PREVENTIVE

MAINTENANCE
SCHEDULE IN PAKISTAN
INTERNATIONAL LINES
[Document subtitle]

SECTION : D
BATCH : 2011-12
DATE : 2ND NOVEMBER 2015

SUBMITTED TO : SYED MUNAWER HASAN

GROUP MEMBERS
S.NO

NAME

ROLL NO.

MUHAMMAD ADNAN

ME-009

SYED MOIZ

ME-012

KASHAN AKRAM SHEIKH

ME-020

MUHAMMAD ZAIN

ME-038

ASAD AKTHER NAQVI

ME-048

OVAIS MAHFOOZ

ME-082

ASAD SIDDIQUI

ME-090

BILAWAL MAHER

ME-092

USMAN ARSHAD

ME-093

10

MUNEER ALI

ME-096

11

MUHAMMAD ARIF

ME-149

12

AHMED NAWAZ

ME-156

ABOUT PIA
In 1946, Quaid-e-Azam Muhammed Ali Jinnah realized the need for a flag carrier for the
prospective country and requested financial help from a wealthy businessman Mirza Ahmad
Ispahani and Adamjee Haji Dawood for this purpose. Around that time, a new airline 'Orient
Airways was registered in Calcutta on 23 October 1946.
On 7 June 1954, Orient Airways started its operations. On 11 March 1955, Orient Airways
merged with the government's proposed airline, becoming Pakistan International Airlines
Corporation.

FLEETS
PIA's fleets of modern aircraft are spacious, comfortable, and designed to get you to your
destination safely.

Boeing 777
The Boeing 777 family comprises of long-range, wide-body twin-engine airplanes. PIA was the
first airline in the world to operate all the three variants of the 777 family: 777-200LR, 777200ER and 777-300ER, all of them are well loved by PIA's seasoned travelers for their
spaciousness and comfort. PIA also holds the privilege of being the launch customer for 777200LR, one of PIAs aircraft which holds the record for the longest commercial jet flight in
aviation history.

Boeing 747
The Boeing 747, often referred to as Jumbo Jet, is amongst the world's most iconic and
recognizable jet airplanes. This 4 engine long haul wide-body airplane has a two-deck
configuration. PIA operates one variant of 747 family i.e. 747-300. At present due to its

capacity, 747-300 fleet is mostly deployed to cater high density requirements like carrying
intending pilgrims to and from Saudi Arabia.

Airbus A310
The Airbus A310 is a medium to long range wide-body airplane providing a spacious interior to
its travelers. PIA has deployed the A310-300 fleet on Far East, Regional as well as Domestic
routes.

Airbus A320
The Airbus A320 is one of the world's favorite narrow-body short/medium haul jet airplane. By
virtue of right-sized fuselage, it enhances comfort for passengers and at the same time enjoys
the reputation of fuel-efficient aircraft. A320 aircraft mostly serve its domestic and regional
routes.

ATR42
This modern technology turbo prop is the latest type inducted in PIAs fleet. PIAs fleet of
ATR42-500 and ATR72-500 aircraft is configured in comfortable two class seating arrangement.
This aircraft has enabled the airline to provide its valued customers the most convenient way to
fly to far flung and remote destinations of the country which are sparsely served by other
means of transport.

MAJOR COMPONENTS OF PLANE

An airplane is a semi-cop structure that is aerofoil shaped so as to assist lifting.

MANUFACTURERS:
Plane:

Boeing (American company)

Airbus (conglomerate of Germany, France etc)

Engine:
Three engine manufacturers with whom PIA deals are:
General Electric
Pratt and Whitney
Rolls Royce

MAIN PLANE PARTS

Control surfaces:
Moveable surfaces on an airplanes wings and tail allow a pilot to maneuver an airplane and
control its attitude or orientation. In light of the adoption of nautical terms, the motion about
the airplanes longitudinal axis is called roll; motion about its lateral axis is referred to as
pitch. Finally, an airplane moves about its vertical axis in a motion, which is termed yaw
that is, a horizontal (left and right) movement of the airplanes nose. The three motions of the
airplane (roll, pitch, and yaw) are controlled by three control surfaces. Roll is controlled by the
ailerons; pitch is controlled by the elevators; yaw is controlled by the rudder.

The three motions of the airplane (roll, pitch, and yaw) are controlled by three control surfaces.
Roll is controlled by the ailerons; pitch is controlled by the elevators; yaw is controlled by the
rudder.
There are three major control surfaces:

Ailerons

Ailerons control roll about the longitudinal axis. The ailerons are attached to the
outboard trailing edge of each wing and move in the opposite direction from each other
Moving the control wheel to the right causes the right aileron to deflect upward and the
left aileron to deflect downward.

Rudder

The rudder controls movement of the airplane about its vertical axis. This motion is
called yaw. Like the other primary control surfaces, the rudder is a movable surface
hinged to a fixed surface, in this case, to the vertical stabilizer, or fin. Moving the left or
right rudder pedal controls the rudder.
When the rudder is deflected into the airflow, a horizontal force is exerted in the
opposite direction.
By pushing the left pedal, the rudder moves left. This alters the airflow around the
vertical stabilizer/rudder, and creates a sideward lift that moves the tail to the right and
yaws the nose of the airplane to the left.

Elevator

The elevator controls pitch about the lateral axis. Like the ailerons on small airplanes,
the elevator is connected to the control column in the cockpit by a series of mechanical
linkages. Aft movement of the control column deflects the trailing edge of the elevator
surface up. This is usually referred to as up elevator.

Engines:
There are two types of engine in an aircraft:

Main engine
The main engine provides the main thrust power for the aircraft and is also used to get bleed
air. A turbofan engine is much the same as a turbojet, but with an enlarged fan at the front that
provides thrust in much the same way as a ducted propeller, resulting in improved fuelefficiency.

Auxiliary Power Unit (APU)

The APU is used for electrical power and to start the main engine. It provides power (electric,
pneumatic, or hydraulic, depending on the design) to start the aircraft's main engines. This
allows the cabin to be comfortable while the passengers are boarding before the aircraft's
engines are started. Electrical power is used to run systems for preflight checks. This function
can also be used, on some aircraft, as a backup in flight in case of engine or hydraulic failure.

BRAKING SYSTEM:
The braking system of a plane is made up of three major parts:
The spoilers: are present on the wings and are lifted up to provide air-drag.
The turbine thrust reversal: is used to reverse the high velocity exhaust gases to provide
braking.
The brakes of landing gear: are disc brakes and are used to stop the landing gear.

LIFT AUGMENTATION DEVICES:

Slats and flaps

These are used during takeoff to assist lifting by increasing the area of the aero foil
shape. CGC= Center Gravity Control: is used to move fuel and maintain the C.G point

MOTIONS OF PLANE:
There are three motions of a plane:
Apart from Yawing, Pitching, Rolling some other motions related to aircraft are:
Mooring : is the fixing of a plane in case of storms
Towing: is the puling of plane when engine power is killed
Taxing: is the movement of plane on land using engine power
Shoring : is supporting the plane on jacks
Yawing and rolling is done together to decrease the radius of rotation

LOADS ON AN AIRCRAFT:
There are the following main loads on an aircraft:

Pressurization loads
Aerial loads
Bending loads
Tensile loads
Compressive loads

AIRCRAFT MAINTENANCE
PROPER AIRCRAFT MAINTENANCE IS ESSENTIAL FOR KEEPING AIRCRAFT AND AIRCRAFT PARTS IN
OPTIMAL CONDITION, AND ENSURING THE SAFETY OF PILOTS, CREW, AND PASSENGERS.

Maintenance is required for three principal reasons:

Operational: To keep the aircraft in a serviceable and reliable condition so as to

generate revenue.
Value Retention: To maintain the current and future value of the aircraft by minimizing
the physical deterioration of the aircraft throughout its life.
Regulatory Requirements: The condition and the maintenance of aircraft are regulated
by the aviation authorities of the jurisdiction in which the aircraft is registered. Such
requirements establish standards for repair, periodic overhauls, and alteration by
requiring that the owner or operator establish an airworthiness maintenance and
inspection program to be carried out by certified individuals qualified to issue an
airworthiness certificate.

Repair stations and maintenance technicians perform maintenance and inspections on aircraft.
The Federal Aviation Administration is responsible for certifying the repair stations and aircraft
maintenance technicians (AMTs).
Repair stations are certified under FAR Part 145. AMTs are certified under FAR Part 65.FAR Part
43 details the standards regarding the maintenance, preventative maintenance, and alterations
of aircraft and aircraft articles and systems.

ROUTINE MAINTENANCE TASKS

Maintenance of aircraft is a comprehensive, ongoing process. The entire aircraft needs to be
examined, maintained, and have the necessary parts replaced to uphold the safety standards.
Aircraft are required to be maintained after a certain period of calendar time or flight hours or
flight cycles. Also, some aircraft articles have a specific life (flight cycle) limit, and need to be
replaced immediately upon reaching the maximum use requirements.
Besides the aircraft articles that are due for replacement, all other parts need to be checked for
faults or faulty performance. Because of the noise of testing different systems, working long
hours, and the expectations of maintaining high safety standards, being an AMT can be a
stressful job.
Here are just some of the routine maintenance tasks performed by an AMTs in Pakistan
international Airlines:

cleaning aircraft and components

application of corrosion prevention compound
lubricating parts
draining and troubleshooting fuel systems
checking and servicing hydraulic and pneumatic systems

replacing components
inspecting for general wear and tear

A newer field of aircraft maintenance is working in avionics, which deals with electronic
systems. These parts are vital for navigation and communications, and include radar,
instruments, computer systems, radio communications, and global positions systems (GPS).
A strong knowledge of wiring and technical skills is required for working in avionics
maintenance.

PREVENTIVE MAINTENANCE SCHEDULE

PIA clientele comprises of large numbers of international operators and its experience of over
50 years enables to find the right solutions for all operational and maintenance needs. PIAs
highly qualified engineering personnel offer comprehensive engineering services, backed up by
excellent equipment and systems. They have sufficient aircraft support dock installations in the
hangars, as well as trained manpower and tooling, to undertake simultaneous work on various
types of aircraft in pia fleet, around the clock.
Preventive maintenance for the air crafts are carried out in different intervals, which are
specially needed to be carried out for larger aircrafts. All aircraft have periodic inspections,
aircraft have to go through an extensive inspection process, also referred to as checks. There
are several checks that need to be done according to calendar dates, flight hours, or flight
cycles. A flight cycle is one flight, with a take-off and landing.AMTs maintain specific areas of
aircraft depending on their certification and rating. The different aircraft ratings are airframe
(the aircraft body, such as the tail, fuselage, wings, and landing gear), power plant (engines and
propellers), and avionics (electrical systems and instruments).Most AMTs hold a dual airframe
and power plant FAA certification, and are referred to as A&P mechanics.
PIA is performing preventive maintenance program on regular and satisfactorily basis. PIA is
fulfilling the 10 elements required of an air carrier maintenance program. These 10 elements
are:
Airworthiness responsibility
Air carrier maintenance manual
Air carrier maintenance organization
Accomplishment and approval of maintenance and alterations
Maintenance schedule
Required Inspection Items
Maintenance recordkeeping system
Contract maintenance
Personnel training
Continuing Analysis and Surveillance System (CASS)
In PIA we found out that maintenance department categorized the intervals with letters from A
to D. A-check is a light routine inspection. On the opposite end of the spectrum, a D-check is the
most intensive, long-term check.

A-checks are performed at around 500 flight hours (FH). This is a routine check, to make sure
everything is functioning safely and efficiently. It can usually be completed overnight at an
airport gate, and can even be delayed if an aircraft meets certain predetermined conditions.

B-checks are more extensive than a checks, but can also be completed overnight.

C-checks require aircraft to be docked at a hangar or repair station for detailed inspections.
These are generally performed every 12-18 months, depending on the type of aircraft and
the manufacturers specifications.

D-checks are done approximately every 4-5 years, and are the most intensive, timeconsuming aircraft inspection. The aircraft needs to have every fastener, nut, wire, hinge, and
component inspected, repaired, maintained, or replaced.
B777-200/ 300
Service
Line Checks

Routine A
checks
C
Major
Mid-D
Checks
D
C of MR issuance

Inspection time
Transit (Outstation & Base)
Service Check 1
After 250 flight hours
Service Check2
After 500 flight hours
75days/1000FH
750 days
3000 Days
As per PCAA ANO 0001 Requirement

B747-300
Service
Line Checks

Routine A
checks
C
Major
Mid-D
Checks
D
C of MR issuance

Inspection time
Transit (Outstation & Base)
Daily Check
36elphrs
Weekly Check
Not exceeding 8 elp days
Not exceeding 600 flight hours
6000 flight hours/18 months
6 Years
As per PCAA ANO 0001 Requirement

B747-200
Service
Line Checks

Routine A
checks
C
Major
Mid-D
Checks
D
C of MR issuance

Inspection time
Transit (Outstation & Base)
Daily Check
36elphrs
Weekly Check
Not exceeding 8 elp days
Not exceeding 600flight hours
6000 flight hours/18 months
6 Years
As per PCAA ANO 0001 Requirement

A310-300
Service
Line Checks

Routine A
checks
C
Major
Mid-D
Checks
D
C of MR issuance

Inspection time
Transit (Outstation & Base)
Daily Check
36elphrs
Weekly Check
8 calendar days
500flight hours /04 months
6000 flight hours/24 months
6 Yearly
12 Years
As per PCAA ANO 0001 Requirement

B737-300
Service
Line Checks

Routine A
checks
C
Major
Mid-D
Checks
D
C of MR issuance

Inspection time
Transit (Outstation & Base) ( Preflight elapsed 12 hrs at Base)
Turnaround
(First flight from KHI, LHR, ISB, PEW)
250flight hours
4000 flight hours/15 months
24000 flight hours
As per PCAA ANO 0001 Requirement

INSPECTIONS

Ageing Aircraft Corrosion Prevention and Control Program (CPCP)

Supplemental Structural Inspection (SSI)

STRUCTURE REPAIR SHOP:

In structure repair shop certain components like nose cowl, nose etc. are repaired. First the
damaged area is removed than a piece of part confirming the shape of the damaged area is
machined and attached with blind rivets. A similar piece of plate is than cut and machined and
is riveted by blind rivets on to the part. Everything is done as per manual instruction. Aluminum
for most of the skin actually is ALCLAD used, which is a special type of aluminum alloy. Most of
rivets and structure is made of DURAL, which is other aluminum based alloy, and parts subject
to higher stress are made of steel, Nimonic and titanium like engines parts. Many aircraft have
also parts made of composite materials (commonly named as plastic) used as streamliners.

TOOL STORE:
The aviation maintenance technician (AMT) spends a major portion of each day using a wide
variety of hand tools to accomplish maintenance tasks. PIA tool store contains following tools:
Spanner
Socket
Wrench
Feeler gage
Jigs
Micrometer Screw gage
Fixture
Vernier Caliper
Ratchet
Screw driver
Speed Handle
Hammers

REPAIR STRUCTURE IN PIA

The FAA classifies repairs into two categories. Major and minor. Following is the FAAs
definition of both:

Major repair means a repair:

That, if improperly done, might appreciably affect weight, balance, structural strength,
performance, power plant operation, flight characteristics, or other qualities affecting
airworthiness; or
That is not done according to accepted practices or cannot be done by elementary
operations.

Minor repair means a repair other than a major repair.

Aircraft Structural Repairs

Structural repairs are made to aircraft that have sustained damage to the structure. There are
several ways an aircraft structure can be damaged. It is usually caused by ground service
equipment, maintenance stands, bird strikes, or lightning strikes.
Component repairs
Component repairs range from simple part replacements to an entire overhaul. If a component
fails to operate properly, it is removed from the aircraft and replaced by one the does operate
properly. The component is disassembled, cleaned inspected, repaired, reassembled, tested,
and returned to service.
Systems Repairs
Some repairs to aircraft systems (i.e., hydraulic, pneumatic, fuel, etc.) simply consist of
replacing a part or component. The faulty part is removed and replaced with a new part.
Engine Repairs
Some limited repairs can be done while the engine is on the aircraft. Those repairs usually
consist of parts replacements.
Avionics Repairs
Avionics repairs are treated a bit differently than other components because of their delicate
circuit boards and small fragile electrical or electronic parts.

General Flow Chart of How the Repairs & Alteration decisions are made

SAFETY AND MAINTENANCE

The primary goal of the aviation industry is to maintain airplane and helicopter safety
standards and protect the interests of the mechanics, flight crew, and passengers.
Problems with the aircraft or aircraft components can also lead to safety risks. These problems
include electrical, mechanical or hydraulic component failures. They also include metal fatigue
that result in cracks, or materials that become delaminated or corroded. These risks are
minimized by the continuous inspections performed on the aircraft and all aircraft articles.

What happens when maintenance is conducted improperly.

These problems include electrical, mechanical or hydraulic component failures. They also
include metal fatigue that result in cracks, or materials that become delaminated or corroded.
These risks are minimized by the continuous inspections performed on the aircraft and all
aircraft articles.
Sadly, the circumstances of each new accident are often remarkably similar to those of previous
accidents. What it means that the concerned authorities are not taking advantage of the
lessons learned from previous such tragedies that could help them avoid making same
mistakes.

What is needed to be done

Continuous maintenance re-training;

Create mechanisms for reporting, investigate reports, and provide legal protections to
the people who informed them
Human factors training for management and technicians/engineers.

From organizational point of view

Training and selection of

appropriate personnel.
Quality of resources as distributed.
Organizational Structure.
Opportunities for career
development.

From individual point of view

Knowledge and skill of personnel.

Quality of resources on hangar floor.
Work environment.
Morale & personalities of employee.

Name
Roll No
Sec

Muhammad Zain
ME-038
D

Conclusion
Here, I would like to appreciate the efforts made by my group members and especially towards
staff of PIA to help us study and analyze their maintenance schedule in a very short interval of
time.

Preventive Maintenance
Our core objective of this visit lies with preventive maintenance. The term preventive
maintenance commonly refers to the practice of regularly servicing equipment on a predetermined schedule so that it does not develop catastrophic failures.
Nothing lasts forever, so the saying goes, but with some care and regular servicing and
maintenance, products can provide normal anticipated operation. What I believe from the
course of plant maintenance throughout this semester and from practical exposure, preventive
maintenance

Extends the useful lifecycle of assets decreasing the need for capital replacements.

Enhances the efficiency of equipment keeping them running more efficiently and
lowering power expenses.

Enhances the performance of assets by increasing uptime.

Enhances customer (internal or external) service because maintenance teams have

less unplanned maintenance and can respond quicker to new problems.

Contributes positively to the reputation of companies

Maintenance at PIA
Now towards the maintenance program at PIA, here it means the preservation, inspection,
overhaul, and repair of aircraft, including the replacement of parts. The purpose of
maintenance is to ensure that the aircraft remains airworthy throughout its operational life.
Although maintenance requirements vary for different types of aircraft, from our study we got
that some aircraft need maintenance every 25 hours or less of flying time, and minor
maintenance at least every 100 hours while others are scheduled to be checked over years.
PIA is performing maintenance program on regular and satisfactorily basis. PIA is fulfilling the
required specifications of an air carrier maintenance program.

Keeping in mind the responsibility, keeping maintenance manual up to date, technically stable
Schedule, Necessary tools and equipment Record keeping and database system are the major
aspects and for these an effective maintenance organization is primary objective.
Repairs and alterations are carried out side by side with maintenance, conducted in tool shops
or in hanger based on type of operation needed. The procedure includes
Testing
Replacing with appropriate part
Detections
Alterations
Back into operation

My recommendations
Over 80% (plus) of our accidents are due to Human Error. To understand the human
contribution to major accidents and disasters, organizational and management factors have to
be taken into account.

What management should do at PIA?

Introduce policy provided its development and implementation.

Organization with effective communications, the promotion of competence at all levels
the
Planning to minimize risks by setting bench marks.
Auditing and performance review from lowest to higher grade

What can maintenance technicians do?

For aviation professionals, proper training and safety awareness is imperative for flying and
maintaining aircraft.

Learning about and adhering to sound risk management practices can help prevent
common errors that can lead to tragic consequences.

Understand the safety hazards associated with human fatigue and strive to eliminate
fatigue contributors in your life.

Pay particular attention to the safety and security of the items that undergo
maintenance and any surrounding components that may have been disconnected or
loosened (possibly to ease access) during that maintenance.

Carefully follow manufacturers instructions to ensure that the work is completed as

Be thorough when performing routine inspections. Ensure that items needing

immediate attention are addressed rather than deferred.

Name
Roll No
Sec

Syed Moiz
ME-012
D

Conclusion
It is responsibility and duty of an airline to perform preventive maintenance for airplanes not
only to bring reliability but also to secure hundreds of passengers precious lives. Using statistics
of death and injuries as compared to road and sea, air travel is considered the safest way to
travel and to keep its reliability an airline has to perform strict preventive maintenance.
Furthermore, country aviation authority has to keep check and balance.
Preventive maintenance is considered to be simple or minor preservation operations and the
replacement of small standard parts, not involving complex assembly operations. It is the
activity performed in some routine or regularly scheduled fashion designed to keep equipment
in an existing state, prevent deterioration or failure, and identify work of a corrective nature to
keep equipment from causing non-productive time in any capacity.
PIA is performing preventive maintenance program on regular and satisfactorily basis. PIA is
fulfilling the 10 elements required of an air carrier maintenance program. These 10 elements
are:
1. Airworthiness responsibility
2. Air carrier maintenance manual
3. Air carrier maintenance organization
4. Accomplishment and approval of maintenance and alterations
5. Maintenance schedule
6. Required Inspection Items
7. Maintenance recordkeeping system
8. Contract maintenance
9. Personnel training
PIA preventive maintenance program comprises on a large basis.
After completion of flight hours, removal, installation, and repair of landing gear tires and
shock cords; servicing landing gear shock struts by adding oil, air, or both; servicing gear
wheel bearings; replacing defective safety wiring or cotter keys; lubrication not requiring
disassembly other than removal of nonstructural items such as cover plates, cowlings, and

fairings; making simple fabric patches not requiring rib stitching or the removal of
structural parts or control surfaces.
Replenishing hydraulic fluid in the hydraulic reservoir; refinishing decorative coating of
fuselage, balloon baskets, wings, tail group surfaces (excluding balanced control surfaces),
fairings, cowlings, landing gear, cabin, or flight deck interior when removal or disassembly
of any primary structure or operating system is not required; applying preservative or
protective material to components where no disassembly of any primary structure or
operating system is involved and where such coating is not prohibited or is not contrary to
good practices; repairing upholstery and decorative furnishings of the cabin, flight deck, or
balloon basket interior when the repair does not require disassembly of any primary
structure or operating system or interfere with an operating system or affect the primary
structure of the aircraft; making small, simple repairs to fairings, nonstructural cover
plates, cowlings, and small patches and reinforcements not changing the contour to
interfere with proper air flow; replacing side windows where that work does not interfere
with the structure or any operating system such as controls, electrical equipment, etc.
Replacing safety belts, seats or seat parts with replacement parts approved for the
aircraft, not involving disassembly of any primary structure or operating system, bulbs,
reflectors, and lenses of position and landing lights.
Replacing wheels and skis where no weight-and-balance computation is involved;
replacing any cowling not requiring removal of the propeller or disconnection of flight
controls; replacing or cleaning spark plugs and setting of spark plug gap clearance;
replacing any hose connection, except hydraulic connections; however, prefabricated fuel
lines may be replaced.
The interchange of balloon baskets and burners on envelopes when the basket or burner
is designated as interchangeable in the balloon type certificate data and the baskets and
burners are specifically designed for quick removal and installation; adjustment of
nonstructural standard fasteners incidental to operations.
Inspection and maintenance tasks prescribed and specifically identified as preventive
maintenance in a primary category aircraft type certificate or supplemental type
certificate holders approved special inspection and preventive maintenance program
when accomplished on a primary category aircraft.

Name
Roll No
Sec

Syed Mohammad Asad akhter

ME-048
D

Conclusion
We are very thankful to Pakistan International Airlines that they provided us with necessary
requirements and data to achieve our target.

Preventive Maintenance
Preventive maintenance is planned maintenance of plant and equipment that is designed to
improve equipment life and avoid any unplanned maintenance activity. PM includes painting,
lubrication, cleaning, adjusting, and minor component replacement to extend the life of
equipment and facilities. Its purpose is to minimize breakdowns and excessive depreciation.
Neither equipment nor facilities should be allowed to go to the breaking point. In its simplest
form, preventive maintenance can be compared to the service schedule for an automobile.

Five Important Reasons Preventative Maintenance Makes Perfect Sense

Preventative Maintenance, these two words alone imply the benefit of this practice, but many
in the industrial industry abide by the if it isnt broke, dont fix it rule. Below are five
important reasons that Preventative Maintenance makes sense.
Plant Safety- In order to avoid injuries to your equipment operators, it is important that the
equipment used is maintained at the highest standards. Regularly scheduled preventative
maintenance can confirm that the machine is working properly and avoid emergency situations
and outages.
Efficiency- Preventative maintenance assures the efficiency and speed of your equipment. Over
time normal wear and tear can result in diminishing efficiency.
Immediate Savings- For many reasons, money can be saved when conducting preventative vs.
emergency maintenance. One, preventative maintenance costs less to facilitate than a large
repair or replacement.
Long-term Savings-During an emergency shutdown situation, the immediacy required can cause
both parts and labor to be priced at a premium, if they are available at all.

Time Savings- Preventative maintenance procedures, for the most part, take less time to
complete than emergency repairs and replacements. Also, because you can plan for equipment
outages during maintenance, you can avoid an outage when you need the machine the most.

Maintenance at PIA
Maintenance in Airline is industry is very important as it is directly related to the passengers
life. There are some standards of Civil Aviation Authority Pakistan that must be followed by
Pakistan International Airlines in order to keep them in service. Pakistan International Airlines
have their own preventive maintenance schedule according to which they perform
maintenance of their aircrafts.
The maintenance of aircrafts due after some flying hours. PIA preventive maintenance program
comprises on a large basis. After completion of flight hours, removal, installation, and repair of
landing gear tires and shock cords; servicing landing gear shock struts by adding oil, air, or
both; servicing gear wheel bearings; replacing defective safety wiring or cotter keys;
lubrication not requiring disassembly other than removal of nonstructural items such as cover
plates, cowlings, and airings; making simple fabric patches not requiring rib stitching or
the removal of structural parts or control surfaces.
There are four checks of each air crafts namely: A, B, C and D. A and B perform on a short
interval of time and are different for different aircrafts. C and D are known as major checks of
an aircrafts and depends on the flying cycles whereas A and B depends on the number of days
in operations. If D check is applied twice on any aircraft it means that now aircraft should be
scrap.

Steps for the betterments in Maintenance related issues

They should improve their skills in order to wind up their work with in time.
They should provide proper uniform to the workers as they work without the care of
their dresses.
In case of inconvenience in terms of new issues, appropriate authorities should be
approached.

Name
Roll No
Sec

Kashan Akram
ME-020
D

Conclusion
We visited Pakistan International Airlines (PIA) for the purpose of studying preventive
maintenance schedule as asked in the assignment. Throughout the course we came forward
different strategies that are applied in industries for the maintenance of their equipment. Here
in Aviation we usually carry out preventive maintenance which is scheduled to be carried out
either after every flight or after some particular intervals of time.

Types of Maintenance
Breakdown Maintenance:
Waiting until equipment fails before repairing or servicing it

Preventive Maintenance (PM):

(Time-based or run-based) Periodically inspecting, servicing, Cleaning, or replacing parts to
prevent sudden failure. On-line monitoring of equipment in order to use important/expensive
parts to the limit of their serviceable life

Corrective or Predictive Maintenance:

Improving equipment and its components so that preventive maintenance can be carried out
reliably

Benefits of Preventive Maintenance

the cost of breakdown maintenance is usually much greater than preventive
maintenance.

Keeps equipment in good condition to prevent large problems

Extends the useful life of equipment
Finds small problems before they become big ones
Is an excellent training tool for technicians?
Helps eliminate rework/scrap and reduces process variability
Keeps equipment safer
Parts stocking levels can be optimized
Greatly reduces unplanned downtime

Base Maintenance
PIA clientele comprises of large numbers of international operators and its experience of over
50 years enables to find the right solutions for all operational and maintenance needs. PIAs
highly qualified engineering personnel offer comprehensive engineering services, backed up by
excellent equipment and systems. They have sufficient aircraft support dock installations in the
hangars, as well as trained manpower and tooling, to undertake simultaneous work on various
types of aircraft in PIA fleet, around the clock.
Inspection and maintenance tasks prescribed and specifically identified as preventive
maintenance in a primary category aircraft type certificate or supplemental type
certificate holders approved special inspection and preventive maintenance program
when accomplished on a primary category aircraft.
In PIA the maintenance department has categorized the checking intervals with letters from A
to D. A-check being a light routine inspection and a D-check being the most intensive long-term
check.

A-checks are performed at 500 flight hours (FH). This is a routine check, to make sure
everything is functioning safely and efficiently.

B-checks are more extensive than A-checks and can also be completed overnight.

C-checks require aircraft to be docked at hanger or repair station for detailed

inspections. These are generally performed every 12-18 months.

D-checks are done approximately every 4-5 years, and are the most intensive, timeconsuming aircraft inspection.

Suggestions for betterment

There should be proper arrangements for visitors.

Those who visits engineering stations must be provided with necessary PPEs.
Hierarchy of management should be followed
Employees should be encourage to compete at all levels
There should be a proper costume for engineers as well as for technicians without which
they should be banned to enter in the engineering workplace.

Name
Roll No
Sec

Muneer Ali
ME-096
D

Conclusion
Maintenance is inspection, overhaul, repair, preservation and replacement of parts.

Preventive maintenance

can be defined as those actions performed to detect the

degradation of the components. It involves routine scheduled activities intended to keep a
system performing at its best and has the goals of preventing the systems breakdown and
extending its useful life.
Preventive maintenance has several advantages. By performing preventive maintenance the
full design life of the components may be realized.
Preventive maintenance (e.g., lubrication, filter changes, sealing pavement joints) will generally
help equipment run more efficiently. This results in reduced costs and improved user
satisfaction. Airlines can plan and assign staff appropriately by applying scheduled preventive
maintenance.

Importance of Preventive Maintenance

Safety Airlines maintenance directly contributes to keeping airports and their facilities safe for
users. Preventive maintenance helps ensure that those systems used by pilots are functioning
properly. Similarly, well-maintained fueling facilities and airport vehicles help improve safety
for their users.
Economics Preventive maintenance extends the life of facilities and avoids costly and early
replacement or rehabilitation. An aircraft or personal accident related to poor airport
maintenance is not only tragic but can be costly to the airlines owner. Increased energy usage
caused by poorly maintained electrical systems is also costly.
Reduction in Energy Usage Poorly maintained electrical and mechanical systems lead to
increased use of energy. Airfield lighting systems with aging cable and loss of energy drive
electrical bills up. This can be managed through an effective preventive maintenance program.
Similarly, poorly maintained HVAC units or weatherproofing in a general aviation terminal
building will increase energy costs.
System Longevity The life of many airport infrastructure systems can be extended with proper
preventive maintenance. Examples of PM are crack sealing, servicing HVAC equipment, regular

oil changes for airlines vehicles, checking and replacing airfield lighting, greasing door
components, and keeping drainage free so can drain properly.
Environmental Impacts Some airlines infrastructure can adversely affect the environment if not
well-maintained. Examples include drainage systems that start backing up and allow poor
quality runoff to environmentally sensitive areas. Fuel leakage from poorly maintained fueling
facilities will harm the environment.

In PIA the steps taken for preventive maintenance program are as follows,
Replacing hose connection except hydraulic connections removing, checking, and
replacing magnetic chip detectors and replacing any cowling.
Removal of the prop is required to get the nose bowl off.
Replacing prefabricated fuel lines cleaning or replacing fuel and oil strainer or filters
replacing or cleaning spark plugs and setting gap.
Landing gear tires, servicing struts wheel bearings safety wire or cotter keys lubrication,
not requiring disassembly.
Replenishing hydraulic fluid Replacing side windows. Repairing upholstery replacing
safety belts replacing seats or seat parts.
Replacing & servicing batteries.
Trouble shooting and repairing broken circuits in landing light wiring.
Replacing bulbs, reflectors, & lenses or position or landing lights.
Simple fabric patches refinishing decorative coatings applying preservative or protective
materials.
Making simple repairs to fairings, nonstructural items.
Replacement or adjustment of nonstructural fasteners etc.

Tools and Equipment

Hand tools, Mowers, Weed trimmers, Snow removal equipment, Maintenance vehicles,
Maintenance equipment storage, and Personal safety equipment for maintenance personnel.
Suggested steps that PIA should adopt for developing or improving an airlines preventive
maintenance program are:
1. Understand and embrace important guiding principles.
2. Establish a baseline of information about the airlines infrastructure and condition.
3. Identify the preventive maintenance needed for each system.
4. Prioritize maintenance based on airfield safety, economics, operations, contractual
requirements, and extension of the life of each facility.
5. Obtain resources (funding, staffing, equipment/tools, and outside contracts). Ensure that
staff is properly trained.

Name
Roll No
Sec

Ovais mahfooz
ME-082
D

CONCLUSION
Following are the things, with that, I would like to conclude my visit knowledge.

History
In 1946, Quaid-e-Azam Muhammed Ali Jinnah realized the need for a flag carrier for the
prospective country and requested financial help from a wealthy businessman Mirza Ahmad
Ispahani and Adamjee Haji Dawood for this purpose. Around that time, a new airline 'Orient
Airways was registered in Calcutta on 23 October 1946.
On 7 June 1954, Orient Airways started its operations. On 11 March 1955, Orient Airways
merged with the government's proposed airline, becoming Pakistan International Airlines
Corporation.

Fleet
PIA's fleets of modern aircraft are spacious, comfortable, and designed to get you to your
destination safely. PIA operates a range of advanced aircraft, ranging from the world's
preferred Boeing 777 airplane to the super-quiet Airbus A-310. A brief introduction of PIA fleet
is given below:

1. Boeing 777
The Boeing 777 family comprises of long-range, wide-body twin-engine airplanes. PIA was the
first airline in the world to operate all the three variants of the 777 family: 777-200LR, 777200ER and 777-300ER, all of them are well loved by PIA's seasoned travelers for their
spaciousness and comfort. PIA also holds the privilege of being the launch customer for 777200LR, one of PIAs aircraft holds the record for the longest commercial jet flight in aviation
history. At present PIA is serving destinations in USA, Canada, UK and Europe through its 777
fleet.

2. Boeing 747
The Boeing 747, often referred to as Jumbo Jet, is amongst the world's most iconic and
recognizable jet airplanes. This 4 engine long haul wide-body airplane has a two-deck
configuration. PIA operates two variants of 747 family which includes 747-300 and 747-200
Combi. 747 Combi is so called as it has mixed pax and cargo configuration on the main deck. At
present due to its capacity, 747-300 fleet is mostly deployed to cater high density requirements
like carrying intending pilgrims to and from Saudi Arabia.

3. Airbus A310
The Airbus A310 is a medium to long range wide-body airplane providing a spacious interior to
its travelers. PIA has deployed the A310-300 fleet on Far East, Regional as well as Domestic
routes.

4. Boeing 737
The Boeing 737 is one of the world's favorite narrow-body short/medium haul jet airplane.
Amongst its many credits, it has the distinction of being the most ordered and produced com

Base Maintenance
PIA clientele comprises of large numbers of international operators and its experience of over
50 years enables to find the right solutions for all operational and maintenance needs. PIAs
highly qualified engineering personnel offer comprehensive engineering services, backed up by
excellent equipment and systems. They have sufficient aircraft support dock installations in the
hangars, as well as trained manpower and tooling, to undertake simultaneous work on various
types of aircraft in PIA fleet, around the clock.

Name
Roll No
Sec

Asad Siddiqui
ME-082
D

Why Preventive Maintenance?

Preventive maintenance is predetermined work performed to a schedule with the aim of
preventing the wear and tear or sudden failure of equipment components. Preventive
maintenance helps to:
Protect assets and prolong the useful life of production equipment
Improve system reliability
Decrease cost of replacement
Decreases system downtime
Reduce injury
Mechanical, process or control equipment failure can have adverse results in both human and
economic terms. In addition to down time and the costs involved to repair and/or replace
equipment parts or components, there is the risk of injury to operators, and of acute exposures
to chemical and/ or physical agents. Preventive maintenance, therefore, is a very important
ongoing accident prevention activity, which you should integrate into your operations/ product
manufacturing process.

What is involved?
To be effective, your preventive maintenance function should incorporate the following
elements:
Planned replacements of components designed around the following:
Reliability of components (equipment failure is usually caused by its least reliable
component
Maintaining equipment service records
Scheduling replacement of components at the end of their useful service life
Acquiring and maintaining inventories of:
least reliable components
critical components
components scheduled for replacements
Replacing service-prone equipment with more reliable performers
By introducing the element of planning into your maintenance function, you are likely to reduce
your repair and manpower requirements.

Exploratory maintenance to anticipate and prevent breakdowns. Diagnostic measures to

analyze your plant requirements include:
- Operating and performing specifications of equipment
- Past experience with components:
- Inspection records
- servicing records
- Replacement frequency
- inspected component failures
Regularly scheduled lubrication program:
identify lubrication points on equipment
color code in order to identify lubrication frequency
consult manufacturer and accepted industry best practices to establish schedule
check manufacturers information
Check accepted industry best practice

Identifying Maintenance Hazards

The hazards associated with maintenance activities can be classified as follows:
Safety Hazards
Mechanical
Electrical
Many of these hazards are interrelated. Examine your process, the layout of your process area,
and the process equipment used, to determine the exact nature of the hazards likely to be
encountered during your maintenance activities. For example, maintenance work carried out in
confined spaces carries a greater risk of critical injuries and acute exposures to chemical and
physical agents.
These risks are associated with equipment and materials in the space itself and from nearby
operations. Fatalities are quite common.

Controlling Maintenance Hazards

Ideally, the hazards likely to occur during maintenance activities should be addressed in the
planning stage.
Health Hazards
Chemical Agents
Physical Agents

Name
Roll No
Sec

Muhammad Adnan
ME-009
D

Conclusion
Our sole objective was to study preventive maintenance.
Preventative maintenance is maintenance that is regularly performed on a piece of equipment
to lessen the likelihood of it failing. Preventative maintenance is performed while the
equipment is still working, so that it does not break down unexpectedly.
Preventative maintenance is planned so that any required resources are available.
The maintenance is scheduled based on a time or usage trigger. A typical example of an asset
with a time based preventative maintenance schedule is an air-conditioner which is serviced
every year, before summer. A typical example of an asset with a usage based preventative
maintenance schedule is a motor-vehicle which might be scheduled for service every 10,000km.
Preventative maintenance is more complex to coordinate than run-to-failure maintenance
because the maintenance schedule must be planned. Preventative maintenance is less complex
to coordinate than predictive maintenance because monitoring strategies do not have to be
planned nor the results interpreted.

Advantages

Planning is the biggest advantage of preventative maintenance over less complex

strategies. Unplanned, reactive maintenance has many overhead costs that can be
avoided during the planning process.
Preventative maintenance does not require condition-based monitoring. This eliminates
the need (and cost) to conduct and interpret condition monitoring data and act on the
results of that interpretation. It also eliminates the need to own and use condition
monitoring equipment.

Disadvantages

Unlike reactive maintenance, preventative maintenance requires maintenance planning.

This requires an investment in time and resources that is not required with less complex
maintenance strategies.
The frequency of preventative maintenance is most likely to be too high. This frequency
can be lowered, without sacrificing reliability when condition monitoring and analysis is
used.

Routine Maintenance:

The routine maintenance tasks performed by an AMT in Pakistan International Airlines are:
Cleaning Aircraft and Components
Application of Corrosion Prevention Compound
Lubricating Parts
Draining and Troubleshooting Fuel Systems
Checking and Servicing Hydraulic and Pneumatic Systems
Replacing Components
Inspecting for General Wear and Tear

Maintenance engineers usually perform

Replacing hose connection except hydraulic connections removing, checking, and replacing
magnetic chip detectors and replacing any cowling. Removal of the prop is required to get the
nose bowl off. Replacing prefabricated fuel lines cleaning or replacing fuel and oil strainer or
filters replacing or cleaning spark plugs and setting gap. Landing gear tires, servicing struts
wheel bearings safety wire or cotter keys lubrication, not requiring disassembly. Replenishing
hydraulic fluid Replacing side windows. Repairing upholstery replacing safety belts replacing
seats or seat parts. Replacing & servicing batteries. Trouble shooting and repairing broken
circuits in landing light wiring. Replacing bulbs, reflectors, & lenses or position or landing lights.
Simple fabric patches refinishing decorative coatings applying preservative or protective
materials. Making simple repairs to fairings, nonstructural items. Replacement or adjustment of
nonstructural fasteners etc.

Type of advancements that should be done

Newer and updated applications can be used for maintenance data bases
Inviting foreign experts to help PIA keeping up with moderns standards
Encourage employees with workshops, safe environment and good financial structure.

Name
Roll No
Sec

Bilawal Mahar
ME-092
D

Conclusions
The maintenance in an airline industry is carried out for three principle reasons:
Operational: To keep the aircraft in a serviceable and reliable condition so as to generate
revenue.
Value Retention: To maintain the current and future value of the aircraft.
Regulatory Requirements: Regulated by the aviation authorities of the jurisdiction in which the
aircraft is registered. It establish standards for repair, periodic overhauls, and alteration by
requiring that the owner or operator establish an airworthiness maintenance and inspection
program to be carried out by certified individuals qualified to issue an airworthiness certificate.
Repair stations are certified under FAR Part 145 and Aircraft Maintenance Technicians (AMTs) are
certified under FAR Part 65.FAR Part 43.
Preventive Maintenance:
PIA is conducting it preventive maintenance program excellently and fulfilling the 10 elements
required for an Air Carrier Maintenance Program. These 10 elements are:
Airworthiness Responsibility
Air Carrier Maintenance Manual
Air Carrier Maintenance Organization
Accomplishment and Approval Of Maintenance And Alterations
Maintenance Schedule
Required Inspection Items
Maintenance Recordkeeping System
Contract Maintenance
Personnel Training
Continuing Analysis and Surveillance System (CASS)
The preventive maintenance program is to be based on the flight hours or flight cycles. Flight hours
represent the amount of time aircraft has been operational whereas one flight cycle is completed when
an aircraft takes off and then lands. Some of the components are maintained as per flight hours and
some are on the basis of flight cycle, depending on the manufacturer that how it has defined the
maximum useful life of the component. Aircrafts have to go through an extensive inspection process,
also referred to as checks.
In PIA the maintenance department has categorized the checking intervals with letters from A to D. Acheck being a light routine inspection and a D-check being the most intensive long-term check.
Inspection in PIA is based on the following two programs:

Ageing Aircraft Corrosion Prevention and Control Program (CPCP)

Supplemental Structural Inspection (SSI)