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

2. THIS DAY IN AVIATION September 29
1928 — William Brock and Edward Schlee in a Bellanca monoplane at Rockwell Field, California, make a duration flight of 59 hours 10 minutes 15 seconds.

3. THIS DAY IN AVIATION September 29
1928 — Air Races held at Boise, Idaho.

4. THIS DAY IN AVIATION September 29
1938 — B/Gen. H.H. “Hap” Arnold named Chief of the Army Air Corps.

5. THIS DAY IN AVIATION September 29
1964 — The first take-off and landing of the LTV (Ling-Temco-Vought) XC- 142A vertical take-off transport is made in Dallas, Texas.
The aircraft has four 2,850-hp General Electric turboprops mounted on the wings that can pivot 90 degrees to allow for a vertical take-off.

6. Questions / Comments

7. Management of Aeronautical Science
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.
Monday

8. Management of Aeronautical Science
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.
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.

14. Assignments Due – Module 4 (9/26/16 – 10/9/16)
Management of Aeronautical Science
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)
Review Questions – Aircraft Systems and Maintenance – Importance to Management
(Due - Fri Oct 7) – 5 Questions

15. September/October 2016
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday 25 26
Module 4 Intro
Aircraft Systems / Maintenance 27
Module 4
Aircraft Systems / Maintenance 28 29
Aircraft Systems / Maintenance 30
Flightline Friday 1 2 3 4 5
Discussion Due 6
Beaufort County Airport (ILT) 7
Review Questions Due 8 9 10
Module 5
Intro
Aviation Safety and Security 11
Aviation Safety and Security 12
1st Quarter Grades Due 13 14
Flightline
Report Cards Sent Home 15 16 17 18 19 20 21 22

16. Questions / Comments

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

18. Understand management perspective of aviation maintenance

19. 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

20. 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

21. 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

22. 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 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.

23. 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

24. 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

25. 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.

26. 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

27. 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

28. 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.

29. 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

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

31. 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

32. 14 CFR Parts 121 Airlines Maintenance
Part 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 Provides detailed requirements for manual contents.
Part 135 also has a manual requirement

33. 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.

34. 14 CFR Part 119 Operations Specification (OpSpec)
Issued to air carriers
Lists authorizations and specifications
Legally binding and has 8 broad categories
General
Enroute authorizations and limitations
Airport authorizations and limitations
Maintenance
Weight and Balance
Schedules
Equipment interchange
Aircraft leasing

35. 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.

36. 5 Types of Maintenance Inspection Unscheduled 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

37. Questions / Comments

38. 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)

39. 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

40. 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

41. 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.

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

43. 3rd 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

44. 14 CFR Part 145 Repair Stations
Considered 3rd party maintenance
Discussed previously in course
Repairman certified under Part 65
Many different types and classifications of repair stations

45. 3rd Party Types of Contracts
Maintenance Labor only agreement
Labor and parts agreements
Preventive maintenance
Complete maintenance management
Complete major repair, modification, and alterations

46. 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

47. 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.

48. 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

49. 4 Categories of 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.

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

51. Inventory Costs Inventory Carrying or Holding Costs Ordering 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

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

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

54. 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

55. 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

56. 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

57. 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.

58. Questions / Comments