracting out decision Most 3rd party facilities are well established and expanding Services performed – Modifications – Overhauls – Letter checks Especially C & D (Heavy maintenance) – Corrosion control and painting – Avionics upgrades – Cargo conversions – Maintenance away from company base or line stations 57

58. 14 CFR Part 145 Repair Stations Considered 3 rd party maintenance Discussed previously in course Repairman certified under Part 65 Many different types and classifications of repair stations 58

59. 3 rd Party Types of Contracts Maintenance Labor only agreement Labor and parts agreements Preventive maintenance Complete maintenance management Complete major repair, modification, and alterations 59

60. Maintenance Costs Some examples – Maintenance personnel and support – Spare/repair parts – Test and support equipment maintenance – Maintenance training – Maintenance facilities – Technical data changes – Technical manuals/data Transportation and handling 60

61. Managers’ Perspective Understand the basics of – Maintenance Management Considerations Minimum Equipment List (MEL) Deferred Maintenance Items (DMI) – Maintenance personnel duty time limitations Physical fatigue can lead to mistakes, incidents, and accidents. See 14 CFR Part 121 for air carrier maintenance personnel. 61

62. Maintenance Planning and Controlling Maintenance planning is coordinated with the flight department or operations. – Scheduling is very important to verify the following are available Parts Personnel for shifts Special equipment (jacks, engine change equipment, etc.) Inspection work cards, types, and frequencies Airworthiness Directives (ADs) Life limiting or time change parts Corrections of deferred maintenance items (parts and processes) Corrosion control and painting 62

63. Inventory Aircraft-on-ground (AOG) waiting parts is another critical management responsibility. 4 Categories of Inventory – Raw materials – Work in Progress (WIP) – Finished goods Parts, components, engines, etc. – Maintenance, Repair, and Operating (MRO) Stock Bench stock – Bolts, washers, nuts, gaskets, and rivets, etc. 63

64. Inventory Costs Unlimited inventory – Financial drain on the company Minimum inventory – Aircraft grounded – Parts canned (removed) from another aircraft – Growth of deferred maintenance items (DMI) 64

65. Inventory Costs Inventory Carrying or Holding Costs – Considered warehousing and material handling. – Costs of maintaining and handling materials and inventory for a specific period of time. Ordering Costs – Considered purchasing and transportation costs – Costs of placing and receiving an order Total Costs – = carrying costs + ordering costs 65

66. Quality Conformance to customer requirements Conformance to specifications or standards Airlines – 14 CFR Part 121.373 requires the operator to provide a system of continuous analysis and surveillance. Repair Stations require a quality program under 14 CFR Part 145. 66

67. Quality Control Process of – Measure actual performance – Compare it with specifications – Take action if difference Consists of – Inspection – Acceptance – Reporting or Feedback – Evaluation of personnel and procedures 67

68. Quality Assurance (QA) Oriented to prevent quality problems Emphasis on feedback and corrective actions Evaluates such functions as – Reliability reports – Audits – Component tear-down reports – Inspection procedures and results – Tool calibration program – Cause of any recurring discrepancy – Investigation of FAA write-ups 68

69. ISO 9001:2008 ISO = equal or uniform International Organization for Standardization (IOS) – Headquartered in Geneva Requires quality manual, process, procedures and work instructions. New spec is ISO 9001:2015 – ISO 9001:2008 is still being used 69

70. ISO 9001:2008 Provides guidance for an effective quality management system (QMS) Company must manage the process – Process control Top management support Documentation is a key factor Continuous improvement 70

71. AS9100 Aerospace Standard Aerospace Industry Specification Follows requirements of ISO 9001 by requiring specific requirements for the aerospace industry quality and safety. Released in 1999 by Society of Automotive Engineers (SAE) and European Association of Aerospace Industries. 71

72. Questions / Comments