“Wd ‘uosiuuly 'y Auey ae twos Mesuesooq aA 38 VORA A-AEDH ABA Y S09 SDUEUA}UIEW SZILIUN = Buruuejd sadoud Aq @WIQUMOP YEIJIC SZILWIUIY « spuay) pue swia|qoud a2ueueUuIeLL Joyuow pue Ajnuap) aouevaquaew ul siope} ueWiNy 249 0} tpeosdde snoA auMy-2ULy « sass Ayayes pue “spuepueys Auqeijau ‘10.909 Ayjenb ‘soueunsse Ayjenb uo do} uo Aeys spuan pue suajgoid wei8oid aoueuaqurew soyuow pue AYRUDp} = ‘uaurauinbay AsoyeynBau Suqaaw ui Aouanyye anowduy « ‘Suorpuny Sujuossmoud pue je>1uypes apes8dn, » INAINJDVNV/) EPL AEN I aAY NOLLWIAY :nok sdjay y Yeyp ued auowy ‘Buuuns pue dh y 3um8 pue wer8oxd anueuajurew e Sunuueyd yo dats Avera noA smoys juawebouDy) SDUDUAIUIDW UORDUY suosiuUTy Aue} JaUpea} AySFaAIUN) JeDANeUOIBY alpPR-AIqUA ‘MOU pUE JeDUIO Bulgog sauNO4 “swesBOId a>UEUaIUIEW auyste BANPeYD-1S09 Pue ‘ajqerjas ‘juapiye uns pue dojanap sseBeuew sdjay a>anosai anbuun sit INI WOLLOS YdGNNOS V GNV SLAVYDUIV Y4sVS NIVLNIVIN AVIATION MAINTENANCE MANAGEMENT eeAviation Maintet Manage Harry A. Kinnis Nowe Chicago an Fanlace Ua ‘ion Gy lan Row Be SomeLibrary of Congress Cateloging-n-Publication Data into, Mary A. “pinion maintenance management / Harry A. Kinison. spoon tezsix nd repeit, 2 AiplaneeManagenent. I. Tie oaseonacae “Copyright© 2004 by The Metra Hil Company, oe. Al igha reserved. Printed {nthe United States of Amerie, Except as permited der the Une States any ctf 976 pat tin pation may be reproduced or ated “20 oy any tec or stein ta Ss eva eum, witout ‘he prior writen permibln ofthe panier 91011 12 19 1415 181718 19 DOCDOC 1548210 ISBN 0-07-142261-% ‘Thasponsrin itr for thi book was Stephen 8. Chapman andthe production ‘tes eas Pamala A Paton tas at n Canary Sehciboh 9 “Intemational petting and Composition Theat diver or the coer wat ‘Antony andi ‘rite and bound by RR Donne. [McGra-Hl books are availabe a apeca quantity dacauntato we a premiums ‘ed eles protic, ot for une ncororets traning Programe. For mare ine” ‘Eatin, please write tothe Ditetorof Spec San, Profesional Publaing. ‘isGraw Hil. Two Penn Pan, New York, NY 101212296 Or contact yur lal ‘prmaton coving in Wie work as ben obtained by The NcQrew AUD ‘Epatn 10 rary fom saree baoed to be rab However einer Mr lot autor porns the corny o compete ef ‘Etoraatn pblsd ere, and iter McGrew ul sar Se eattre sal be ‘opener any err cin of darage ming et owe of iar SSE‘ wok x pba ih th nertanding that Mra an tre ‘2c rupling norman tare attempting fo ror engineering cet In memory of Dave Ross and Al FarrisPart |: Fundamentals of Maintenance (Chaptor 1. Why We Have to Do Malstonance “Teamodyamlos Rawat ‘Saw Bla He With ‘The Role ofthe Engineer “The Role of he Machanlo ‘TwoTypes of Mantenance laity Redesign Fate Rate Pate ‘Other Malntnance Considerations “Eetibshing « ainenance Program ‘Chapter 2. Development of Maintenance Programs: ‘The Malntonance Steering Group (SG) Approach Process‘Orente Maintenance ‘ask-Oreted Maintenance ‘The Current MSG Proceso—MSG-9 “The Malntnance Program Decumens airtnance Intervals Deed ‘Changing Basle Maintenance tare {Chapter 3. Definitions, Goals, and Objectives Denntins of important Terme, alrtonance Contents 888 SBREksea se se sInerent Ratity Mechanics, Technicing, antainers, Engineers ‘Word Pale Usd In Avion Gomi and Objective of Maintenance uintanance Program Content Discussion ofthe Five Objectives Summary ‘Chapter 4. Aviation Industry Certiiation Requirements Ineoducton ‘or Corteation Dative pectin (Operator Cartieation CCertteaton of Personne ‘Aviation nduatry Interaction (Chapter 5. Documentation for Maintenance [ACloer Look athe TPP ‘Chapter 6. Requirements fora Maintenance Program (Objectives of «Maintenance Program ‘Alton Maintenance Program Outlined (AC 120-160) ‘Summary ot FAA Requroments ‘Aaaiion! alntnance Program Requrements ‘summary CChapter7. The Maintenance and Engineering Organtzaton ‘Organizton of Maintenance and Engineering ‘Organizational Sircture ‘TheAe Orgenzationl Chart General Groupings Manager Lave Functions Technical Services Dictorte Mandger Love Functions Overhaul Shope Drectorate Manager Level Funetons—Mterl Directorate Manager Lave Functlons—Mintansnce Program ‘Evalustion Drctorate ‘Summary of Management Levels Organiztonal Svuctre andthe TPPM Variations trom the Typlal Organization ggenes 9 geese teseese geeua a Part it: Technical Services CChaptor 8. Engineering Introduction Makeup of Ergheering Mechanics and Engineers Engineering Depariment Functions Engineering Order Preperation Chapter 9. Production Planning and Control Introduction Forecasting Prodoctlon Planning Production Conot Feedback or Penning Organization of PAC (Chapter 10, Technical Publcations Introduction Functions of Technle!Pubilatons Aine brace Cont of Pubestions ‘Document Oistbuton (Chaptor 11. Technical Training Introduction ‘Organizaton ‘Trang for Aviation Walntonance Naintananc Resources Management ‘Airrame Manutecturers Ting Courses ‘ther Aline Taming Courses (Chapter 12. Computer Support Watts Computer? ‘Aisne Uses of Computers Seocing «Comper yee Part Il: Maintenance and Materiel Support Chapter 19, Line Maintenance (on-Areratt) Maup of Line Maintenance Functions that Coto! Maltenance Malntanance Control Cantor Reeporaliiies oT m 83 3 va va 13 135 138 18 138,Une Matntnance Operations—General ‘Alrrat Logbook amp and"ermin! Operations (Other Line Maintenance Activites Line Staton Activites Maintenance Crew Sk Requlrments morning teeing ‘Chapter 14, Hangar Maintenance on-Alreratt) Organization of Hangar Mainenance Problem Areae In Hangar Malnionexce Maintenance Support Shops. Ground Support Equlpment Hangar Maintenance Actvty—A Tpleal"C" Check Chapter 16. Maintenance Overhaul Shops (ot-Areratty Organization of Overhaul Shops Types of Shope | ‘Operation of Overhaul Shops ‘Shop Data Coteton ‘Chapter 16. Materiel Support (Organization and Function of Mater ‘Te Materiel Directorate Oversight Functions: Chapter 17. Quality Assurance Requirement fr Qualty Assurance (QA) ‘ust Auate 180 9000 Guay Standard “eahols! Records (ter Functions of OA Chapter 18, Qualty Contro! Introdvetion ‘Quetty Control Organization FAA and JAA Oterences ‘2c inspector Qualifications Basle Inspection Policies Other QC Activin ‘Chepter 19. Relabity Types of Rey {oetnton of Rely ‘AReabitty Program Eloments ofa Rei Program (Other Functions of the Rett Program ‘Adminstration and Management of he Relality Program ‘Chepter 20. Maintenance Setety nut Safety Sefety Regulations Maintenance Seety Program ‘General Responetiies for Saoty (General Satay utes ‘Acldent and nary Reporting PartV: Appendixes ‘Aapendbx A. Systems Engineering Inoducton Systema vera Systems Approach ‘Systems Engineering Detintions| _Bystem irterace Conv ‘system Optimization ‘An Example of Bystem—The “Onion Layee” Structre ‘summary ‘Aopendix 8. Human Factors In Maintenance Background Basle Detntons ‘Human Factor and Systems Engoeerieg ‘Goa ofthe System vrsus Goals ofthe User Deeigring for the Human ntertece Human Factors in Maintenance ‘Human Fctors Responses satey Summary ‘Appendix C. The Art and Sclence of Troubleshooting Introduction ~ NESSES 8 Seeggge & BERRRSESR R BSSERR Bsee se‘Bulking Your Own Knowledge Base ‘Understanding the Sequence of Event Eight Bole Concepts of Troubeshooting ‘summary ‘Append D. inveetigtion of Rellablity Alerts Introduction ‘Review of Rettty ‘Alert Invetigion—A Crose-Functlonal Activity Zoroing In onthe Problem ‘About he Alert Anaya Flow Charts ‘Appendix E. Extended Range Operations (ETOPS) Introduction Background Deviton frm the 6-nate Rule [ETOPS Maitenancevernue Conventional ifalnanance, [TOPS for non ETOPS Arplonee ‘Summary ‘Appendix F. Glossary Index SEER ggsgg3 8 Fue 1-1 ge 12 Figure 19 Figwe 14 Foure 21 Figure 29 Fire Figure et Figure 42 Figure 43 Figure 4 Figures Figure 51 gure 74 Figure rt Figure ot Figure igre 13-4 igre 19.2 Figure 161 Figure nt Figure 184 Figure 102 Figure 199 Figure 104 igre 1-8 Pure At igre Ot Pure 2 Figure 03 Pure Pure Os List of Figures SRURTEEANRR Seen eaatad SSEBaeibe 11 Tabet Tape 64 Tale 52 Tab0 59 abe 4 abe 55 be sé abeot “Taboo? v0 99 Teno ot “Taio 104 Tie 102 Talo 124 Tie 122 aie 194 Tie 144 Tle 172 Tio 174 ano 104 “rie 102 Tako 194 “ato 204 Tato at “te Bt Tec ate C2 List of Tables Feature Rate Petros 190-2 Process Steps Manutacturers oeuentation Regulatory Documenta [Arne Ganerted Documantaton {ATA Standerd Chapter Numbere ‘Aplane Malnterance Manuel Page Block Assignments ‘echnlal Plces and Procedures Manual (TPP) ‘Arerft Malntonance Chock Schedule (Types! A Example) ‘Average Check Package Man-houre (Example) {yplal Aorat"A" Cheek and" Chack Schedule ‘Summary of Ara Check Package Manure (Example BI Check for A290 alee) Sette Liters ‘Conrad Documants ting ‘Computer Stare Modules (Examples) ‘Buying a New Computer Syston ‘Typleal 4-Hour Check CvinEngine Jet) ‘ypleal Transit Check Twi-Engine Jt) LUstot Ground Support Equipment (GSE) Heme ‘ust Aveta 180 9000 Requrements for Quay Organizations ‘Continuous Recorde Routine Records ‘eptive Records [NOTNDY Techniques Mechanleal Rly Reports Pot Reports per 100 Lanaings oy ATA Chapter) ‘Occupational Seety and Hath Standards ‘Sytem and Subeystoms Human Factors Design Guldoines Detain ‘Guestlons to Askin Toubleshooting dassensse 7Preface never read the “begat chapters” in the front of books until I became a writer ‘myzelf, Twanted to see just what it took to write a book and was quite surprised toaay the least. Although only one name appears on the book as “author” it takes ‘maay, many people (as well as numerous books, articles, and experiences) to pro-