Maintenance Operation Centre E2-R3 - 24012014 PDF

ENGINEERING PROCEDURES MANUAL
ENGINEERING & MAINTENANCE (MAINTENANCE OPERATION CENTRE)

(MAINTENANCE OPERATION CENTRE)
EPM DISTRIBUTION CONTROL NO. ____

APPROVAL NO. EQA/EPM/MOC/E2R3
Maintenance Operation Centre

PIA Engineering & Maintenance
Jinnah International Airport
Karachi-75200, PAKISTAN
Telephone: (92 21) 9904-3127
Fax: (92 21) 9924-2237
E-mail: piaplng@piac.aero
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PART-1: PREAMBLE
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1-1 TABLE OF CONTENTS
PART-1 PREAMBLE ISSUE

1-1 Table of Contents Edition 2, Revision 3
1-2 Record of Revisions Edition 2, Revision 3
1-3 List of Effective Pages Edition 2, Revision 3
1-4 Introduction & Structure of Engineering Procedures Manual Edition 2, Revision 0
1-5 Organizational Commitment by the Chief Engineer Edition 2, Revision 3
PART-2 DIVISIONAL ORGANISATION, FACILITIES & WORKSCOPE ISSUE

2-1 Divisional Structure Edition 2, Revision 3
2-2 Human Resource Edition 2, Revision 0
2-3 Facilities Edition 2, Revision 0
2-4 Workscope Edition 2, Revision 3
PART-3 FUNCTIONS, DUTIES & RESPONSIBILITIES ISSUE

3-1 Main & Specific Function Edition 2, Revision 3
3-2 Duties & Responsibilities Edition 2, Revision 3
PART-4 PROCESSES & DOCUMENTS ISSUE

4-1 Processs & Flow Charts Edition 2, Revision 3
4-2 Sample of Forms Edition 2, Revision 0


1-2 RECORD OF REVISIONS
Manual holders shall update their copies upon receipt of revisions. Revised pages shall be
inserted in the Manual and record revision table given below shall be completed. Removed
pages must be discarded immediately to avoid any confusion.
Upon completion of this Record of Revisions, acknowledgement shall be sent through a

signed copy of “Manual Status Letter”.
Insertion
Edition Revision Issue Date
Date By
0 AUG-2009
1
1 JAN-2011
2 0 DEC-2011
1 MAR-2012
2 AUG-2012
3 MAR-2013


1-3 LIST OF EFFECTIVE PAGES
PART – 1: PREAMBLE
Chapter Sub-Chapter Page No. Edition Revision Issue Date
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PART – 3: FUNCTIONS, DUTIES & RESPONSIBILITIES

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PART – 4: PROCESSES & DOCUMENTS

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1-4 INTRODUCTION & STRUCTURE OF ENGINEERING PROCEDURES MANUAL
1-4.1 INTRODUCTION
Engineering Procedures Manual of MOC Division is developed on the

recommendations of the Competent Authority to present, clear picture of facilities
and divisional procedures, followed by all personnel working in MOC Division.
Compliance with these procedures shall demonstrate fulfillment of the applicable
PCAA Regulations, Company Exposition Manual (CEM) Policies and Associated
Procedures.
1-4.2 STRUCTURE
Engineering Procedures Manual has been structured, for ease of use, as follows:
PART-1 Preamble
PART-2 Divisional Organisation, Facilities & Workscope
PART-3 Functions, Duties & Responsibilities
PART-4 Processes & Documents
U 1-4.3 ENGINEERING PROCEDURES MANUAL DISTRIBUTION
a) External Distribution
Control No. Addressee
C01 Director Airworthiness,

Airworthiness Directorate, Pakistan Civil Aviation Authority,
Jinnah International Airport, Karachi, Pakistan
C02 Controller of Airworthiness (South),
Pakistan Civil Aviation Authority,
Jinnah International Airport, Karachi, Pakistan
b) Internal Distribution
Control No. Addressee
M01 Director (Engineering & Maintenance)

M02 Chief Engineer (Maintenance Operation Centre)
M03 Chief Engineer (Quality Assurance)
M04 Dy.Chief Engineer (Quality Audit)
M05 Dy. Chief Engineer (Rotable Planning)
M06 Dy. Chief Engineer (Material Management)
M07 Dy. Chief Engineer (Repair Abroad)
M08 Dy. Chief Engineer (Schedule & Check Planning)
M09 Main Technical Library
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1-5 ORGANIZATIONAL COMMITMENT BY THE CHIEF ENGINEER
Engineering Procedures Manual defines Organization, procedures and responsibility at

divisional level in accordance with the regulations laid down by the Competent Authority.
Procedures are based on PIA Engineering & Maintenance ‘Safety & Quality Policy’ and
shall be complied with by all personnel of the MOC Division, at all times. It is further
ubnderstood that the Competenet Authority under CAR 94 reserves the right to suspend,
revoke or limit Organizational Approval, if the Competenet Authority has evidence that
procedures are not fulfilled or standards are not held.
The MOC Division will ensure that in respect of all work performed under the terms of this
Organizational Approval, adequate human resources, appropriate facilities and proper
equipment are utilized and the approved procedures are adopted.
Engineering Procedures Manual shall be reviewed by MOC Division on as and when

required basis. Manual and subsequent amendments, resulting from Divisional review /
Surveillance Audits by Authorities, shall be submitted to Chief Engineer (Quality
Assurance) for approval. Approved revision shall only be incorporated into the Manual and
distributed as per distribution list.



PART- 2: DIVISIONAL ORGANISATION, FACILITIES & WORKSCOPE

U

2-1 DIVISIONAL STRUCTURE
2-1.1 MAINTENANCE OPERATION CENTRE DIVISION
Admin Officer Chief Engineer

(Maintenance Operation Centre)
Dy. Chief Engineer Dy. Chief Engineer

(Rotable Planning) (Material Management)
Dy. Chief Engineer Dy. Chief Engineer

(Schedule & Check Planning) (Repair Abroad)
Office Attendant

2-1.2 ROTABLE PLANNING SECTION
Dy. Chief Engineer
Manager Aircraft Engineer
Assistant Manager Assistant Manager Assistant Manager

(I/c Parts Control Section) (Provisionining Group) (LS / Loan / AOG)
Shift-A SHIFT – Buffer A Planning Officer Planning Officer

ATR Provisioning Line Station Inventory /
Planning Officer Engineering Assistant Literature
Engineering Assistant Engineering Helper

Planning Officer Planning Officer
A310 / B737 Loan / Borrow
Engineering Helper Provisioning
SHIFT – Buffer B Engineering Assistant

Shift-B Planning Officer
AOG / Critical
B777 / B747
Engineering Assistant Cannibalization
Planning Officer Provisioning
Engineering Supervisor Engineering Helper

Engineering Supervisor
B777 Provisioning
Engineering Helper
General Shift
Shift-C Sr. Planning Officer
Planning Officer Engineering Supervisor
Engineering Assistant Engineering Assistant

Assistant Manager
Engineering Helper Driver (I/c Sanitation Cell)
Base Maint / ACOH

Shift-D
Planning Officer Planning Officer Engineering Assistant
Planning Officer
Engineering Assistant Engineering Supervisor
Engineering Helper Engineering Assistant
Store Attendant
Store Attendant

2-1.3 MATERIAL MANAGEMENT SECTION
Dy. Chief Engineer
Aircraft Engineer
I/c Engineering Budget I/c Catalogue Group I/c Avionics Group I/c Boeing Group
(Manager) (Sr Planning Officer) (Sr Planning Officer) (Sr Planning Officer)
Assistant Manager Sr. Planning Officer Sr. Planning Officer Planning Officer
Sr. Planning Officer Officer Engineering Planning Officer Material Plng Suprv
Admin Officer Material Plng Suprv Material Plng Suprv Material Plng Suprv
Material Planner Material Plng Suprv Material Plng Suprv Material Plng Suprv
Material Planner Material Planner Material Planner Material Planner
Office Attendant Material Planner Engineering Assistant Engineering Assistant
Driver Material Planner
I/c CMP/PNE Group I/c Engine Group I/c Commercial Group I/c Airbus Group
(Sr Planning Officer) (Assistant Manager) (Sr Planning Officer) (Sr Planning Officer)
Planning Officer Planning Officer Planning Officer

Planning Officer
Material Planner Material Plng Suprv Material Planner
Material Plng Suprv
Material Planner Material Plng Suprv Material Planner
Material Planner
Material Planner
Sr. Technician
Technician
Office Attendant

2-1.4 REPAIR ABROAD
Dy. Chief Engineer

Repair Abroad
Admin Officer Assistant Manager Sr. Planning Officer Admin Officer

(I/c Repair Abroad) (I/c Invoice Cell) (I/c Market Research)
() (
Planning Officer Planning Officer Planning Officer

Component Warranty (CEP)
Engineering Officer Comp & Technician

Supervisor Sys Coordinator
Engineering Engineering Material

Supervisor Supervisor Controller
Engineering
Supervisor
Engineering
Assistant
Office Attendant

2-1.5 SCHEDULE & CHECK PLANNING
Dy. Chief Engineer Aircraft Engineer

(Maintenance Planning)
I/c Maintenance Planning I/c Engine Forecast / PDM Assistant Manager

Assistant Manager Manager I/c SB Warranty & Insurance
Engineering Supervisor Planning Officer Sr. Planning Officer
Engineering Assistant Planning Officer
Material Controller


2-2 HUMAN RESOURCE
MAINTENANCE OPERATION CENTRE
PAY GROUPS
No. Designation
SPL X IX VI/VII/VIII VIII VII VI V IV III I/II/III LOC TOTAL
1 Chief Engineer 1 1
2 Deputy Chief Engineer 4 4
3 Aircraft Engineer 3 3
4 Manager 2 2
5 Assistant Manager 8 8
6 Officer Engineering 4 4
7 Sr. Planning Officer 11 11
8 Planning Officer 16 16
9 Admin Officer 3 3
Computer Operator
10 System Coordinator 1 1
11 Trainee Engineer 1 1
12 Senior Technician 1 1
13 Engineering Supervisor 10 10
14 Material Planning Supervisor 10 10
15 Technician 3 3
16 Engineering Assistant 11 11
17 Material Controller 2 2
18 Material Planner 13 13
19 Engineering Helper 6 6
20 Office Attendant 4 4
21 Driver 2 2
GROUP WISE TOTAL 1 4 7 2 8 14 18 22 29 12 116
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2-3 FACILITIES
2-3.1 MAINTENANCE OPERATION CENTRE DIVISION
Figure 1: Geographical Locations Map
8
Power Plant
Overhaul
9
7 Fokker
6 Hanger
Wide Body
Hanger
4
LM-II
3
Hanger
2
Avionics Overhaul Division

10
12
11
13
LM-I Hanger

LEGEND
NUMBER AREA
1 Chief Engineer (MOC) Office
2 Chief Engineer (MOC) Secretariat
3 DCE (Repair Abroad) Office
4 Invoice Cell
5 DCE (Rotable Planning) Office
6 DCE (S&CP) Office
7 Material Management (CMP / PNE Provisioning Group)
8 Material Management (Engine Provisioning Group)
9 Material Management Secretariat
10 Material Management (Radio Overhaul Shop Group)
11 Material Management (Instrument Overhaul Shop Group)
12 Material Management (Electrical Overhaul Shop Group)
13 Parts Control Section
U

2-4 WORKSCOPE
2-4.1 GENERAL
MOC Division shall act as coordinator for all Divisions to ensure effectiveness of
major production planning activities in the Organization.
2-4.2 DESCRIPTION OF ACTIVITIES
PREMESIS WORKSCOPE
MOC  Ensure that all personnel and Management of the Division are fully
Secretariate aware of Organizational Procedures.
 Maintain Database of applicable Tooling / Test Equipment required by
Maintenance.
 Conduct Pre-Dock Meetings for review prior to the aircraft Base Check.
 Coordinate with Divisional Heads for cost analysis to finalize proposal
on the annual budget.
 Conduct regular meetings to ensure effective coordination of Sectional
activities.
Rotable  Initial Provisioning for newly inducted aircraft in PIA Fleet.

Planning  Technical Handling/Assistance agreements at Domestic / International
Line Stations.
 Movement of Aircraft components in Parts Control.
 Positioining / Retrieval of HAJJ Inventory.
 Loan / Lease of Aircraft components for PK fleet on AOG.
 Administration of Aircraft Component Support Programs for PK fleet.
Material  Provisioning of consumable spares / materials as per the requirements

Management for Maintenance.
 Determination of Stock Level and Re-Order Level (ROL) for high cost
and critical items.
 Initial Provisioning for new aircraft before induction in PIA Fleet.
Repair  Explore new suitable sources for buying and selling of Repair and
Abroad Engineering Services.
 Conduct Engineering & Maintenance Commettee (EMC) Meetings
under Chaired by Director (E&M).
S&CP  Project Fleet Availability

 Heavy maintenance plan for all PIA fleet
 Issue MIC and Bill of Work
 File and reimburse warranty and insurance claim.
 Performance analysis of heavy maintenance and EOH



PART-3: FUNCTIONS, DUTIES & RESPONSIBILITIES


3-1 MAIN & SPECIFIC FUNCTIONS
3-1.1 ROTABLE PLANNING FUNCTIONS
 Positioning of Aircraft Components (LRUs) at Domestic / International Line Stations and

Company Procedures Manual (MOE/CEM/AMP) (soft copies) at Int’l Line Stations.
 Technical Handling / Assistance Agreements at Int’l Line Stations.
 Technical Handling / Assistance Agreements to other Airlines at Domestic Line Stations.
 Movement of unserviceable Aircraft Components from Maintenance and dispatch to

concerned Overhaul Shops.
 Movement of serviceable Aircraft Components from Overhaul Shops and dispatch to

concerned Stock Room.
 Positioning / retrieval of HAJJ Inventory.
 Aircraft Components (LRUs) availability by,
 Initial Provisioning
(Provisioining of LRUs for Aircraft newly inducted in PIA Fleet)
 Provisioning against SRC
(Provisioining of LRUs against float scarapped at PIA Engineering Overhaul Shop / Vendor facility)
 Enhancement in spare float
(Provisioining of LRUs against enhancement in spare float)
 Provisioning gainst AOG
(Provisioining of LRUs against AOG demand by Maintenance / Aircraft held-up at Outstation)
 NIL Expeditors / Flight Pack shortages intimation to Overhaul Shops / Repair
Abroad to replenish stock.
 Loan / Lease of Aircraft Components (LRUs) and Engines for PK Fleet.
 IATP Pooling activities.
 Administration of Aircraft Component Support Programs for PK fleet to meet operational

requirements.

3-1.2 MATERIAL MANAGEMENT FUNCTIONS
 Ensure that the aircraft maintenance activity is supported by maximum availability of

spares through efficient material provisioning stock control and development of Inventory
management policies, procedures and systems including determination of stock levels and
Re-Order Level (ROL) for high cost and critical items.
 Establish Initial Provisioning Levels for spares associated with the purchase of new
equipment and ensure that purchase orders are placed and spares have arrived before the
new equipment or new aircraft does.
 Coordinate with the Procurement & Logistic Department for receipt of spares.
 Maintain and up-to-date record of components held-up awaiting spares and expedite
deliveries from Suppliers in co-operation with the Technical Purchase Section of the
Procurement & Logistic Department.
 Assist the Airworthiness Management in economic evaluation of Manufacturer’s Servive

Bulletins and other possible Modifications.
 Prepare budgets for aircraft spares and once approved, control expenditures against the
budget during the course of the year.

3-1.3 REPAIR ABROAD FUNCTIONS
 Ensure that adequate overall control is maintained over the components which are sent
abroad to the repair agencies for repair, modification, testing, overhaul etc.
 Ensure the proper framing and administration of Engineering Contracts, including warranty
and guarantee agreements, in the most beneficial manner for the Company for all sub-
contract work done by PIA on aviation equipment for customers within and outside
Pakistan.
 Monitors the Market Research to explore new suitable sources for buying and selling of
Repair and Engineering Services.
 Ensure on time processing of Invoices which are then submitted to Finance (ENGG)
Section for making the timely payment.
 Implements a system of evaluation, justification and control of Repair Abroad Budget to

effectively regulate and economize the expenditures.
 Ensure the Repair Abroad personnel are in possession of correct skills, are given
appropriate training are up-to-date on the latest methods, procedures and requirements
and of sufficient strength to accomplish their work effectively.
 Assist in development of procedure for new aircraft / equipment in PIA and handles new
projects as directed. Monitor the cost of projects against approved budgets and highlight
any deviation.

3-1.4 SCHEDULE & CHECK PLANNING FUNCTIONS
 To forecast and schedule fleet maintenance checks specifying the location and duration of
fleet heavy maintenance with the available resources and to utilize maintenance capacity
for fulfillment of PIA and other third party maintenance requirements.
 To monitor life of aircraft major components like engine, propeller and landing gear for their
necessary removal for overhaul, also prepare and issue bill of work for Base Maintenance.
 To ensure claim of every accident/incident covered in insurance policy.
 To file and reimburse warranty cases for the SB accomplishment on PIA fleet.
 Performance analysis of heavy maintenance and engine overhauling activities carried out
on PIA fleet.

3-2-1.1 Deputy Chief Engineer (Rotable Planning)
 Positioning of Aircraft Components (LRUs) at Domestic / International Line Stations.
 Administer Technical Handling / Assistance Agreements at Domestic / Int’l Line Stations.
 Administer movement of Aircraft Components from Maintenance and dispatch to

concerned Overhaul Shops & from Overhaul Shop to respective Stock Room.
 Manage positioning / retrieval of HAJJ Inventory in liason with P&L, Repair Abroad and
Overhaul Shops.
 Administration of Aircraft Component Support Programmes.
 Administration of IATP Pooling activities through Manager Rotable Planning.
 Initial Provisioining of LRUs for new Aircraft inducted in PIA Fleet as per RSPL
recommendations and IATA Calculating formula through P&L.
 Initiate Requisition to Purchase Orders against SRC / Spare Float Enhancement / AOG.
 Administer loan / lease of Rotables / Engines for PIA Fleet Aircrafts.
 Administer NIL Stock Expeditor to Overhaul Shop.

3-2-1.2 Deputy Chief Engineer (Material Management)
 Remain abreast of developments in the field of inventory control techniques and theory for
possible appropriation based upon the feed back from the Maintenance Planning
Section/Development Engineering for forward Planning.
 Maintain liaison with the Data Processing Department concerning the operation of
computer based inventory control systems.
 Formulate inventory management policies and procedures including determination of stock

levels and re-order level (ROL).
 Establish initial provisioning levels for spares associated with the purchase of new
equipment and ensure that purchase orders are placed and spares received before the
 Co-ordinate with the Stores & Purchasing Department for receipt of spares and the issue of
spares from stores to the floor or to the overhaul shops.
 Maintain an up to date record of components held up awaiting spares and expedite

deliveries from suppliers in co-operation with the Technical Purchasing Section of the
Logistic Division.
 Identify & take Management’s decision against surplus inventory and co-ordinate with
Logistic Division for competitive disposal.
 Assist Manager Financial Planning in budget preparation for Engineering and once
approved, control expenditures against the budget during the course of the year.

3-2-1.3 Deputy Chief Engineer (Repair Abroad)
 Management / Control of tools and equipments in Engineering Department. Administer all

functions for invoice payment.
 Ensure that adequate overall control is maintained over the components which are sent
abroad to the repair agencies for repair, modification, testing, overhaul etc.
 Ensure timely processing of invoices to be submitted to MTS (Finance) for making

payments.
 Implement a system of evaluation, justification and control of Repair Abroad budgets to

effectively regulate and economize the expenditure.
 Assist in development of procedure for aircraft / equipment in PIA and handle new projects
as directed. Monitor the cost of projects against approved budgets and highlight any
deviation.
 To function as Secretary EMC (Engineering and Maintenance Committee).
 Ensure EMC Meeting for approval of the cases as per laid down procedures and within
EMC financial limits.
 Ensure data collection of special tools and equipment and enter in the data base.
 Review demand, price and frequency of use of tools and equipments required by different
section.
 Check for tools and equipments available in use in other section of Engineering and
Maintenance.
 Purchase tools through P&L or borrow on loan basis depending on the requirement.
 Control repair abroad components.
 Search market and explore suitable sources for buying and selling aircraft parts and repair
services.

3-2-1.4 Deputy Chief Engineer (Schedule and Check Planning)
 Plan all long term heavy maintenance of the fleet both those overhauls undertaken by the
department and those sub-contracted to other operators.
 Convert the Corporate Plan into maintenance, aircraft overhaul and engine overhaul plan
which is then issued to concerned sections of the department.
 Ensure compliance of airworthiness to the extent of regulating flying hours of airframe,

engines and components and scheduling of inspections and modifications so that no over
flying occurs.
 Plan maintenance checks, prepare and issue the bill of work and maintain a record of
elapsed time for each check.
 Work with other sections to find to reduce elapsed time for each type of maintenance
service and incorporate these improvements in the maintenance schedules.
 Performance analysis of heavy maintenance and engine overhauling activities carried out
on PIA fleet.
 Exercise effective human resources management in terms of selecting, training, motivating,

evaluating and disciplining staff subordinates.

3-2-2.1 Manager (Rotable Planning)
 Assist Dy. Chief Engineer in carrying out functions of spare parts ordering, parts control
day to day office activities.
 Negotiate and finalize technical handling contracts at Out Stations for PIA Fleet. This
includes new stations opened by PIA or where current Technical Handling Agents give
Termination Notice.
 Negotiate and finalize contracts for technical handling of foreign carriers operation
through Pakistan.
 To maintain PIA inventory at foreign station is properly maintained.
 Submission of Biodata of Technical Handling Agents and their Engineers for fresh /
renewal of PCAA approval to PIA Quality Assurance.
 Deal with IATP (International Airlines Technical Pool) administration.
 Maintain records of Loan / Borrowed items for PIA Fleet and their earliest return.
 Arrange leasing of Engine for PIA aircraft whenever needed.
 Certification / verification of Technical Handling, Loan, Pool and Component Support

Program Invoices.
 To verify Billing of Technical Handling Services and Loan of Parts for PIA Fleet.
 Maintain updated Technical Handling contact list and sent to all concerned through E-
mail.
 Prepare yearly budget for Rotable Planning Section.

3-2-2.2 Manager (Material Management)
 Close co-ordination with DCE Material Management for the Development in the field of
inventory control techniques and theory for possible appropriation based upon the feed
back from the Maintenance Planning Section / PO O/H Division / O/H Shops Technical
Planning & Development Engineering for forward Planning.
 Maintain liaison with the Data Processing Department concerning the operation of
computer based inventory control systems.
 Formulate inventory management policies and procedures including determination of stock

levels and Re-Order Level (ROL) with the consultation of Dy.Chief Engineer Material
Management.
 Establish initial provisioning levels for spares associated with the purchase of new
equipment and ensure that purchase orders are placed and spares received before the
 Co-ordinate with the Stores & Purchasing Department for receipt of spares and the issue of
spares from stores to the hangar floor or to the overhaul shops.
 Maintain an up to date record of components held up awaiting spares and expedite

Logistic Division.
 Identify surplus inventory and co-ordinate with the Logistics Division for competitive
disposal.
 Assist Manager Financial Planning in budget preparation for Engineering and once
approved, control expenditures against the budget during the course of the year.
 Ensure that the aircraft maintenance activity is supported by maximum availability of spare
parts and components through efficient material provisioning stock control and
development of inventory management policies, procedures and systems.

3-2-3.1 Assistant Manager (Rotable Planning)
 Maintain record of rotables / repairables component removed from aircraft, loaded to/from
Overhaul Shops and concerned stock room.
 Upon receiving input from Flight Pack Section for flight pack requirement, the same is
highlighted to concern for necessary action.
 Collection of serviceable / unserviceable components from Domestic Cargo.
 Preparation of SRV (Stock Return Voucher) and handover serviceable components to

respective stock room.
 All E-mail messages relating to rotable / repairable are properly taken care of and
auctioned.
 To expedite AOG & Critical demands against aircraft requirements of maintenance for
Rotable / Repairable availability within PIA network and send Expeditor to concerned
Overhaul Shops / Repair Abroad.
 The spares loaned to other Airlines at Karachi and Line Stations are returned to Karachi.
 To obtain spares from other airlines and agencies on AOG during weekly-off / holidays.
 Coordinate with Motor Transport Section for all Vehicles when sent for maintenance.
 To make alternate arrangement for Lifter / transportation in case of Parts Control

equipments are unserviceable.
 General cleanliness / maintenance of Parts Control area, specially during various audits.

3-2-3.2 Assistant Manager (Material Management)
 There are four distinct areas in Material Management i.e. Airframe, Engine, O/H Shops and
Catalogue/Commercial, which are being looked after by their respective Assistant
Managers. Following are their duties & responsibilities:
 Initial / subsequent provisioning in their respective areas.
 Keep close co-ordination with Users & Purchasing Department and resolves all queries.
 Assistant Manager Catalog / Commercial acts as a liaison Officer between Provisioning

Groups, Shops concerned, DPS, Stores/Purchase and Finance Department.
 Maintain close co-ordination with all working Cells in existing Material Provisioning Section
specially with Catalogue Section.
 Carry-out specific follow-up of AOG/Critical demand and inform all concerned.
 Initiate the purchase of spare parts by placing indents on the Technical Purchasing section
of Logistic Division as re-order levels are reached or a requirement develops.
 Anticipate spares requirements well in advance of major overhauls and planned

maintenance checks and ensure that necessary parts are, or will be, on hand when
required.
 Co-ordinate with the Logistic Division for receipt of spares and with user for issue of spare.
 Maintain an up-to-date record of components held up awaiting spares and expedite

Logistic Division.
 Identify surplus inventory and co-ordinate with the Stores & Purchasing Department for
competitive disposal.
 Prepare Engineering and control expenditure during the course of the year.
 Ensure that the aircraft maintenance activity is supported by maximum availability of spare
parts and components through efficient material provisioning stock control and
development of inventory management policies, procedures and systems

3-2-3.3 Assistant Manager (Shedule & Check Planning)
 To control the warrnty of Boeing 777 / ATR42-500 aircraft.
 Comps send abroad covered under warranty.
 First check the comp histrory of lru to meet the warranty or not.
 After checking of warranty generate the repair order with “w” marked.
 Follow-up on r/o file till close the file.
 Track & monitor all evaluation notice issued by Development Engineering warranty
remedies are available in notices. We claim to manuafacturers for Lab / man hours
consumed in mod.

3-2-3.4 Assistant Manager (Repair Abroad)
 Administration of component Overhaul / Repair sub contract work.
 Assists in negotiation of component overhaul / repair work sub contracted to outside repair
agencies for which facilities do not exist in PIA.
 Organize and administers all functions related to work sub contracted as per contractual
arrangement.
 Arranges dispatch of components to repair agencies through part control / stores.
 Maintains approved list of components to be sent abroad for overhaul / repair.
 Certifies invoices for items repaired abroad and records expenses incurred.
 Follows up with repair agencies for ensuring on time delivery of components.
 Expedites delivery of items by repair agencies for IOR / AOG situation.
 Monitor maintenance of components status cards for each movement along with its
dispatch and receipt details
 Performs any other duties assigned to him by his superiors.
 Works under the administrative and functional control of DCE (Repair Abroad) Component
Control.

3-2-4.1 Senior Planning Officer (Rotable Planning)
 Control receipt / movement of unserviceable / serviceable components to and from

Maintenance / Overhaul Shops and Stores.
 Maintain a daily input / output record for each Overhaul Shop.
 Highlight the Base / Line Maintenance IOR / AOG demand in LMD (Line Maintenance
Demand) in PAMMIS.
 Coordinate with Stores for ensuring dispatch of spares to outstations in case of aircraft
grounded due non-availability of spares.
 Intimate Store for replenishment of Line Stations demands.
 Coordinate for removal of all pool / loan components borrowed at Line Stations on arrival of
aircraft at Karachi in Coordination with Maintenance.
 Manage dispatch of components through Stores / Logistics to outside Repair Agencies and
maintain records as necessary.

3-2-4.2 Sr. Planning Officer (Material Management)
 Act as Provisioning Group Incharge, initial Spares Provisioning and subsequent material
planning of spares.
 Handle daily spares inabilities reported by respective Technical areas.
 Ensure that abnormalities, such as, excessive issues, nils, rack life expiry, price variations,
delayed supplies, re-order levels, re-provisioning policy, etc., are highlighted promptly and
corrective actions taken.
 To co-ordinate between user & P&L and also attends queries from consumers,
stockrooms, foreign purchase, etc., and takes prompt and proper action.
 Expedite critical materials required by shop sections in coordination with the concerned
shop.
 Take necessary action on spares for which components get held up in the shops or for
which aircraft is liable to be grounded and maintain up-to-date and complete records of the
hold-ups of his group.
 Familiarize himself with the Operating and Technical Plans and the revisions thereto,
issued by the sections concerned and convert the same for planning purposes.
 Review maintenance and overhaul spares, not initially stocked, well in advance before the
Overhaul is due on the aircraft, in the light of Overhaul's anticipated requirements and past
experience and take necessary provisioning action in time.
 Meet any campaign programme requirements, takes necessary material planning action, if
required, well in advance. Also study and takes necessary action on Service Bulletins,
Modifications, Technical Orders, Technical Notices, Manufacturer's Revisions and
Bulletins, etc.
 Primarily responsible to ensure that the estimates of future annual consumption are made
as accurately as possible.
 Maintain close co-ordination with all other working cells in the existing Material Planning
Section, such as, the Catalogue Section, Central Document Control Section and Material
Planning Analysis Section etc.

3-2-5.1 Admin Officer (Repair Abroad)
 Administer of component overhaul / repair sub contract work.
 Organize and administer all functions related to work sub contracted as per contractual
arrangements.
 Works under the administrative and functional control of Assistant Manager (Component
Control).
EPM Chapter 3-2 Edition: 2 Revision: 0 Issue: Sep, 2011 Page 1 of 2

3-2-5.2 Admin Officer (Material Management)
 To maintain daily attendance, yearly leave roster, leave record and to maintain daily diary
receipt/dispatch.
 Responsible for clean and neat maintenance of all records pertaining to attendance, leave,
files and correspondence.
 Responsible for receipt/dispatch and movement record of all types of letters/.
 Record all Normal/Priority Purchase Orders on daily dispatch register for delivery to
Logistic Division.
 Assist and provide all necessary information to Dy.Chief Engineer Material Management
respect of Personnel matters.
 Maintain complete statement of all ACRs, Airport Entry Passes, delivered to Personnel
Department and individual employee of the section.

3-2-6.1 Planning Officer (Rotable Planning)
 Coordinate for removal of all pool / loan components borrowed at Line Stations on arrival of
aircraft at Karachi in Coordination with Maintenance.
 Locate spares on loan from other Airlines for grounded aircrafts at Karachi and outstations.
 Assist Manager Rotable Planning in negotiation of contracts with International Agencies for
Technical Handling of PIA aircrafts.
 Assist Manager Rotable Planning to update the contact list of technical handling agents
and intimate the updates to Line Stations.
 Liason and communication for return of all spare parts removed at Line Stations to the
Base.
 Co-ordinate with Stores for recoupment of Oils / Lubricants at Line Stations.
 Liason with Logistics for return of Loan / Lease components.
 Highlight the Base / Line Maintenance IOR / AOG demand in LMD (Line Maintenance
Demand) in PAMMIS.
 Prepare procurement cases of rotables against SRC / SFE for Management approval.
 Assist Manager Rotable Planning for preparation of the yearly budget.
EPM Chapter 3-2 Edition: 2 Revision: 3 Issue: February, 2013 Page 1 of 4

3-2-6.2 Planning Officer (Material Management)
 Initial Spares Provisioning and subsequent material planning of spares.
 Ensure that abnormalities, such as, excessive issues, nils, rack life expiry, price variations,
delayed supplies, re-order levels, re-provisioning policy, etc., are highlighted promptly and
corrective actions taken.
 Act as a liaison and also attend queries from consumers, stockrooms, foreign purchase,
etc., and takes prompt and proper action.
 Expedite critical materials required by shop sections in coordination with the concerned
shop.
 Take necessary action on spares for which components get held up in the shops or for
which aircraft is liable to be grounded and maintain up-to-date and complete records of the
hold-ups of his group.
 Handle SRCs as per the laid down policy of Corporation.
 Review Engineering spares, well in advance before the Block Overhaul or MBC is due on
the aircraft, in the light of Block Overhaul's / MBC's anticipated requirements and past
experience and takes necessary provisioning action in time.
 Meet any campaign programme requirements; take necessary material planning action, if
required, well in advance.

3-2-6.3 Planning Officer Warranty & Insurance (S&CP)
 Lodge Warranty/ Insurance claim with Manufacture/Insurance for defective / damage / lost
Spares & parts of the aircraft.
 Reviews the claims before submission and correspondence with Manufacture / Insurance /
clarifying their quires.
 Negotiates with the Manufacturers / Insurance Surveyor for pending claims. Coordinates
with overhaul shops for claims submission.
 Reviews Manufacture / Insurance offers prior to the final settlement of claims.
 Maintain proper records of Warranty / Insurance received from Vendor / Manufactures /

Insurance Companies.
 Insurance Work order(s) are opened immediately in case of damage to PIA Aircraft /
Engines / Components due to accident / incident / FOD.
 To inform Manager Insurance in writing the initial accident / incident / FOD details giving the
claim number.
 Aircraft Station of Accident.
 Engine Type / ESN (in case of damage / FOD to engine)
 Tracking & Monitor tech delay reports / incident report / CAA form 055 / Monthly Bird Strike
/ FOD and items Lost.
 Review, work out any delay, and file claims on Insurance and quick settlement.
 Recover the Repair Cost / Losses of Aircraft / Engine / Spares form Insurance / under
writers.
 Settlement of Insurance Claims of Equipments / Spares damaged during transportations.
 Settlement of Spares Claims for the items lost during transit in specified period.
 Constant review of the renewal of our aircraft HULL & liabilities Insurance policy for the
period 2008-2009.

3-2-6.4 Planning Officer (Repair Abroad)
 Administration of component overhaul / repair sub contract work.
 Assists in negotiation of component overhaul / repair work sub contracted to outside repair
agencies for which facilities do not exist in PIA.
 Organize and administers all functions related to work sub contracted as per contractual
arrangement.
 Monitor maintenance of components status cards for each movement along with its
dispatch and receipt details
 Maintains approved list of components to be sent abroad for overhaul / repair.
 Certifies invoices for items repaired abroad and records expenses incurred.
 Works under the administrative and functional control of Assistant Manager (Component
Control).

3-2-7.1 Officer Material Controler Warranty & Insurance (S&CP)
 To control the warrnty of boeing 777 / 737 / 747 / A310 aircrafts.
 Components sent abroad covered under warranty.
 First check the comp histrory of LRU to meet the warranty or not.
 After checking of warranty generate the repair order with “w” marked.
 Floow-up on R/O files till close the file.
 Incase of denied the warranty by any vendor. We are checking the warranty throughly and
request to vendor for repair (FOC).
 In case of liability accepted by vendor. We submit a alaims to vendor for foc replacment or
credit amountre-inbursement.
 Track & monitor all evaluation notice issued by Dev. Engg warranty remedies are available
in notices. We claim to manuafacturers for Lab / man-hours consumed in mod.
 Review of agreements from Boeing / ATR Vendor and sign the in-house repair
agreements. To repair the new aircraft components in PIA Overhaul Shops for realizing the
foreign exchange.
 By save do on time of removed components from aircraft and dispatch to OEM for repair
under warranty to reduce the TAT in number of days.

3-2-7.2 Material Planning Supervisor (Material Management)
 Assist Planning Officer in the initial and subsequent planning effort.
 Initiate and prepare indents / PMRs as required by the existing procedure.
 Maintain close co-ordination with various shops and Sections. Determine reasons for non-
availability of spares in his area and takes remedial action as per procedure.
 Attend all enquiries from stock rooms, foreign purchases and Shops.
 Maintain technical brochures, technical orders, Manufacturer's Catalogs, to be used in

estimating identifying and ordering material.

3-2-7.3 Material Planner (Material Management)
 Maintenance of planning / provisioning records.
 Updating all documents / dates related to his area.
 Responsible for clean and need maintenance record.
 Verify stock availability on interchangeable / alternate part Numbers as advised by Officer

Material Planning / Sr. Material Planner.
 Make manual entries on Purchase Order Files for indented quantities.
 Assist and provides all necessary information to Officer Material Planning / Sr. Material
Planner in respect of hold-up of spares.
 Incorporate amendments / revisions to the entire Catalogue held in his area.


3-2-8.1 Engineering Supervisor (Rotable Planning)
 Ensure proper and timely movement of all serviceable / unserviceable components to and
from Line / Base maintenance and Overhaul Shops.
 Collect serviceable / unserviceable components from Cargo.
 Collect serviceable components from shops, prepare stock return vouchers and hand them
over to respective Stock Rooms.
 Assist Sr. Planning Officer for removal of loan items from the aircraft and return as soon as
possible.
 Receive Scrap Rejection Certificates (SRC) from various overhaul shops and pass it on to
concerned Planning Officer for their procurement process.

3-2-8.2 Engineering Supervisor (S&CP)
 Prepare (Bill of work) list of Cardex Controlled items for the PIA fleet (B743, B742, B777,
B737, A310 & ATR) in co-ordination with Cardex Section / Technical Record Section /
WBHM Planning / LM-I & LM-II & all concerned shops. Major Checks 20 days before
grounding of Aircarft and 2 Months before grounding in smaller checks prepare.
 Co-ordination daily basis and correspondence with concerned Bays, Shops and sections
for days work & review for task left over briefing with DCE (S&CP),
 MIC Sheet from LM-I & LM-II / Cardex for Major checks & smaller checks and MIC Sheets
review on daily basis for concerned aircrafts.

3-2-8.3 Engineering Supervisor (Repair Abroad)
 Follows up with repair agencies for ensuring on time delivery of components.
 Expedites delivery of items by repair agencies for IOR / AOG situation.
 Works under the administrative and functional control of DCE (Repair Abroad) (Component
Control).


3-2-9.1 Engineering Assistant (Rotable Planning)
 Ensure proper and timely movement of all serviceable / unserviceable components to and
from Line / Base Maintenance and Overhaul Shops.
 Collect serviceable components from Shops, prepare Stock Return Vouchers and
handover to respective Stock Rooms.


3-2-10.1 Engineering Helper (Rotable Planning)
 Proper and timely movement of all unserviceable / serviceable components to and from
respective Stock Rooms and Overhaul Shops.
 Receive unserviceable items with work order tags / sheets and routes them to respective
Overhaul Shops.
 Collect serviceable components from Shops, prepares Stock Return Vouchers and
handover to respective Stock Rooms.


3-2-11.1 Office Attendant (All Section of MOC Division)
 Distribution, collection & delivery of all out going & incoming mails.


3-2-12.1 Driver Rotable Planning (Parts Control)
 Drive and maintain the allotted vehicles.
 Keep him self familiar with the regulations as prescribed by Civil Aviation Authority and
follow their rules properly.
 Submit daily report regarding serviceability and un-serviceability of the vehicles under him
to Sr. Planning Officer (Parts Control)
 Check Vehicles Engine Oil / Water on daily basis in the morning.
 Check Battery water on weekly basis.
 Maintain the Apron Driving Permit in valid condition.


3-2 DUTIES & RESPONSIBILITIES
REFERENCE DESIGNATION SECTION

3-2-1.1 Deputy Chief Engineer Rotable Planning
3-2-1.2 Deputy Chief Engineer Material Management
3-2-1.3 Deputy Chief Engineer Repair Abroad
3-2-1.4 Deputy Chief Engineer Schedule & Check Planning
3-2-2.1 Manager Rotable Planning
3-2-2.2 Manager Material Management
3-2-3.1 Assistant Manager Rotable Planning
3-2-3.2 Assistant Manager Material Management
3-2-3.3 Assistant Manager Schedule & Check Planning
3-2-3.4 Assistant Manager Warranty & Claim (S&CP)
3-2-3.5 Assistant Manager Repair Abroad
3-2-4.1 Senior Planning Officer Rotable Planning
3-2-4.2 Senior Planning Officer Material Management
3-2-5.1 Admin Officer Repair Abroad
3-2-5.2 Admin Officer Material Management
3-2-6.1 Planning Officer Rotable Planning
3-2-6.2 Planning Officer Material Management
3-2-6.3 Planning Officer Warranty & Claim (S&CP)
3-2-6.4 Planning Officer Repair Abroad
3-2-7.1 Material Planning Supervisor Material Management
3-2-7.2 Material Planner Material Management
3-2-7.3 Material Controller Schedule & Check Planning
3-2-8.1 Engineering Supervisor Rotable Planning
3-2-8.2 Engineering Supervisor Schedule & Check Planning
3-2-8.3 Engineering Supervisor Repair Abroad
3-2-9.1 Engineering Assistant Rotable Planning
3-2-10.1 Engineering Helper Rotable Planning
3-2-11.1 Office / Store Attendant All Sections of MOC Division
3-2-12.1 Driver Rotable Planning



PART- 4: PROCESSES & DOCUMENTS


4-1 PROCESS FLOW CHARTS / PROCEDURES
REFERENCE DESCRIPTION PAGE NO

4-1.1 Unserviceable items removed from Aircraft 2
4-1.2 Loan from other Airline 3
4-1.3 Technical Handling of PIA Aircraft at Line Stations 4
4-1.4 Procedure for Providing Spare for Aircraft Held-up at Line Stations 5
4-1.5 Collection of serviceable components from Overhaul Shops 6
4-1.6 Re-Provisioning 7
4-1.7 Initial Provisioning 8
4-1.8 Contracted Mainteannce Services 9
4-1.9 Cannibalization 10
4-1.10 Disposal of Aircraft Surplus Spare Inventory 12
4-1.11 Loan to other Airline 13
4-1.12 International Line Station Inventory 14
4-1.13 Positioning / Retrieval of HAJJ Inventory 15
4-1.14 Normal Procurement (Non AOG) 16
4-1.15 AOG Procurement 17
4-1.16 To Meet Maintenance Demand 18
4-1.17 SRC Handling Procedure 19
4-1.18 Assigning Alternate Part Number to Aircraft Component 20
4-1.19 Hangar Visit Plan 21
4-1.20 Procedure for Insurance claim of Aircraft and its Parts 24
4-1.21 Procedure for Service Bulletin warranty claim of Boeing 777 25
4-1.22 Procedure for Heavy Maintenance Performance Monitoring 27

4-1.1 UNSERVICEABLE ITEMS REMOVED FROM AIRCRAFT
Maintenance
Unserviceable item(s) removed from an Aircraft

by Maintenance and handover it to Parts Control
Parts Control
If found damaged
Unserviceable item(s) must be checked by Parts
Control personnel for any abnormality / damage.
Maintenance
Parts Control Maintenance personnel shall sign

on back side of the LRU /
Parts Control personnel shall receive Unserviceable Tag to describe
unserviceable item(s) with receiving sheet. the condition of the item.
Parts Control
Parts Control personnel shall post unserviceable

item(s) data in PAMMIS and handover to
concerned Overhaul Shop through receiving
sheet.

4-1.2 LOAN FROM OTHER AIRLINE ON AOG
Airlines are contacted for required component * * In case of Weekly Off / Holidays
/ Off Duty Hours, Parts Control
shall handle the loan issues
Against positive response from any Airline, Loan

Order is passed on to Airline
PIA Rep / Station Manager / Maintenance

Manager / Handling Agent is contacted to collect
the component and dispatch by most expeditious
way to the required Station
Despatch information passed on to Logistics and

Cargo Sections for earliest possible custom
clearance
Component received in Stock Room and issue to

Aircraft.
Liase with Line Maintenance for earliest possible

removal and return of Loan Item
Parts Control handover component to Dispatch

Section in Logistics
Despatch information [AWB, Flight No. & Date]

passed on to PIA Rep / Station Manager /
Maintenance Manager / Handling Agent for
earliest possible custom clearance and delivery
to Loan Provider
Loan Provider confirms the receipt of the unit

and date
Invoice is received through IATA Clearing House

for payment which is verified for payment

4-1.3 TECHNICAL HANDLING OF PIA AIRCRAFT AT LINE STATIONS
Qutations from Agencies / Airlines for Technical Handling of PK Flights
Rotable Planning contacts / obtain Quotations from various Airlines / Handling

Agencies through E-mail.
A study is prepared on basis of Airlines / Handling Agencies replies by

correspondence and negotiation with various Airlines / Handling Agencies
MINUTE / Management Approval
Based on comparative study, Minute is raised by Dy. Chief Engineer

(Rotable Planning) for Management Approval and routed through:
 Dy. Chief Engineer (Line Stations) * * DCE (LS) evaluate the

 Chief Engineer (LM) quotation against
 Chief Engineer (MOC) establishment of PIA
 Chief Engineer (QA) Engineers and gives his
 DGM (Tech Service) Finance recommendation.
 Director (Engineering & Maintenance)
 G.M (Budget)
 Chief Financial Officer
 Dy. Managing Director
 Managing Director / Chairman
Approval of Handling Agency / Agreement
Subsequent to approval by Management, Application Form Number CAAF-

113-AWXX-2.0 duly signed with Profile of Handling Agency and Bio data of
Engineers is submitted to PCAA for approval in favor of Handling Agency
through Chief Engineer (Quality Assurance). Subsequent upon completion of
all formalities including PCAA Approval Agreement (SGHA) is signed
between PIA and Handling Agency.
PCAA Approval
PCAA grants Provisional Approval for the period of 3 to 6 months. Handling

Agency starts providing handling to PIA aircraft.
In the mean time PIA Quality Assurance and PCAA perform Audit of Handling
Agency Facilities. On satisfactory performance, permanent approval is
granted by PCAA.
Technical Literature / Documents
Latest Aircraft Technical Literature’s CDs (IPC, AMM, AWM, ASM, TSM,
ACRT etc) and Transit Check Sheets are delivered to PIA Technical Handling
Agents at outstations as per Mailing List provided by Rotable Planning and in
the flight pack of all PIA Fleet by Technical Publication.
Reference Quality Advisory No. 316/GEN-36 all latest Procedures Manuals

(CEM / MOE / AMP) provided to PIA Technical Handling Agents through
Rotable Planning.

4-1.4 PROCEDURE FOR PROVIDING SPARE FOR AIRCRAFT HELD UP AT LINE STATIONS
Aircraft held-up at Line Station due to spare(s) with NO-GO status. A

Technical Handling Agent / PIA Maintenance Manager / Onboard
Aircraft Engineer check availability of required spare(s) from Flight
Pack / PK Inventory / IATP Providership. Parts Control
Incharge Parts Control send E-mail / Letter / Memo

to Line Maintenance for removal the POOL / LOAN
NO item when aircraft returned back to Base and handed
Available in over to Parts Control with Serviceable Tag indicating
Flight Pack as “POOL” / “LOAN” item.
YES
Flight Pack items list is available in the cockpit of Parts Control

aircraft. Technical Handling Agent / PIA
Maintenance Manager / Onboard Aircraft Engineer The POOL /LOAN items return as soon as possible.
shall draw item(s) from flight pack.
After replacement make entry in Tech Log and Parts Control delivered item to Dispatch Section
place unserviceable item in the same Flight Pack. (Logistic) with a letter mentioning Provider’s shipping
address and flight details.
Cargo Section is responsible to ship the Pool / Loan

Flight Pack Section personnel collect item(s) from item within 03 days to receipt from Dispatch Section
Flight Pack after aircraft arrival at Base and (Logistic) and transmit information (AWB, Flight No.
handover to Parts Control for onward dispatch to and shipping details) through E-mail.
concerned Overhaul Shop.
Available in
PK Inventory
NO
YES
PIA positioned some essential spares at particular Line Stations.

After replacement, make entry in the Tech Log and dispatch U/S Available
unit to KHI and inform dispatch details (AWB & Flight #) through in POOL
E-mail to KHIMPPK@piac.aero & rotplng@piac.aero.
YES
Parts Control shall send spares(s) for replenishment of stock

and informed dispatch details (AWB & Flight #) through E-mail to NO
Technical Handling Agent / PIA Maintenance / Station
Managers.
Confirmation received from Technical Handling Agent / PIA

Technical Handling Agent / PIA Maintenance
Maintenance / Station Managers.
Manager / Onboard Aircraft Engineer shall
contact Airlines, operating at that station and
check availability of the item and raise Loan
Request Form on behalf of PIA.
 As per IATP (International Airlines Technical Pool)

Agreement, Pool Parts availability List is available at all After replacement, make entry in the Tech
Line Stations. Log, listing the item as “Loan” and mention
 Technical Handling Agent / PIA Maintenance Manager Parts Provider
/ Station Manager arrange the required item.
Inform all details through E-mail.
 After replacement, make entry in the Tech Log and
provide details of the Part / Pool Provider and inform
through E-mail.
A
A

4-1.5 COLLECTION OF SERVICEABLE COMPONENTS FROM OVERHAUL SHOPS
Overhaul Shops / Parts Control
Overhaul Shops release serviceable

components and enter data into PAMMIS on
daily basis.
Parts Control generate same list from

PAMMIS.
Parts Control
Parts Control collects serviceable item(s) from

all Overhaul Shops as per list generated
through PAMMIS
Parts Control
Parts Control post all collected serviceable

item(s) into PAMMIS.
Segregate serviceable item(s) as per allocated

Stock Room.
Final Lists generate Stock Room wise.
Parts Control hand-over serviceable item(s) to

concerned Stock Room as per list and take
receiving on the list.

4-1.6 REPROVISIONING
MATERIAL MANAGEMENT
The Model Calculates Economical Order Quantity (EOQ) & Re-order Level (ROL):
EOQ on the basis of:

 Purchase Order Cost
 Monthly demand
 Inventory Holding
 Average Unit Price
ROL on the basis of:
 Monthly demand
 Mean Lead Time
 Safety Stock
 Safety Factor
 Service Level
MATERIAL MANAGEMENT
Reports are generated for editing/ altering/ confirming the order

figures prior to the printing of formal Purchase Order.
MATERIAL MANAGEMENT
On Weekly Provisioning reports, Decision making process and

allocation of priorities are done by concerned Specialists &
Provisioning Officers.
AOG /
HOLD-UPS?
MATERIAL MANAGEMENT MATERIAL MANAGEMENT
 Raise Source 70/75  AOG Requirements along with NIL Voucher

 Dispatch to catalogue section mentioning Aircraft Tail No. to be received by
concerned Provisioning Group,
 HOLD-UP Forms, raised by Overhaul shop,
being NIL Stock/ No-Set-up to be received by
MATERIAL MANAGEMENT concerned Provisioning Group,.
 For No Set-up items manufacturer’s literature
 Printing of Computerized is also provided by the User.
Purchase Order
 Dispatch to DGM Purchase
Technical
MATERIAL MANAGEMENT
 Establish new set-up parts on computer

(in case of No-Setup items)
 Raise Source 70/75
 Dispatch to catalogue section
MATERIAL MANAGEMENT
 Printing of Computerized Purchase

Order on PRIORITY
 Dispatch to DGM Purchase Technical
 Carries-out specific follow-up until
demand is met

4-1.7 INITIAL REPROVISIONING
MATERIAL MANAGEMENT
Based on:
 MTBR/MTBUR
 Estimated Service Life
 Construction Material
 Usage relevant to Maint/Overhaul both
 QPA (Quantity per Aircraft)
 SPC
MATERIAL MANAGEMENT
 Turn Around Time

 Service Level
 Stage Length
 Flight Hours
 Line Stations
 Flight Packs
Spares
FOR NEW TYPE OF AIRCRAFT OVERHAUL SHOP

Mostly Done at Manufacturer’s Facility On the basis of:
 Annual Shop Arising
FOR NEW AIRCRAFT OF EXISTING TYPE  RSPL
Done for peculiar item only  Component Maintenance Manual
 Experience
Obtain provisioning documents from

manufacturer as per PIA parameter: MATERIAL MANAGEMENT
Refer to Recommended Spares Part List (RSPL)
 Line Maintenance Parts (LMP) From Manufacturer
 Initial Provisioning Document (IPD)
 Recommended Spare Parts List
OVERHAUL SHOP
 In Absence of RSPL, detail of break down
MATERIAL MANAGEMENT part number & quantity is provided by Shop
Planning as CMM (Component Maintenance
Manual).
Cross check on computer & IPC for Set-up  Shop arising provided by Shop Planning
Parts & their Availability giving due concerned
consideration to Alternate Part number
MATERIAL MANAGEMENT
MATERIAL MANAGEMENT  Requirement is established as per shop
arising provided by Shop Planning
 Establish new set-up parts on computer concerned.
 Raise Source 70/75  Cross Checking of RSPL & SMM
 Dispatch to catalogue section requirement with on-line system with
consideration to Alternate Part Numbers, No
set-up items & ordered quantities.
 Establish Part Number quantities required
MATERIAL MANAGEMENT
 Printing of Computerized Purchase Order

 Dispatch to DGM Purchase Technical

4-1.8 Contracted Maintenance Services
This procedure defines PIA Engineering & Maintenance policy regarding contracts managemengt for
outsourced maintenance services.
Maintenance services may be contracted to PCAA Approved Technical Handling Agents at line stations,
under technical handling agreement, to ensure that aircraft is fit for intended flight. Contract shall be based
on effective IATA Standard Ground Handling Agreement.
Substantial maintenance such as heavy aircraft maintenance and engine / APU / landing gear overhaul may
be outsourced under maintenance contracts to maintenance providers, holding valid PCAA Approval.
Other aircraft components and tooling / test equipment shall be sent for repair / calibration to service
providers, approved by PIA Engineering Quality Assurance.
Unless otherwise not possible or not in interest of Organisation, maintenance contracts shall be non-
exclusive. For all contracts (exclusive / non-exclusive), final authority shall be in accordance with the
effective Schedule of Powers.
Chief Engineer (Maintenance Operation Centre), in consultation with Chief Engineer (Quality Assurance),
shall manage maintenance contracts for outsourced substantial maintenance such as heavy aircraft
maintenance and engine / APU / landing gear overhaul, in addition to technical handling agreements.
Deputy General Manager (Finance) Engineering shall provide expertise on financial issues. Draft contract
shall be submitted to obtain clearance from Legal department, if deemed necessary.
Once finalised, Chief Engineer (Maintenance Operation Centre) shall sign maintenance contract on behalf of
PIA Engineering & Maintenance, being integral part of the Operator.
It shall be ensured by the Signatory that maintenance contract, made with maintenance provider
(Contractor), identify specifically industry standard to be used during maintenance and certification activities.
Contracts shall further include:
 Reference to approval process for Contractor by Operator and Operator’s Authority

 List of facilities including satellite locations where maintenance is to be performed
 Scope of approvals, technical requirements and level of maintenance
 Obligations of both parties and their regulatory counterparts on airworthiness issues
 Reference to Contractor’s approved exposition explaining applicable regulations, safety requirements
and quality management system
 Provisioning and control of logistics, turn around times, warranties, etc.
 Effective reporting process to immediately notify any significant defect to Operator
 Access to Contractor’s facilities for Operator’s Quality Assurance / Authority
 Process for control of deviations from maintenance data
 Provisioning of technical records to Operator for assessment of achievement of ongoing quality levels
 Agreement on periodic reviews for issues related to workscope planning, technical updates, logistics,
quality and reliability.
Qualification of Contractor is based on quality of maintenance services, provided to PIA Engineering &
Maintenance. Tehcnical / administrative issues of outsourced maintenance shall be reviewed in PIA
Engineering Coordination and PIA Reliability Review Board meetings. Achievement of maintenance in
accordance with maintenance contarcts is assessed by Deputy Chief Engineer (Technical Services
Engineering) concerned through review of technical records, received from maintenance services provider.
Whenever deviation from any clause / sub-clause is observed during validity period of maintenance service
contarct or advice from above-mentioned activities is received, Chief Engineer (Maintenance Operation
Centre) shall report such deviation immediately to Chief Engineer (Quality Assurance for root cause analysis
and further action required thereof.

4-1.9 CANNIBALIZATION
PURPOSE
This procedure describes the policy / conditions and methods to be observed when it becomes necessary to
cannibalize component to meet an emergency need of an aircraft.
GENERAL
The following terms with explanation stated below shall be used in this procedure.
Robbed Part: The required part removed from a donor unit to service a recipient unit.
Donor Unit: The unit from which the robbed part is removed. It shall have the parts breakdown.
Recipient Unit: The unit which uses the robbed part. It is most likely an aircraft or engine and less
frequently other compoenents.
Robbed Position: The position on the donor part from which the robbed part has been removed.
PROCEDURE
1- Unless operational requirements justify the necessity, cannibalization action shall be as far as
possible avoided.
2- Cannibalization action may be initiated only if the requisition (issue voucher) submitted for the
required part has been confirmed by stores as “NIL IN STOCK”.
3- However if because of urgent operational requirements, the cannibalization action must be
performed first, then the Maintenance personnel shall after the departure of the aircraft take the
necessary subsequent action to ensure that stores is informed to procure the replacement part
through Rotable Planning.
4- The approval of the Dy. Chief Engineer (Line / Base Maintenance) OR Shift Incharge must be
obtained before cannibalization may be initiated.
5- Maintenance Personnel shall fill Part ‘A’ & ‘B’ of Form # DE/92/003 and forward it to Rotable
Planning for providing required part details i.e. spare float detail, Shop detail if part is lying in
Overhaul Shop.
6- DCE (Rotable Planning) filled the Part ‘D’ on behalf of Chief Engineer (MOC) for final action.
i. Send intimatation to DCE (Repair Abroad) to retrieve the required compoenent from Vendor
facility as soon as possible, and ask for advance exchange unit if repair unit lead time is long.
ii. Obtain EMC approval for spare float enhancement and initiate the procurement process.
iii. Send intimation to concerned Overhaul Shop to serviceable the compoenent on urgent basis.
Release / Shop-out immediately if the required component is repair abroad unit.
Pre Cannibalization Action
Cannibalization Data along with a list of HOT components is being formulated indicating that the
demand of these components prevails throughout the year.
The same is forwarded to respective Shops on daily basis indicating the Stock position as well.
Based on this, the Shop Production and Shop Planning define the spares requirement. Which is
then forwarded to Material Management for Provisioning. Plan staggered over the year which is
ultimately processed and forwarded to P&L Department for procurement. So that the availability of
HOT Items is ensured throughout the year.
Post Cannibalization Action

Cannibalization list is flashed on daily basis to all concerned Sections / Overhaul Shops indicating
the components cannibalized on the previous day.
This is to highlight severity of the situation & stock position, so that the concerned Section / Shop take the
necessary action on the most urgent basis to improve the stock position and to curtail the future
cannibalization.

4-1.10 DISPOSAL OF AIRCRAFT SURPLUS SPARE INVENTORY

PURPOSE
Declaration of Surplus Inventory of Aircraft Parts.
GENERAL
All Aircraft parts including Consumables, Rotables and Insurance type shall be reviewed periodically as to
their obsolence and utilization / serviceability by PIA for their Fleet of Aircraft. Items which become obsolete
and / or surplus to requirement shall be disposed off.
Aircraft Parts may be disposed-off / deleted from PIA Spare Inventory due to one of the following reasons,
1- Obsolence of the component system
2- Standarization
3- Post Modification requirement
4- Mandatory Compliance of the Regulatory Body requirements
PROCEDURE
The following guidelines are to be followed while declaring any Aircraft Parts as Surplus to PIA
requirements,
- AIRCRAFT AIRFRAME ITEMS
Shall be declared Surplus after eight (08) years if no movement occurs during the period keeping in
view the “D” Check Cycle which is completed on the basis of average flying hours.
- ROTABLE & REPAIRABLE COMPONENTS
All items falling under this category having no consumption during past five (05) years shall be
declared as surplus.
- MODIFICATION KITS
Items under this category having no movement for five (05) years shall be reviewed and declared
surplus if no further requirement exists.
- INSURANCE ITEMS
All these items of Long Lead Time with no movement during five (05) years shall be reviewed
individually for declaration of surplus or partial surplus quantities.
- LIFE EXPIRED ITEMS
All items found with expired life shall not be offered for sale and shall be scrapped after getting
necessary write-off approval from the competent Authority.
Data Processing Services (ISD) shall prepare listings of all aircraft items (Vendor-wise) and provide for
review by the Engineering Department, Dy. Chief Engineer (Material Management) shall get these report
reviewed / scrapped in coordination with Shop Planning / Respective Provisioning Groups to advise deletion,
if any.
These lists shall be prepared annually by DPS, under following pattern / details,
- Part Number
- Old Part Number
- Alternate Part Number
- NHA, Alternate Part Information
- Key-Word
- Category
- Aircraft System
- Commonity to the other Aircraft
- Manufacturer Code
- Supplier Code
- Average Annual Consumption
- Catalogue Price
- Issue & Last Receipt Data
- Average Unit Price
- Last Invoice Price
- On Hand Quantity
- Extended Value
- Stock Room Location

TRANSFER OF ITEMS TO STOCK ROOM-20 (SURPLUS INVENTORY)
After review, some parts found to be needed are retained and rest all parts declared surplus, DPS prepared
Final Listing stock-room-wise for onward dispatch to Manager (Stores Technical) for transferring surplus
material to Stock Room – 20.
APPROVAL OF SURPLUS BY COMPETENT AUTHORITY
DGM (Logistics) / Manager Inventory Control shall obtain approval from Competent Authority for declaration
of disposable surplus items as per Schedule of Power Para 12.56.
SEGREGATION OF SURPLUS STOCK FROM CURRENT INVENTORY LISTINGS
The stocks declared surplus and listed in the Surplus Sales existing shall be treated and accounted for as
“Inactive Inventory” and shall not be intermixed with the current Inventory. DPS shall take necessary action
for segregation on computer files.
DISPOSAL OF SURPLUS AIRCRAFT INVENTORY
All out efforts shall be made by Inventory Control Section to dispose-off Surplus Aircraft Items by sale to
Users and other Agencies handling such items. Results achieved shall be reviewed annually by the
Management to examine the desirability to write-off unsold material with the cocurrence of the Competent
Authority.
DISPOSAL OF UNSOLD AIRCRAFT SURPLUS INVENTORY
Inspite of all efforts if the surplus items are left unsold, the write-off action shall be initiated, after a review by
the Management and disposed-off through local auction by Manager Inventory Control Section.

4-1.11 Loan to other Airline
AOG Requirement received from Airlines
Rotable Planning check stock position
Component Available NO
and determined that Regret through E-mail
unit could be spared
for loan.
YES
Documentation and delivery to other Airline
NO
Unit receive with Unit sends to Overhaul
serviceable tag Shop for rectification
NO
Route unit to Overhaul Inhouse facility
Shop for packing available
YES
Unit sends to repair Repair carried out and

abroad for rectification unit sends to Store
Serviceable Unit position

at Store and Invoice to
PIA Finance
Advise Finance for Billing

4-1.12 International Line Station Inventory Positioning
Demand Receive from

International Line Stations
Advice sends to Stock Room-4 Advice sends to Stock Room-

for Hydraulic / Turbo Oils A1 for Aircraft Wheels /
Components
Stores dispatch the demanded items

to concern Line Station through
Logistics with Cargo manifest.
Rotable Planning receives

shipping details and forward it
to concern Line Station.
Confirmation from Line Station

after receiving item(s).

4-1.13 Positioning / Retrieval of HAJJ Inventory
A List of Rotables / Consumables items receive

from Line Maintenance to be position at Jeddah
for the support of HAJJ flights
Check Stock position
YES YES
NO NO
Rotable Consumable
Availability Availability
Intimation / Expeditor send to Intimation / Expeditor send

concerned Shop for immediate to Material Management for
release of held-up and Repair immediate availability.
Abroadfor immediate availability Rotable Planning send advise to Stock
Room for dispatch to Jeddah
Unit received in Stock Room after Consumable received in

release from concerned Shop / Stock Room dispatch all Aircraft Parts to Stock Room after
retrieved from Repair Abroad. Dispatch Section. procurement by Material
Management
Dispatch Section sends all Aircraft Parts to Cargo for

onward dispatch to Jeddah and provides shipping
details to Rotable Planning.
Despatch information is passed to JEDMMPK,

JEDFAPK, KHIFRPK, KHIFAPK, KHIFTPK, KHIFYPK
Confirmations received from

JEDMMPK (PIA Maintenance Manager at Jeddah)
JEDFAPK (PIA Cargo Manager at Jeddah)
After completion of HAJJ operation, Maintenance

Manager (Jeddah) sends all HAJJ Inventory to KHI
pass-on shipping details to Rotable Planning / Cargo /
Logistics / Stores.
Parts Control collects HAJJ Inventory from Foreign

Receipt Section and delivers to concern Stock Room
with Strock Return Voucher.

4-1.14 Normal Procurement (Non AOG)
Normal Procurement
Spare Float
Scrapped Unit Enhancement
Procurement
against
Market Research Request sends Market Research Request sends

to P&L Department to P&L Department
Market Research received from Market Research received from

P&L Department P&L Department
After concurrence from Enduser After concurrence from Enduser

Management approval initiated Case submit in EMC for spare
along with CES for Budget float enhancement
allocation
Upon Management Approval, YES NO

Indent along with CES, Market APPROVAL
Research and SRC send to P&L
for procurement action
Management approval initiated along No Procurement
with CES for Budget allocation
Unit received and position in

stock room
Upon Management Approval, Indent

along with CES, Market Research
sends to P&L for procurement action
Unit received and position in stock

room
Spare Float is enhanced in PAMMIS

System by Rotable Planning

4-1.15 AOG Procurement
AOG Procurement
Spare Float
Scrapped Unit Enhancement
Procurement
against
Raise Indent in favor of OEM / Aircraft Raise Indent in favor of OEM / Aircraft
Manufacturer and send it to P&L for Manufacturer send it to P&L for
procurement action with remarks procurement action with remarks CES
“CES / Management Approval to / EMC regularization / Management
follow basis Approval to follow basis
P&L Action P&L Action
Rotable Planning Rotable Planning

Action Action
SRC retrieved from P.O is placed to OEM / Case submit in EMC for
concerned Overhaul Shop Aircraft Manufacturer for spare float enhancement
Procurement action
Management approval After EMC Approval

initiated along with CES for Unit receives and Management approval
Budget allocation position in stock room initiated along with CES for
Budget allocation
Management approval /
CES send to P&L for EMC Approval /
Regularization Management Approval /
CES send to for
Regularization

4-1.16 To Meet Maintenance Demand
Request / Demand received

from Maintenance
YES NO
Spare Float
Exists
Procurement
In Repair Arrange required
Circuit In Shop
Loaner
Unit Location Required
A Action
Intimate Repair Intimate Overhaul Shop Follow the Remove U/S item Procees as per
Abroad for earliest for earliest release of the Loaner unit & get it repaired on procedure
possible retrieval unit from Shop procedure 4-1.2 priority if AOG/Normal
from repair circuit circumstances Procuremtents
allow 4-1.14 & 4-1.15
YES NO YES NO
Quick retrieval Expedited Provide the unit back

from repair release of the
circuit possible unit possible
to A/C
Unit retrieved Ask Repair Unit Arrange for loaner

back and Agency for Released to unit. Ask MM to A
available in exchange meet A/C expedite the
Stock Room unit demand required spares
If authorized SF is greater
YES NO YES NO than Existing Float. RSPL
also supports
Exchange Unit Loaner Unit
Available Available
Initiate the SF
enhancement case &
present in EMC
Unit received Rotable Follow the
and available Planning to Loaner
in Stock arrange for a Process 4-1.2 After EMC Approval take
Room loaner unit management approval &
budget allocation on CES
YES NO
Inform Engineering
Management and follow the Raise indent & send
Loaner Unit Management instruction Management approval
Available either ground the aircraft CES to P&L for
OR procure the unit as per procurement
process 4-1.14 & 4-1.15
Inform Engineering Unit Received

Follow
Process Flow Management and follow the
4-1.2 Management instruction
either ground the aircraft OR
procure the unit as per
process 4-1.14 & 4-1.15

4-1.17 SRC Handling Procedure
Scrap Rejection Certificate (SRC)

received from Engineering
Overhaul Shop / Repair Abroad
SRC Data enter in manual register
Rotable Planning Section

personnel fill second column with
action to amend spare float in
POSSESA
NO
Recoupment
required
YES
Refer Procurement
against SRC Process
4-1.14 & 4-1.15
Copy retained in file and third

copy sent to Accounts Officer
Assets for record amendments

4-1.18 Assigning Alternate Part Number to Aircraft Component
New Equipment introduced into the fleet or Alternate Authority

from Shop/ Maintenance/ Repair Abroad received
Readiness Log
sends to AWM
Alternate Part
NO ascertaining
Document
Provided
Readiness Log
provided to
Inspection Cardex
YES
Cross check by
Contacting Vendor,
Website
Readiness Log
provided to
Sanitation Cell
CMM / IPC
Reference Attached
Necessary amendment in PAMMIS & POSS carried out

4-1.19 HANGAR VISIT PLAN
INTRODUCTION
Hangar Visit Plan is a year wise plan to forecast and schedule fleet maintenance checks. It gives overview of
all major checks / heavy maintenance to accomplish in the upcoming year. It also specifies the location and
duration of accomplishment of these maintenance activities.
As multiple checks of aircraft may fall simultaneously or closely one after the other, it is mandatory to
schedule the aircraft grounding in such a way that its maximum work done with minimum grounding time.
Furthermore, there are multiple aircraft to be maintained in the small number of maintenance bays. Every
aircraft requires airworthy condition to continue its operation.
Hangar Visit Plan is prepared for the whole year, however, quarterly revisions are issued. In addition, brief
monthly hangar visit plans are also issued.
Hangar Visit Plan is prepared by S&CP and approved by CE (MOC).
PURPOSE
The purpose of this procedure is to describe the development process of Hangar Visit Plan to cater for the
fleet heavy maintenance with the available resources.
PROCEDURE
1. The beginning point of hangar visit plan preparation is; database containing information about due
dates of all the maintenance checks due in the upcoming year. The due dates are calculated from
the inputs mentioned below.
• Preambles of all aircraft types – gathered from AWM. Preamble specifies the interval of the
maintenance check. The check interval can be specified in terms of flight cycles, flight
hours, aircraft landings or the calendar time.
• Current Flight Hours, Cycles and Landings of every aircraft – gathered through PAMMIS.
• Average utilization of every aircraft – gathered through PAMMIS.
2. Based upon the due dates, aircraft is assigned a slot in approved bay for specified maintenance
activity with appropriate grounding time.
3. The SB/AD due in the upcoming year, third party business and aircraft pending maintenance tasks
(if any), are catered for in the plan as they may affect the grounding schedule.
• Evaluation Notice of SB/AD issued by AWM. An SB/AD can also be MTB. SB can limit the
scope of maintenance to single component, or it may expand to engine and whole airframe
as well.
• In addition to above, third party business is also considered in this plan. This information is
provided by EBD.
• There can be some pending or carried forward tasks to be accomplished in heavy
maintenance. Major item replacement may also be planned during the check. This
information is obtained from various sections of production planning.
4. The interim plan is circulated to the approved list of recipients to collect their inputs / feedback.
5. After reviewing inputs / feedback and incorporating necessary changes (if any), the final plan is
approved and circulated to the approved list of recipients.
6. Hangar Visit Plan is revised on quarterly basis.
7. Monthly Hangar Visit Plan is also issued to provide a brief.

DISTRIBUTION LIST
1- ENGINEERING & MAINTENANCE DEPARTMENT
1.1- Director Engineering
1.1.1- Director (Engineering & Maintenance)
1.2- Base Maintenance
1.2.1- Chief Engineer (Base Maintenance)

1.2.2- DCE (Planning & Development)
1.2.3- DCE Bay-I, II, III & ACOH (Aerospace)
1.2.4- DCE Bay-I & III (Avionics)
1.2.5- DCE Bay-II & ACOH (Avionics)
1.2.6- I/C Planning (All Bays)
1.2.7- DCE (Aircraft Furnishing)
1.2.7- DCE (Structure Repair)
1.3- Line Maintenance
1.3.1- Chief Engineer (Line Maintenance)

1.3.2- DCE B777 (Aerospace, Avionics)
1.3.3- DCE B747/737 (Aerospace, Avionics)
1.3.4- DCE Planning (Line Maintenance)
1.3.5- DCE A310/ATR (Aerospace, Avionics)
1.3.6- DCE (IFE)
1.3.7- DCE (Aircraft Appearance)
1.3.8- DCE (North)
1.3.9- EMOD
1.3.10- DGM (Schedule)
1.3.11- Situation Room
1.4- Engine Overhaul
1.4.1- Chief Engineer (Engine Overhaul)

1.4.2- DCE Planning (Engine Overhaul)
1.4.3- DCE (CFM, CF6, GE90)
1.4.4- DCE (APU/PW/RP/LDG)
1.5- Avionics Overhaul
1.5.1- Chief Engineer (Avionics Overhaul)

1.5.2- DCE (Instrument Overhaul)
1.5.3- DCE (Electric Overhaul)
1.5.4- DCE (Radio Overhaul)
1.5.5- DCE Planning (Avionics Overhaul)
1.6- Aerospace Overhaul
1.6.1- Chief Engineer (Aerospace Overhaul)

1.6.2- DCE Planning (Aerospace Overhaul)
1.6.3- DCE (Repair & Modification)
1.6.4- DCE (Fuel & Miscellaneous)
1.6.5- DCE (Pneumatic Overhaul)
1.6.6- DCE (Hydraulic & Wheel / Brake)

1.7- Airworthiness Management
1.7.1- Chief Engineer (Airworthiness Management)

1.7.2- DCE (Maintenance Program & Reliability)
1.7.3- DCE (Technical Publications & Record)
1.7.4- DCE Technical Service LM (Aerospace, Avionics)
1.7.5- DCE Technical Services (Base Maintenance, Engine O/H, Aerospace O/H, Avionics O/H)
1.7.6- DCE (Aerospace, Avionics)
1.7.7- I/C Modification Planning
1.7.8- I/C Planning (Boeing, Airbus, ATR)
1.8- Maintenance Operation Centre
1.8.1- Chief Engineer (Maintenance Operation Centre)

1.8.2- DCE (Material Management)
1.8.3- DCE (Rotable Planning)
1.8.4- DCE (Repair Abroad)
1.9- Engineering Business Development
1.9.1- Chief Engineer (Engineering Business Development)

1.9.2- DCE (Maintenance)
1.9.3- DCE (Sales & Contracts)
1.10- Quality Assurance
1.10.1- Chief Engineer (Quality Assurance)

1.10.2- DCE (Maintenance)
1.10.3- DCE (Quality Audit)
1.10.4- I/C (JAR145 Quality Audit)
1.11- HR, Training & Automation
1.11.1- Chief Engineer (HR, Training & Automation)
2- MARKETING DEPARTMENT
2.1- Marketing
2.1.1- Director Marketing

2.1.2- G.M (Schedules & Network Planning)
2.1.3- GM (HAJJ & Charter)
3- PROCUREMENT & LOGISTICS DEPARTMENT
3.1- Procurement & Logistics
3.1.1- GM (Procurement & Logistics)

3.1.2- DGM Purchase (Commercial)
3.1.3- DGM Purchase (Technical)
4- CHIEF FINANCIAL OFFICER
4.1- Chief Financial Officer
4.1.1- Chief Financial Officer

4-1.20 PROCEDURE FOR INSURANCE CLAIM OF AIRCRAFT AND ITS PARTS
INTRODUCTION
Insurance coverage is provided against certain incidents / accidents occurring on PIA fleet. The purpose of
insurance management is to provide risk coverage to PIA assets. By policy, all PIA assets are insured and
any damage can be claimed.
S&CP acts as coordinator between Engineering Department and PIA Insurance. The concerned section is
PIA Manager Insurance & Terminal Benefits. S&CP collects all data required for Insurance claim from
Engineering Department and forwards it to Manager Insurance & Terminal Benefits. Insurance section
contacts the Insurance Company for claim.
PURPOSE
The purpose of this procedure is to provide guidelines to file insurance claims. This procedure is laid down
with the specific objective that no insurable damage is overlooked.
PROCEDURE
Initial Information
S&CP receives intimation of incident/accident occurred anywhere at PIA fleet. There can be any source of
this intimation to S&CP.
- Technical Delay Report – an email broadcasted everyday by khieqpk@piac.aero

- CAA Form CAAF-114-AWXX-5.0 raised by TSE
- Any person providing formal or informal news
- Media, news, press etc
- The concerned personnel of accident/incident area have to report the incident to S&CP as soon as
possible.
Information Verification
- S&CP needs verification of the incident/accident from concerned DCE.

- Verification request will be formally sent on email and formal response will be required.
- The verification email will contain the request for details provision to S&CP.
– Nature of the damage

– Repair / rectification done
– List of material / spares consumed on repair / rectification
– Designation wise man-hours consumed on repair / rectification
- The verification request contains all above mentioned points. The details may be received in the
series of emails. The initial reply should contain the nature of damage and incident report at the
minimum.
Claim Initialization
- Upon verification, the information is passed to PIA Insurance section who contacts the Insurance
Company for claim.
- PIA Insurance forwards the CTA queries to S&CP.
- S&CP coordinates with the concerned DCEs to reply/sort out the query.
- S&CP also coordinates with the surveyor, if any is appointed by the Insurance Company.
- As further details are received, provisional claim bill is developed.
- Once the work is completed, the final claim bill is prepared by S&CP.
- The Insurance Company works with insurance broker for proposal of settlement.
- The proposed settlement is sent to S&CP, who coordinates with the respective sections for final
approval and submitted to PIA Insurance.
- Final Memorandum of Settlement is developed and copy is sent to S&CP.
- Claim stands closed.

4-1.21 PROCEDURE FOR SERVICE BULLETIN WARRANTY CLAIM OF BOEING 777
INTRODUCTION
Aircraft manufacturer gives warranty of its purchased aircraft. The manufacturer issues Service Bulletins,
Service Letter and Airworthiness Directives for design inspections and modification. Some of the documents
offer warranty remedies too. Boeing 777 aircraft has 4 years of warranty and warranty can be claimed for
following heads consumed in accomplishment of SB.
– Man-hours
– Material
– Freight charges
– Shop Supplies
– Technical Assistance
– Others
Warranty claim can only be filed after SB has been accomplished on at least one aircraft in the effected
fleet.
PURPOSE
The purpose of this procedure is to provide guideline to monitor SB accomplishment for its timely claims.
This procedure will ensure that all required data is collected and complete claim is filed for reimbursement.
PROCEDURE
SB Evaluation
- AWM circulates an email about SB evaluation meeting. The agenda includes the title of SBs along
with their brief description and warranty status. The complete text of SB can be viewed at
www.myboeingfleet.com -> Maintenance Documents.
- S&CP is invited in evaluation meeting. Go prepared about SB details required to file warranty claim.
- Sometimes, a modification is subject to inspection findings. In such case, the consumed man-hours
need proper recording to claim the correct man-hours. In Evaluation meeting, S&CP requests AWM
to design feedback performa and attach it with related Task Card or Engineering Order.
- AWM circulates Evaluation Notice to all concerned, including S&CP. It contains all information
related to scheduling, man-hours and material requirements of SB. In case of inspection SB, Task
Card # is also mentioned in the Evaluation notice.
SB Accomplishment
- Inspection SB is scheduled by CARDEX, I/C Mod schedules modification SB.
- I/C Mod procure required material for accomplishment of SB.
SB Warranty Claim Data Collection
- S&CP monitors the SB accomplishment status on PAMMIS at defined screen. The procedure is
attached at the end.
- PAMMIS provides accomplishment date only.
- Though man-hours are mentioned in SB and Evaluation Notice too, still in case of ambiguous
information in both, particularly when man-hours are inspection findings dependent, correct man-
hours data is gathered from AWM Avionics or Aerospace Group against feedback performa.

- I/C Mod provide Purchase Order No. against any SB.
- POSS is used to retrieve related information about that PO.
- POSS provides Import No of particular PO. Import No. is provided to COMAT / FRS / P&L for freight
data collection.
- COMAT provides source and destination address and shipment weight of consignment.
- Freight charges are collected from CARGO rate manual (document attached) provided by CARGO /
Marketing.
SB Warranty Claim Filing
- www.myboeingfleet.com is accessed for filing warranty claim.
- The procedure is available at www.myboeingfleet.com.

4-1.22 PROCEDURE FOR HEAVY MAINTENANCE PERFORMANCE MONITORING
4.1. PURPOSE
This procedure gives guidelines to establish the effectiveness of base / heavy maintenance performance.
4.2. PROCEDURE
st
1. The base maintenance performance report shall be generated bi-annually. The 1 half yearly report
shall be generated after 5 months of end of HAJJ Operation. The final annual report shall be
generated after start of next HAJJ Operation.
2. Below are the steps of this procedure.
a. Collection of data related to hangar visit plan and actual maintenance activities. There are
two main fields required in this data.
i. Type of maintenance activities (Planned and Actually Performed)

ii. In and Out date of maintenance activities (Planned and Actually Performed)
b. Analysis of data according to Key Performance Indicators.

c. Summarizing the findings of analysis.
d. Performance projections for the current period in the light of findings established.
e. Submission to higher management for review and action.
Key Performance Indicators
• Capacity Utilization
• Order Fulfillment
• Percentage of Planned Ground Time Compliance
• Product and Process Data Accuracy
Basic Definitions
• Activity
– The smallest activity of heavy maintenance (e.g. Check C) whose duration is 15 days and
above is considered as a unit activity.
– All the remaining activities are defined in terms of that smallest activity e.g.
• Check C – 25 Working Days – 1 Activity
• Check D – 45 Working Days – 1.8 Activity
KPI-1: Capacity Utilization
• Capacity is the availability level of heavy maintenance facility e.g. 261 days in a year.
• Capacity Utilization indicates the duration of time, the maintenance hangar was occupied.
• High capacity utilization means more occupancy of maintenance hangar.
• It is calculated including both PIA and third party maintenance activities.
• Planned Capacity Utilization = Total Working Days Planned / Total Capacity * 100
• Actual Capacity Utilization = Total Working Days Actual / Total Capacity * 100
KPI-2: Order Fulfillment
• Order is a maintenance activity to take place in maintenance hangar.

• Order Fulfillment = 100 – ((Number of Activities Planned - Number of Activities Completed) /
Number of Activities Planned *100)
• Number of Activities Completed is the total number of activities completed within the duration of
plan.

• In case, the duration of completed activity is different from the planned duration, the planned
duration will be used in calculation.
• An activity which was not planned but completely carried out by base, will be included in order
fulfillment.
Note: This KPI is calculated excluding third party activities.
KPI-3: Percentage of Planned Ground Time Compliance
• It is the measure of degree to which maintenance plan is followed.

• In case of performance gaps, both Planning and Production Plans need re-evaluation.
• This KPI is calculated excluding third party activities.
• 100 + (Planned Days per Activity – Actual Days per Activity) / Planned Days per Activity *100
• Planned Days per Activity is Total Planned Grounding Days / Total Number of Planned Activities.
• Actual Days per Activity is Total Actual Grounding Days of completed activities / Number of
Activities Carried Out
• Number of Activities Carried Out is the total number of activities completed within the duration of
plan.
• In case, the duration of carried out activity is different from the planned duration, the planned
duration will be used in calculation.
• An activity which was not planned but completely carried out by base, will be included in order
fulfillment.
KPI-4: Product and Process Data Accuracy
• It measures the quality of work performed during maintenance activity.

• It is judged on the basis of
– Quality Inspection Findings
– Test Flight Results
– A/C Performance Post Heavy Maintenance Activity
• This KPI will be measured at later stages.

4-2 SAMPLE OF FORMS
REFERENCE DESCRIPTION REFERENCE / PAGE NO
4-2.1 Request For Quotation (RFQ) 2

Request / Approval for Loan / Sale of Aircraft
4-2.2 3
Component
4-2.3 PK Inventory Despatch Form 4
Request for Addition/Deletion/Correction in
4-2.4 MOE 5.1
Company Capability List (EM/SD&D/GEN151 R2)
Indent / Purchase Order Change Notice
4-2.5 AMP 2-1
(Form # 9-29-24B)
Requisition to Purchase Order
4-2.6 AMP 2-1
(Form # EM/SD&D/GEN063)
4-2.7 Repair Order Form (EM/SD&D/GEN059) AMP 2-1
Approved Vendor List for Suppliers of Aircraft
4-2.8 AMP 2-1
Parts (E&M/GM(LOG)/001/AVL)
Authorization for one time Repair Abroad
4-2.9 AMP 2-1
(EM/SD&D/GEN157)
Request for Addition/Deletion of Aircraft Parts in
4-2.10 AMP 2-1
Flight Pack (EM/SD&D/GEN172)
One Time Approval of Vendor
4-2.11 AMP 2-1
(EM/SD&D/GEN171
Source 70 Priority & Manual Purchase Orders
4-2.12 AMP 2-1
(Form # 9-35-115A REV1)
Capital Expenditure Sanction Form for
4-2.13 AMP 2-2
Non-Project items (form # 9-35-113)
4-2.14 Internal Requisition (9-35-60C) AMP 2-2
4-2.15 Cannibalization Form (DE/92/003) AMP 2-3
4-2.16 EASA Form 1 (EM/SD&D/GEN097) AMP 2-3

4-2.1 REQUEST FOR QUOTATION

4-2.2 REQUEST / APPROVAL FOR LOAN / SALE OF AIRCRAFT COMPONENT

4-2.3 PK INVENTORY DESPATCH FORM

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ENGINEERING PROCEDURES MANUAL

ENGINEERING & MAINTENANCE (MAINTENANCE OPERATION CENTRE)

ENGINEERING PROCEDURES MANUAL

EPM DISTRIBUTION CONTROL NO. ____

Maintenance Operation Centre

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ENGINEERING PROCEDURES MANUAL

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1-1 TABLE OF CONTENTS

PART-1 PREAMBLE ISSUE

PART-2 DIVISIONAL ORGANISATION, FACILITIES & WORKSCOPE ISSUE

PART-3 FUNCTIONS, DUTIES & RESPONSIBILITIES ISSUE

PART-4 PROCESSES & DOCUMENTS ISSUE

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1-2 RECORD OF REVISIONS

Upon completion of this Record of Revisions, acknowledgement shall be sent through a

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1-3 LIST OF EFFECTIVE PAGES

EPM TITLE 1 of 2 2 3 March-2013

PART – 2: DIVISIONAL ORGANISATION, FACILITIES & WORKSCOPE

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PART – 3: FUNCTIONS, DUTIES & RESPONSIBILITIES

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PART – 4: PROCESSES & DOCUMENTS

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1-4 INTRODUCTION & STRUCTURE OF ENGINEERING PROCEDURES MANUAL

Engineering Procedures Manual of MOC Division is developed on the

U 1-4.3 ENGINEERING PROCEDURES MANUAL DISTRIBUTION

Control No. Addressee

C01 Director Airworthiness,

Control No. Addressee

M01 Director (Engineering & Maintenance)

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1-5 ORGANIZATIONAL COMMITMENT BY THE CHIEF ENGINEER

Engineering Procedures Manual defines Organization, procedures and responsibility at

Engineering Procedures Manual shall be reviewed by MOC Division on as and when

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ENGINEERING PROCEDURES MANUAL

PART- 2: DIVISIONAL ORGANISATION, FACILITIES & WORKSCOPE

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2-1 DIVISIONAL STRUCTURE

2-1.1 MAINTENANCE OPERATION CENTRE DIVISION

Admin Officer Chief Engineer

Dy. Chief Engineer Dy. Chief Engineer

Dy. Chief Engineer Dy. Chief Engineer

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2-1.2 ROTABLE PLANNING SECTION