Chapter 6 Requirements for a Maintenance Program AC

Chapter 6 Requirements for a Maintenance Program

AC 120 -16 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 120 -16 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 • • • Scheduled maintenance • • Engines Propellers Parts Appliances 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 • • Tasks divided into groups • • • Input from MRB report 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 • • • Contractor maintenance personnel • • • Airline policies/procedures Clear authority Responsibility Direction 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

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 • • Purchasing/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