Aviation
Maintenance
Management
SAMENVATTING
-
HOGESCHOOL VAN AMSTERDAM | ENGINEERING LEERJAAR 2
,Inhoudsopgave
Aviation Maintenance Management .................................................................................................4
Week 1.1 – EASA PART M ..................................................................................................................4
Aircraft Airworthiness ....................................................................................................................4
Part-M Aircraft Maintenance ......................................................................................................5
In Summary: ...................................................................................................................................6
Week 1.2 – Introduction Aircraft Maintenance .............................................................................6
What is Maintenance? .................................................................................................................6
Why Maintain an aircraft? ...........................................................................................................7
Maintenance Concepts ..............................................................................................................7
Hard-Time component exchanges (HT) ................................................................................7
On condition maintenance (OC) ..........................................................................................7
Condition monitoring (CM) .....................................................................................................7
Week 2.1 – Composite Airframe ......................................................................................................8
Continued Airworthiness ..............................................................................................................8
Composite Awareness .................................................................................................................9
Composite Awareness Technical Issues .....................................................................................9
Composite Awareness Teamwork ............................................................................................10
Composite Awareness Damage Disposition ...........................................................................10
Repair Approval Needed! .............................................................................................................10
Damage Detection and Characterization .............................................................................11
Damage Types ............................................................................................................................11
Damage Detection and Inspection .........................................................................................12
Composite Repair .......................................................................................................................12
Composite Repair Quality .........................................................................................................12
Bonded Composite Repair ........................................................................................................13
Repair Principles ..........................................................................................................................15
Bolted Composite Repair...........................................................................................................16
Roles and Responsibilities ...........................................................................................................17
Week 2.2 – Metal Airframe .............................................................................................................17
Roles and Responsibilities ...........................................................................................................17
Main Airframe Repair .................................................................................................................17
Maintaining Original Strength....................................................................................................18
Maintaining Original Strength....................................................................................................18
Repair Contour and Weight ......................................................................................................18
Damage Detection ....................................................................................................................19
Damage Classification ...............................................................................................................19
Repairability .................................................................................................................................20
Damage Assessment ..................................................................................................................20
Skin Patch Repair ........................................................................................................................21
Week 3.1 - Engine Condition Monitoring (ECM) (Toezicht houden) .........................................23
Engine Monitoring .......................................................................................................................23
Overview of Trend Monitoring Process .....................................................................................24
Different Methods of Monitoring ...............................................................................................24
EGT Margin:..................................................................................................................................24
1
, Maintenance Concepts ............................................................................................................25
Primary Causes of Engine Removals ........................................................................................25
EGT Margin; Typical Detoriation Causes ...........................................................................25
EGT Margin Deterioration Cycle ...............................................................................................26
Deterioration Curve ....................................................................................................................26
Engine Water Washing .............................................................................................................26
Week 3.2 – Engine Maintenance ..................................................................................................26
Maintenance Concepts ............................................................................................................27
Maintenance Levels & Work Scopes ........................................................................................29
Engine Work scope .....................................................................................................................30
Maintenance Levels & Work scope..........................................................................................30
Engine Life Limited Parts .............................................................................................................31
Turbo Machinery Basics of Life Limited Parts ...........................................................................32
Entire Engine Maintenance Process .........................................................................................33
Post Overhaul/Repair Testing (testing after repair) ................................................................33
Week 5.1 – Part 145 .........................................................................................................................34
What is a Maintnance Repair Organization Facility? .............................................................34
The Organization .........................................................................................................................36
Week 5.2 – Part 145 .........................................................................................................................37
Types of Maintenance ...............................................................................................................37
Heavy & Base maintenance facilities ......................................................................................37
Types of Maintenance ...............................................................................................................38
1. Ramp Line Maintenance ..................................................................................................39
2. Base Hangar Maintenance & Inspection Method ........................................................40
Typical issues during base maintenance .................................................................................41
3. Shop Maintenance ............................................................................................................42
4. Quality Assurance & Control ............................................................................................43
Summary ......................................................................................................................................44
Week 6.1- Troubleshooting .............................................................................................................44
Troubleshooting Model...............................................................................................................44
Systematic vs. Schematic Approach .......................................................................................45
Systematic Appro vs. Schematic Approach ................................................................46
Level 2: Problem Relating Systems and It’s Environment .......................................................47
Level 3: The Interaction or Two or More Systems ....................................................................49
Week 6.2 – Engineering/Product Planning & Stores Material Support .....................................50
Engineering Responsibilities .......................................................................................................50
Large vs. Small Engineering Orgnization ..................................................................................51
Responsibilities Engineering SB & AD ........................................................................................51
Engineering Order (EO) ..............................................................................................................52
Engineering Design Organization Approval (Part 21) ............................................................52
Engineering – Design Organization Approval (DOA) – Type Certificate (TC) .....................52
Engineering Design Organization (PART 21) ............................................................................53
1. Engineering Budgetting & Forecasting ...........................................................................53
2. Heavy Maintenance Support ...........................................................................................53
3. Phase In & Phase Out ........................................................................................................54
Production Planning ...................................................................................................................54
Material Support .........................................................................................................................55
2
, Operations Control Centre ........................................................................................................56
AOG Support ...............................................................................................................................56
Maintenance Control Center ...................................................................................................56
Week 7.1 Safety Management System ........................................................................................57
Closed Loop Control System .....................................................................................................57
Understanding SMS .....................................................................................................................57
Risk Management .......................................................................................................................58
Hazard Identification: Sources ..................................................................................................58
Assessment & Mitigation ............................................................................................................58
Week 7.2 – Safety Policy & Objectives .........................................................................................59
Commitment ...............................................................................................................................59
Accountability .............................................................................................................................60
Week 8 - SMS DEEL 2 .......................................................................................................................61
Monitoring ....................................................................................................................................61
Measuring Safety Performance ................................................................................................61
Statistics on Incidents and Occurrences .................................................................................61
Sources of Information ...............................................................................................................62
Occurrence reporting ................................................................................................................62
Flight Data Monitoring ................................................................................................................62
Example of Predefined Limits ....................................................................................................63
Safety Performance Indicators .................................................................................................63
Week 8 - SMS ....................................................................................................................................63
Black Book Safety Ladder (Hudson) ...................................................................................63
Measuring safety culture............................................................................................................63
3
,Aviation Maintenance Management
Week 1.1 – EASA PART M
Part M:
• Op tijd onderhoud
Part 21:
• Fabrikanten
• Ontwerpen van onderdelen
Part 145 → Onderhoud plegen
Part M → Onderhoud managen
WPI→ Werk Plaats Instructies
Part 21:
Hoe pak ik het aan.
Regelement. Fabrikanten
zorgen ervoor dat het
luchtwaardig is.
Part M:
Part 145 is eigenlijk de garage
Part 66: Zijn mbo’ers
Part-M CAMO Beschreven in het CAME, Continued Airworthiness
Management Exposition
Part-145 AMO Beschreven in het MOE, Maintenance Organization
Exposition
Part-147 MTO Leidt op i.o.m. Part-66 beschreven in het MTOE
Part-21 DO Beschreven in het DOE, Design Organization Exposition
Aircraft Airworthiness
• An aircraft is required to be an Airworthy in order to perform a flight.
4
, • Certificate of Airworthiness (CofA) – in respect of an aeronautical product, means in a fit and
safe state for flight and in conformity with its type design.
• To remain in an airworthy state all requirements for maintenance, repair and alterations are
performed according to the regulations
Hey! What does the regulations say about maintenance? → The owner is responsible!
Part-M Aircraft Maintenance
De eigenaar/gebruiker is verantwoordelijk voor de permanente luchtwaardigheid van een vliegtuig.
• Operators Maintenance Program
• Planning of maintenance
• Aircraft Technical Log (AFL, HIL, ACL..)
• Maintenance Data (AMMM, WDM, Part-21 Data)
• Maintenance records → Alle data’s moet op orde zijn voor de (her)verkoop.
• ARC Inspectie
• Limitated to ‘preflight inspection’
• Activities who needs a ‘Release to Service’ carried out by a Part-145 AMO!
• Contracted maintenance data
• Monitoring of contracted work
The tasks and responsibilities of a CAMO
organization are described in the CAME.
• The CAME thus shows how the CAMO
complies to Part M.
The CAME describes such things as:
o Part 0: General description of company, including personnel and responsibilities
o Part 1: Airworthiness Management procedures
o Part 2: Quality System
o Part 3: Contracted Maintenance
o Part 4: Airworthiness Review Procedures
Hey! All repairs have to documented and based on ‘approved data’.
The following is a list of minimum tasks performed by the CAMO organization:
• Tracking of aircraft data > all needs to be traceable!
• Management of Maintenance program
5
, • Control & Accomplishment of Airworthiness Directives (AD’s) → AD is vanuit
luchtvaartautoriteiten.
• Analysis of Maintenance Program effectiveness
• Embodiment policy of non-mandatory modifications (SB’s) → Dat fabrikanten ingelicht
worden. Wat gaat er goed, wat kan anders? SB is een beveling om aanpassingen te doen. Is
niet verplicht. Een AD wel.
• Major modification standards → Dat is een vrachtdeur erin gezet wordt i.p.v. een normale.
• Defect reports / fault management (including Incidents / occurrences) - Engineering
activities (design Part 21)
• Reliability program (removals, defects, trends)
• Pre-flight check / weighing / check flight procedures
In Summary:
1. The management of Aircraft Maintenance is covered under EASA Part M
2. Aircraft owners are responsible for aircraft maintenance
3. Responsibility can be transferred by contracting a CAMO organization
4. CAMO organization manages the aircraft’s continuing Airworthiness
5. Tasks include the management of scheduled & unscheduled maintenance
6. CAMO organization is the link between the Part 145 and the operator.
Week 1.2 – Introduction Aircraft Maintenance
What is Maintenance?
Those actions are required for restoring or maintaining an item in a serviceable condition including
servicing, repair, modification, overhaul, inspection and determination of condition” [World Airlines
Technical Operations Glossary]
Punt c figuur 5 → Als je te laat bent, heb je kans dat je gaat falen en dat je terecht komt bij de
unscheduled maintenance.
6
, Why Maintain an aircraft?
• Safety first when considering aircraft maintenance
o Guarantee continued airworthiness of the aircraft
o Highly regulated environment
• Operational reasons
o Ensure good technical condition of the aircraft enabling operations without technical
interruptions e.g. delays, cancellations, in-flight turn-backs
• The asset value is also o major driver
o Leased aircraft
o Owned aircraft
Maintenance Concepts
Hard-Time component exchanges (HT)
• Some safety-related components have a defined life limit
• They need to be replaced when this limit is reached
• Examples are:
o Engines life Limited Parts (LLP)
o Some Landing Gear Parts
o Fire extinguishers
On condition maintenance (OC)
• Components that need to be replaced or serviced only when the specific component fails or
shows a degraded performance
• The majority of aircraft components falls within this category
• Examples are:
o Borescope
o BITE
o Ultrasone
Condition monitoring (CM)
• The CM process involves the monitoring of failure rates, removals etc. of individual
components or systems that do not have a definite lifetime or a noticeable wear-out period.
• The CM process in applied when neither the HT nor the OC process can be applied. CM is not
a failure preventive process as are HT and OC.
• Examples are:
Complex systems such as avionics, electronic components and where failure has no serious
effect on safety or airworthiness
Paar benamingen:
• Expandables: Goedkope onderdelen die je weggooit
7
Maintenance
Management
SAMENVATTING
-
HOGESCHOOL VAN AMSTERDAM | ENGINEERING LEERJAAR 2
,Inhoudsopgave
Aviation Maintenance Management .................................................................................................4
Week 1.1 – EASA PART M ..................................................................................................................4
Aircraft Airworthiness ....................................................................................................................4
Part-M Aircraft Maintenance ......................................................................................................5
In Summary: ...................................................................................................................................6
Week 1.2 – Introduction Aircraft Maintenance .............................................................................6
What is Maintenance? .................................................................................................................6
Why Maintain an aircraft? ...........................................................................................................7
Maintenance Concepts ..............................................................................................................7
Hard-Time component exchanges (HT) ................................................................................7
On condition maintenance (OC) ..........................................................................................7
Condition monitoring (CM) .....................................................................................................7
Week 2.1 – Composite Airframe ......................................................................................................8
Continued Airworthiness ..............................................................................................................8
Composite Awareness .................................................................................................................9
Composite Awareness Technical Issues .....................................................................................9
Composite Awareness Teamwork ............................................................................................10
Composite Awareness Damage Disposition ...........................................................................10
Repair Approval Needed! .............................................................................................................10
Damage Detection and Characterization .............................................................................11
Damage Types ............................................................................................................................11
Damage Detection and Inspection .........................................................................................12
Composite Repair .......................................................................................................................12
Composite Repair Quality .........................................................................................................12
Bonded Composite Repair ........................................................................................................13
Repair Principles ..........................................................................................................................15
Bolted Composite Repair...........................................................................................................16
Roles and Responsibilities ...........................................................................................................17
Week 2.2 – Metal Airframe .............................................................................................................17
Roles and Responsibilities ...........................................................................................................17
Main Airframe Repair .................................................................................................................17
Maintaining Original Strength....................................................................................................18
Maintaining Original Strength....................................................................................................18
Repair Contour and Weight ......................................................................................................18
Damage Detection ....................................................................................................................19
Damage Classification ...............................................................................................................19
Repairability .................................................................................................................................20
Damage Assessment ..................................................................................................................20
Skin Patch Repair ........................................................................................................................21
Week 3.1 - Engine Condition Monitoring (ECM) (Toezicht houden) .........................................23
Engine Monitoring .......................................................................................................................23
Overview of Trend Monitoring Process .....................................................................................24
Different Methods of Monitoring ...............................................................................................24
EGT Margin:..................................................................................................................................24
1
, Maintenance Concepts ............................................................................................................25
Primary Causes of Engine Removals ........................................................................................25
EGT Margin; Typical Detoriation Causes ...........................................................................25
EGT Margin Deterioration Cycle ...............................................................................................26
Deterioration Curve ....................................................................................................................26
Engine Water Washing .............................................................................................................26
Week 3.2 – Engine Maintenance ..................................................................................................26
Maintenance Concepts ............................................................................................................27
Maintenance Levels & Work Scopes ........................................................................................29
Engine Work scope .....................................................................................................................30
Maintenance Levels & Work scope..........................................................................................30
Engine Life Limited Parts .............................................................................................................31
Turbo Machinery Basics of Life Limited Parts ...........................................................................32
Entire Engine Maintenance Process .........................................................................................33
Post Overhaul/Repair Testing (testing after repair) ................................................................33
Week 5.1 – Part 145 .........................................................................................................................34
What is a Maintnance Repair Organization Facility? .............................................................34
The Organization .........................................................................................................................36
Week 5.2 – Part 145 .........................................................................................................................37
Types of Maintenance ...............................................................................................................37
Heavy & Base maintenance facilities ......................................................................................37
Types of Maintenance ...............................................................................................................38
1. Ramp Line Maintenance ..................................................................................................39
2. Base Hangar Maintenance & Inspection Method ........................................................40
Typical issues during base maintenance .................................................................................41
3. Shop Maintenance ............................................................................................................42
4. Quality Assurance & Control ............................................................................................43
Summary ......................................................................................................................................44
Week 6.1- Troubleshooting .............................................................................................................44
Troubleshooting Model...............................................................................................................44
Systematic vs. Schematic Approach .......................................................................................45
Systematic Appro vs. Schematic Approach ................................................................46
Level 2: Problem Relating Systems and It’s Environment .......................................................47
Level 3: The Interaction or Two or More Systems ....................................................................49
Week 6.2 – Engineering/Product Planning & Stores Material Support .....................................50
Engineering Responsibilities .......................................................................................................50
Large vs. Small Engineering Orgnization ..................................................................................51
Responsibilities Engineering SB & AD ........................................................................................51
Engineering Order (EO) ..............................................................................................................52
Engineering Design Organization Approval (Part 21) ............................................................52
Engineering – Design Organization Approval (DOA) – Type Certificate (TC) .....................52
Engineering Design Organization (PART 21) ............................................................................53
1. Engineering Budgetting & Forecasting ...........................................................................53
2. Heavy Maintenance Support ...........................................................................................53
3. Phase In & Phase Out ........................................................................................................54
Production Planning ...................................................................................................................54
Material Support .........................................................................................................................55
2
, Operations Control Centre ........................................................................................................56
AOG Support ...............................................................................................................................56
Maintenance Control Center ...................................................................................................56
Week 7.1 Safety Management System ........................................................................................57
Closed Loop Control System .....................................................................................................57
Understanding SMS .....................................................................................................................57
Risk Management .......................................................................................................................58
Hazard Identification: Sources ..................................................................................................58
Assessment & Mitigation ............................................................................................................58
Week 7.2 – Safety Policy & Objectives .........................................................................................59
Commitment ...............................................................................................................................59
Accountability .............................................................................................................................60
Week 8 - SMS DEEL 2 .......................................................................................................................61
Monitoring ....................................................................................................................................61
Measuring Safety Performance ................................................................................................61
Statistics on Incidents and Occurrences .................................................................................61
Sources of Information ...............................................................................................................62
Occurrence reporting ................................................................................................................62
Flight Data Monitoring ................................................................................................................62
Example of Predefined Limits ....................................................................................................63
Safety Performance Indicators .................................................................................................63
Week 8 - SMS ....................................................................................................................................63
Black Book Safety Ladder (Hudson) ...................................................................................63
Measuring safety culture............................................................................................................63
3
,Aviation Maintenance Management
Week 1.1 – EASA PART M
Part M:
• Op tijd onderhoud
Part 21:
• Fabrikanten
• Ontwerpen van onderdelen
Part 145 → Onderhoud plegen
Part M → Onderhoud managen
WPI→ Werk Plaats Instructies
Part 21:
Hoe pak ik het aan.
Regelement. Fabrikanten
zorgen ervoor dat het
luchtwaardig is.
Part M:
Part 145 is eigenlijk de garage
Part 66: Zijn mbo’ers
Part-M CAMO Beschreven in het CAME, Continued Airworthiness
Management Exposition
Part-145 AMO Beschreven in het MOE, Maintenance Organization
Exposition
Part-147 MTO Leidt op i.o.m. Part-66 beschreven in het MTOE
Part-21 DO Beschreven in het DOE, Design Organization Exposition
Aircraft Airworthiness
• An aircraft is required to be an Airworthy in order to perform a flight.
4
, • Certificate of Airworthiness (CofA) – in respect of an aeronautical product, means in a fit and
safe state for flight and in conformity with its type design.
• To remain in an airworthy state all requirements for maintenance, repair and alterations are
performed according to the regulations
Hey! What does the regulations say about maintenance? → The owner is responsible!
Part-M Aircraft Maintenance
De eigenaar/gebruiker is verantwoordelijk voor de permanente luchtwaardigheid van een vliegtuig.
• Operators Maintenance Program
• Planning of maintenance
• Aircraft Technical Log (AFL, HIL, ACL..)
• Maintenance Data (AMMM, WDM, Part-21 Data)
• Maintenance records → Alle data’s moet op orde zijn voor de (her)verkoop.
• ARC Inspectie
• Limitated to ‘preflight inspection’
• Activities who needs a ‘Release to Service’ carried out by a Part-145 AMO!
• Contracted maintenance data
• Monitoring of contracted work
The tasks and responsibilities of a CAMO
organization are described in the CAME.
• The CAME thus shows how the CAMO
complies to Part M.
The CAME describes such things as:
o Part 0: General description of company, including personnel and responsibilities
o Part 1: Airworthiness Management procedures
o Part 2: Quality System
o Part 3: Contracted Maintenance
o Part 4: Airworthiness Review Procedures
Hey! All repairs have to documented and based on ‘approved data’.
The following is a list of minimum tasks performed by the CAMO organization:
• Tracking of aircraft data > all needs to be traceable!
• Management of Maintenance program
5
, • Control & Accomplishment of Airworthiness Directives (AD’s) → AD is vanuit
luchtvaartautoriteiten.
• Analysis of Maintenance Program effectiveness
• Embodiment policy of non-mandatory modifications (SB’s) → Dat fabrikanten ingelicht
worden. Wat gaat er goed, wat kan anders? SB is een beveling om aanpassingen te doen. Is
niet verplicht. Een AD wel.
• Major modification standards → Dat is een vrachtdeur erin gezet wordt i.p.v. een normale.
• Defect reports / fault management (including Incidents / occurrences) - Engineering
activities (design Part 21)
• Reliability program (removals, defects, trends)
• Pre-flight check / weighing / check flight procedures
In Summary:
1. The management of Aircraft Maintenance is covered under EASA Part M
2. Aircraft owners are responsible for aircraft maintenance
3. Responsibility can be transferred by contracting a CAMO organization
4. CAMO organization manages the aircraft’s continuing Airworthiness
5. Tasks include the management of scheduled & unscheduled maintenance
6. CAMO organization is the link between the Part 145 and the operator.
Week 1.2 – Introduction Aircraft Maintenance
What is Maintenance?
Those actions are required for restoring or maintaining an item in a serviceable condition including
servicing, repair, modification, overhaul, inspection and determination of condition” [World Airlines
Technical Operations Glossary]
Punt c figuur 5 → Als je te laat bent, heb je kans dat je gaat falen en dat je terecht komt bij de
unscheduled maintenance.
6
, Why Maintain an aircraft?
• Safety first when considering aircraft maintenance
o Guarantee continued airworthiness of the aircraft
o Highly regulated environment
• Operational reasons
o Ensure good technical condition of the aircraft enabling operations without technical
interruptions e.g. delays, cancellations, in-flight turn-backs
• The asset value is also o major driver
o Leased aircraft
o Owned aircraft
Maintenance Concepts
Hard-Time component exchanges (HT)
• Some safety-related components have a defined life limit
• They need to be replaced when this limit is reached
• Examples are:
o Engines life Limited Parts (LLP)
o Some Landing Gear Parts
o Fire extinguishers
On condition maintenance (OC)
• Components that need to be replaced or serviced only when the specific component fails or
shows a degraded performance
• The majority of aircraft components falls within this category
• Examples are:
o Borescope
o BITE
o Ultrasone
Condition monitoring (CM)
• The CM process involves the monitoring of failure rates, removals etc. of individual
components or systems that do not have a definite lifetime or a noticeable wear-out period.
• The CM process in applied when neither the HT nor the OC process can be applied. CM is not
a failure preventive process as are HT and OC.
• Examples are:
Complex systems such as avionics, electronic components and where failure has no serious
effect on safety or airworthiness
Paar benamingen:
• Expandables: Goedkope onderdelen die je weggooit
7
