NATIONAL INSTITUTE OF TRANSPORT

FACULTY OF AVIATION TECHNOLOGY

DEPARTMENT OF AERONAUTICAL ENGINEERING

HIGHER DIPLOMA IN AIRCRAFT MAINTENANCE ENGINEERING

(HDAME II)

INDUSTRIAL PRACTICAL TRAINNING REPORT (IPT)

STUDENT´S NAME: NICOLAUS, SULEIMAN ADELHARD

REGISTRATION NUMBER:
PLACE OF IPT:
DURATION:
SUPERVISOR FROM NIT:
SUPERVISOR FROM THE INDUSTRY:
NIT/BAME/2021/206
PRECISION AIR
JNIA DAR ES SALAAM
FROM JULY 2023 TO OCTOBER 2023
MR. SAIDI MAULID
MR. CHRISTIAN SHIRIMA

NOVEMBER 2023
 ABSTRACT
This abstract provides the concise overview of my three-month industrial practical
training conducted at Precision Air Service. During this period, I had the opportunity to
work in various tasks. I participated in reduction gearbox borescope inspection, corrosion
removal and surface restored, removal and installation of the aileron, assembling and
disassembling main wheel, removal of the stubborn bolt.
Further-more ore I actively engaged in riveting of a nose landing gear seat and inspection
of water spray nozzle of air conditioning system. The experience was of great
significance as it not only improved my technical proficiency but also instilled a passion
in aviation.
 CERTIFICATION
I hereby certify I have reviewed and evaluated the field report titled “Industrial Practical
Training (IPT)” prepared by SULEIMAN ADELHARD NICOLAUS. I confirm the
report´s accuracy, data collection methods´ alignment with study objectives, adherence to
established protocol, and appropriate citation from external sources for the award of
Higher Diploma in Aircraft Maintenance Engineering.

Signature………………………….

Name MR. SAIDI MAULID

(Supervisor)

Date……………………………
 DECLARATION

I hereby declare that the information presented in this report has been prepared by
SULEIMAN ADELHARD NICOLAUS to fulfill the curriculum requirement of Higher
Diploma in Aircraft Maintenance Engineering offered by the National Institute of Transport
School of Aviation Technology (NIT -SAT) under the department of Aeronautical
Engineering.

Name Signature Date

 ACKNOWLEDGEMENT

Esteemed Precision Air Services, I wish to express my sincere gratitude for the opportunity to
complete my IPT. It has been a valuable experience, and I am thankful for the knowledge and
skills gained during my time here. I extend my appreciation to the entire team at Precision Air
Services for their support, guidance, and mentorship throughout my IPT. I am confident that
the experience and insights I have gained at Precision Air Services will serve as a strong
foundation for my career.

Also, I strongly thank the National Institute of Transport leadership for considering this
valuable time to get exposure to the aviation industry.

Thank you for this enriching IPT experience.

 LIST OF ABBREVIATIONS AND/OR ACRONYMS
A/C – Aircraft
NIT-SAT – National institute of transport-School of Aviation Technology
NLG – Nose landing gear
MLG _ Main Landing Gear
IPT – Industrial Practical Training
 LIST OF FIGURES AND ILLUSTRATION
Figure 1.1: Precision Air logo
Figure 1.3: Precision Air maintenance structure
Figure 2.1: speeder, bit and bit holder
Figure2.2: Description of the aileron assembly
Figure 2.3: Tools used
Figure 2.4: Left and right view of RGB
Figure 2.5: Gear arrangement of RGB
Figure 2.6: service door assembly
Figure 2.7: Tools and a workpiece
 TABLE OF CONTENT
ABSTRACT................................................................................................................................................i
CERTIFICATION.....................................................................................................................................ii
DECLARATION......................................................................................................................................iii
ACKNOWLEDGEMENT........................................................................................................................iv
LIST OF ABBREVIATIONS AND/OR ACRONYMS............................................................................v
LIST OF FIGURES AND ILLUSTRATION...........................................................................................vi
CHAPTER ONE........................................................................................................................................1
1.0 INTRODUCTION OF PRECISION AIR SERVICES....................................................................1
1.1.1 HISTORICAL BACKGROUND.............................................................................................1
1.1.2 PRECISION AIR SERVICE STRUCTURE............................................................................2
1.1.3 MISSION AND VISION..........................................................................................................3
1.1.4 ACTIVITIES PERFORMED BY PRECISION AIR SERVICES........................................3
1.1.5 LEVEL OF TECHNOLOGY...................................................................................................3
1.1.6 CUSTOMERS OF PRECISION AIR SERVICES...................................................................3
1.2 OBJECTIVES OF THE IPT......................................................................................................4
1.3 RELEVANCE OR SIGNIFICANCE OF THE IPT....................................................................4
CHAPTER TWO.......................................................................................................................................5
2.0 INDUSTRIAL PRACTICAL TRAINING PLAN IN DETAILS....................................................5
2.1 TRAINING PLAN IN PRECISION AIR SERVICES................................................................5
2.2 PLACEMENT IN THE ORGANIZATION..............................................................................13
2.3 ACTIVIES/DUTIES/TASKS PERFORMED BY THE STUDENT.........................................14
2.3.1 REMOVAL OF THE AILERON...........................................................................................14
2.3.2 REDUCTION GEARBOX BORESCOPE INSPECTION.....................................................18
2.3.4 REMOVAL OF CORROSION AND SURFACE RESTORED OF SERVICE DOOR
ASSEMBLY....................................................................................................................................21
2.3.5 RIVETTING OF NOSE LANDING GEAR SEAT...............................................................22
2.4 EXPECTATIONS FROM INDUSTRIAL PRACTICAL TRAAINING (IPT)...................24
2.5 WORK ENVIROMENT............................................................................................................24
2.6 CHALLENGES FACED...........................................................................................................24
2.7 SOLUTIONS TO THE PROBLEMS FACED.....................................................................24
2.8 NEW SKILLS/ LESSON LEARNT..........................................................................................24
2.9 OUTCOMES FROM THE IPT.................................................................................................25
2.10 GAPS BETWEEN THEORY AND PRACTICAL.................................................................25
CHAPTER THREE..................................................................................................................................27
3.0 CONCLUSION AND RECOMMENDATIONS..........................................................................27
3.1 CONCLUSION..........................................................................................................................27
 3.2 RECOMMENDATIONS...........................................................................................................27
REFERENCES.........................................................................................................................................28
APPENDICES.........................................................................................................................................29
Appendix 1: Typical aircraft used by Precision Air services..........................................................29
Appendix 2: Propeller shaft.............................................................................................................30
Appendix 3: Water spray nozzle and general inspection of ACS....................................................31
Appendix 4: Job instruction card for removal of aileron.................................................................32
Appendix 5: Job instruction card for installation of the aileron......................................................33
Appendix 6: job instruction card for schedule inspection of Auto Pilot (AP) actuators, connectors
and cables.........................................................................................................................................34
Appendix 7: job instruction card of installation of the flashlight....................................................35
Appendix 08: Top view of the reduction Gearbox..........................................................................36
 CHAPTER ONE
1.0 INTRODUCTION OF PRECISION AIR SERVICES
1.1.1 HISTORICAL BACKGROUND
Precision Air was established in 1993. It started as a private charter air Transport Company
operating a five-seater piper Aztec aircraft. Its initial line of business mainly entailed
providing connections to tourists visiting the rich natural attractions of Serengeti National
Park, Ngorongoro Crater, in northern Tanzania, the Zanzibar Island in the Indian Ocean and
other parts of the country from Arusha town as its base.
The vast nature of Tanzania coupled with a growing demand for air transport services as the
country started to embrace a free market economy soon drove Precision Air into operating
scheduled flights maintaining Arusha as its base. The first flights were scheduled using a
seven-seater one engine Cessna 207, one seven-seater Cessna 402, two eleven-seater Cessna
404s and the nineteen-seater LET 410 until mid1990´s when the airline introduced the bigger
and more comfortable ATR fleet.
Precision Air is currently headquartered in Dar es Salaam- the commercial city of the United
Republic of Tanzania. The airline’s main services include; scheduled flights, chartered and
cargo air services which are growing at an impressive rate. In May 2009, Tanzania Civil
Aviation Authority (TCAA) granted the company a self-handling license and ground handling
operations started at the beginning of November. The airline is seeking a third-party ground
handling license from TCAA.

Figure1.1: Precision Air logo

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1.1.2 PRECISION AIR SERVICE STRUCTURE

ACCOUNTALE MANAGER
(Patrick Mwanri)

HEAD OF QUALITY
SAFETY&SECURTY
(Gaudies Kusekwa)
HEAD OF MAINTENANCE
(Pablo Alves)
lv

MANAGER QUALITY
ENGINEERING
(Stanislaus Maganga)

MANAGER TECHNICAL
SERVICES
(S.Hashim)

WORKSHOP BASE LINE

MANAGER MAINTENANCE MAINTENANCE
(C.Shirima) MANAGER MANAGER
(J.Kambala) (O.Phiri)

Figure1.3: precision Air Maintenance Structure

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 1.1.3 MISSION AND VISION

MISSION
To provide superior airline services that are customer focused, reliable, safe and competitive.

VISION
To be the airline of choice and catalyst for change.
1.1.4 ACTIVITIES PERFORMED BY PRECISION AIR SERVICES

i. Offers Aircraft Maintenance Engineering services.

ii. Offers air transport services.
iii. Offers Cabin crew training course.
1.1.5 LEVEL OF TECHNOLOGY

The precision Air service level of technology is categorized in the following spheres:
i. Infrastructure.
Precision Air Service has a large hangar that can accommodate to about 5 aircrafts of
ATR 45 and ATR 72 type. The hangar is well equipped with modern facilities to
facilitate maintenance activities to be conducted in a safe manner, example platforms,
fire inhibitors, racks for storage purposes, and a bus to transport workers from terminal
II to the base (hangar). Additionally has the advanced system (ALKYM) to retrieve the
work orders.
ii. Training programs.
Precision Air Service has the training program to cutting-edge technologies in aviation
industry. This shows their dedication to technological change.
iii. Certifications and standards.
Precision Air Services has the capabilities of doing maintenance activities that are
certified by the Tanzania Civil Aviation Authority (TCAA), FAA and other authorities.
Still is in progress to expand its capabilities for maintenance of different aircrafts.
1.1.6 CUSTOMERS OF PRECISION AIR SERVICES
i. Cabin crew students.
ii. Students joining for industrial practical training.
iii. Individuals joining for internship.
iv. Passengers.

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 v. Third part airline customers for maintenance purpose.
These are; flight link, tropical air, Efatha ministries.

1.2 OBJECTIVES OF THE IPT

i. The understanding of the use aircraft maintenance manual in maintenance and repair
activities.
ii Identification, use and handling of tools used to perform different tasks.
iii The role of aircraft maintenance organization in facilitation of flight operations.

1.3 RELEVANCE OR SIGNIFICANCE OF THE IPT

i. Skill development.
It is because provides an opportunity for trainees to apply the theoretical knowledge to
gain/ develop the practical skills.
ii. work experience.
Trainees get a chance to gain hands-on hand experience, which is valuable when
seeking future employment
iii. Industry insight.

Trainees get first hand to look how the aviation industry operate, their work culture,
and challenge they face

iv. Soft skills.

Technical skills, trainees develop soft skills such as communication, teamwork, time
management, which are crucial for the job.

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 CHAPTER TWO
2.0 INDUSTRIAL PRACTICAL TRAINING PLAN IN DETAILS
2.1 TRAINING PLAN IN PRECISION AIR SERVICES
i Orientation period.
In this period the trainees get description of the whole training how maintenance
activities are carried out and organized by various departments. Takes 21 day, is
conducted in the training room and trainees pass in different departments for overview
of how performs its function.
The following are departments and their role that are part of the training plan at
Precision Air to which every trainee should be aware:

The Quality Assurance department

The department’s function is to ensure all maintenance activities meet the established
standards and regulations placed by the TCAA. They are responsible for monitoring and
evaluating the quality of work performed by the organization, identifying areas for
improvement, and implementing corrective actions when necessary. The Quality
Assurance department plays a crucial role in maintaining the safety, reliability, and
airworthiness of aircraft by ensuring that maintenance procedures and practices are
followed accurately and consistently. The primary functions of a Quality Assurance
department include:

a. Compliance Monitoring: The department ensures compliance with regulatory

requirements, industry standards, and organizational policies. They review and
assess procedures, processes, and documentation to ensure adherence to established
guidelines.

b. Quality Audits and Inspections: Quality Assurance conducts regular audits and
inspections of maintenance activities to identify any non-compliance, deviations, or
potential risks. They verify that work is being performed correctly and in
accordance with approved standards.

c. Corrective and Preventive Actions: When non-compliance or issues are identified,

the Quality Assurance department takes appropriate corrective actions to address
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 them. They investigate the root causes of problems, implement corrective
measures, and establish preventive actions to prevent recurrences.

d. Documentation and Recordkeeping: They maintain comprehensive documentation

and records related to quality control and assurance activities. This includes
documenting findings, tracking corrective actions, and maintaining audit trails for
regulatory purposes.

e. Training and Education: The department provides training and education to

employees regarding quality standards, procedures, and best practices. They ensure
that personnel are aware of their roles and responsibilities in maintaining quality
and safety.

f. Continuous Improvement: Quality Assurance fosters a culture of continuous

improvement within the AMO. They analyze data, performance metrics, and
customer feedback to identify areas for improvement, implement changes, and
monitor the effectiveness of quality management processes.

Technical record department

The department is responsible for managing and maintaining accurate and

comprehensive records of all maintenance activities performed on aircraft and
components. This department ensures that all necessary documentation, including work
orders, maintenance reports, inspection records, and compliance documents, are
properly recorded, organized, and stored.

The primary functions of the Technical Record department include:

a. Record Keeping: The department maintains a systematic and organized record of
all maintenance activities, which includes details of the work performed, parts
replaced, inspections conducted, and compliance with regulatory requirements.
These records are essential for demonstrating compliance, tracking maintenance
history, and supporting future maintenance actions.

b. Regulatory Compliance: The Technical Record department ensures that all

maintenance activities and records adhere to regulatory requirements set by

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 aviation authorities. They monitor and verify that the organization's records meet
the standards mandated by aviation regulations, such as the Federal Aviation
Administration (FAA) or the European Union Aviation Safety Agency (EASA).

c. Audits and Inspections: The department supports internal and external audits or
inspections by providing the necessary documentation and records.

d. They assist auditors or inspectors in verifying the accuracy, completeness, and

compliance of the organization's maintenance records.

Production, Planning and Control (PPC) department

This department plays a critical role in ensuring efficient and effective maintenance
operations. Here are the key functions of each department:
i. Engineering: The Engineering department is responsible for various tasks, including:

a) Technical Evaluation: They assess the airworthiness of aircraft,

components, and systems, ensuring compliance with regulatory standards
and manufacturer specifications.

b) Design and Modification: They develop and implement engineering

designs, modifications, or repairs to enhance performance, safety, or
efficiency.

c) Technical Documentation: They create and maintain technical manuals,

instructions, and engineering drawings to support maintenance activities.

d) Reliability Analysis: They analyze maintenance data, identify recurring

issues, and propose preventive measures to improve reliability and
minimize downtime.

ii. Production Planning: The Production Planning department focuses on scheduling

and optimizing maintenance activities. Their responsibilities include:

a) Work Order Management: They create and prioritize work orders,

considering factors like resource availability, criticality, and aircraft
downtime.
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 b) Resource Allocation: They coordinate and allocate resources, including
manpower, tools, equipment, and facilities, to ensure efficient workflow
and timely completion of maintenance tasks.

c) Capacity Planning: They assess the organization's capacity and plan

maintenance schedules accordingly, considering workload, maintenance
intervals, and regulatory requirements.

d) Coordination: They liaise with other departments, such as engineering,

logistics, and quality assurance, to ensure smooth coordination and
collaboration during maintenance operations.

iii. Control: The Control function within PPC involves monitoring and oversight to
ensure adherence to established plans and standards. Responsibilities include:

a) Performance Monitoring: They track the progress of maintenance

activities, analyze key performance indicators (KPIs), and identify any
deviations or bottlenecks.

b) Quality Control: They verify that maintenance tasks are carried out in
accordance with approved procedures, standards, and regulations.

c) Non-Conformance Management: They identify and address any non-

conformities or deviations from established processes, ensuring corrective
actions are implemented.

d) Continuous Improvement: They analyze data and feedback to identify

areas for improvement, suggest process enhancements, and support the
organization's continuous improvement initiatives.

Technical Store department

This department is responsible for managing and controlling the inventory of spare parts,
tools, equipment, and other materials necessary for maintenance activities.

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 Technical Library department

This department serves as a central repository of technical information and documentation

related to aircraft maintenance. Its primary function is to provide access to accurate, up-
to-date, and relevant technical data for maintenance personnel and other authorized users.
The specific functions of the Technical Library include:

a. Document Management: The Technical Library is responsible for managing and

organizing a wide range of technical documents, including aircraft manuals,
maintenance manuals, service bulletins, airworthiness directives, and other
technical publications. They ensure that these documents are properly catalogued,
archived, and readily available when needed.

b. Revision Control: The library maintains control over document revisions and
ensures that the latest versions of technical publications are accessible to the
maintenance staff. They track and manage document revisions, distributing
updates and notifying personnel of any changes.

c. Access and Distribution: The Technical Library provides controlled access to

technical documents and publications, ensuring that authorized personnel can
retrieve the necessary information. They may maintain physical or electronic
libraries, offering methods for personnel to search, retrieve, and request
documents as needed.

d. Regulatory Compliance: The library ensures that the AMO's technical

documentation remains compliant with regulatory requirements. They monitor and
update the library's collection to reflect the latest regulatory standards and
directives.

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 e. Information Research and Support: The Technical Library assists maintenance
personnel in researching technical information, troubleshooting procedures, and
obtaining relevant data for maintenance tasks.

f. They provide support in locating specific information and may offer guidance on
interpretation or application of technical documentation.

g. Archiving and Historical Data: The library maintains historical records and
archives of technical documentation, serving as a reference for past maintenance
activities. This information can be valuable for future maintenance tasks, historical
analysis, regulatory audits, or investigations.

Engineering Development and reliability department

This department is responsible for driving innovation, improving product performance,

and ensuring reliability within an organization. They conduct research and development
activities to enhance existing products or develop new ones. This includes designing and
developing products, analyzing failure data, conducting reliability testing, and
investigating the root causes of failures. The department also focuses on continuous
improvement, collaborating with other teams to optimize processes and enhance quality.
They provide technical support, expertise, and ensure regulatory compliance throughout
the product lifecycle. Its functions are;

a. Engineering Development: This department is responsible for conducting

research, development, and engineering activities to improve existing products,
systems, or processes. They analyze and evaluate the organization's operations,
identify areas for improvement, and propose innovative solutions or new
technologies.

b. Product Design and Development: The department plays a crucial role in

designing and developing new products or improving existing ones. They work
closely with cross- functional teams to define product requirements, create design
specifications, conduct feasibility studies, and oversee the development process
from concept to production.

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11
 c. Reliability Engineering: The department focuses on ensuring the reliability and
performance of products or systems. They analyze failure data, conduct reliability
testing, and implement strategies to enhance product reliability, durability, and
maintainability. They also provide recommendations for design improvements and
reliability-centered maintenance practices.

d. Failure Analysis and Root Cause Investigation: When failures or performance

issues occur, the Engineering Development and Reliability department conducts
thorough investigations to determine the root causes. They employ various
techniques, such as failure mode and effects analysis (FMEA), fault tree analysis
(FTA), or statistical analysis, to identify and address underlying issues.

e. Continuous Improvement: The department is involved in continuous improvement

initiatives, collaborating with other departments to identify opportunities for
process optimization, cost reduction, and quality enhancement.

f. They implement engineering methodologies, such as Lean Six Sigma or Kaizen,

to drive improvements across the organization.

g. Technical Support and Expertise: The Engineering Development and Reliability

department provides technical support to other departments and stakeholders.
They offer expertise in areas such as product design, materials selection, reliability
analysis, and troubleshooting technical issues.

h. Regulatory Compliance: The department ensures that engineering activities and

products comply with relevant regulations, industry standards, and safety
requirements. They stay updated on applicable regulations and work to ensure
compliance throughout the development and maintenance lifecycle.

Technical Procurement department

The Technical Procurement department is responsible for managing the procurement

process of technical goods, services, and equipment required by an organization. Its
primary function is to ensure the timely and cost-effective acquisition of technical

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resources needed for the organization's operations. The specific functions of the Technical
Procurement department include:

a. Vendor Selection and Management: The department identifies potential vendors,

evaluates their capabilities, and selects suppliers who can provide the required
technical goods or services. They establish and maintain relationships with
vendors, negotiate contracts, and manage vendor performance.

b. Sourcing and Bid Evaluation: The Technical Procurement department identifies

the technical goods or services needed by the organization and sources them from
the market. They analyze bids, evaluate proposals, and make informed decisions
based on factors such as cost, quality, lead time, and supplier reliability.

c. Cost and Budget Control: The Technical Procurement department monitors costs
associated with technical procurement activities. They analyze budgets, seek cost-
saving opportunities, negotiate prices, and implement strategies to optimize
procurement expenditure while maintaining quality and reliability.

d. Supplier Relationship Management: The department establishes and maintains

positive relationships with suppliers to foster long-term partnerships. They
communicate regularly with suppliers, address concerns, provide feedback, and
collaborate on improving delivery schedules, product quality, and service levels.

e. Inventory and Logistics Management: The Technical Procurement department

ensures efficient inventory management by coordinating with other departments to
determine optimal stock levels of technical resources. They manage logistics,
including shipping, receiving, and warehousing, to ensure timely delivery of goods
and equipment.

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 f. Compliance and Risk Management: The department ensures compliance with
relevant regulations, policies, and quality standards in the procurement process.
They assess and manage risks associated with procurement activities, such as
supplier reliability, quality control, and potential disruptions to the supply chain.

The Technical Procurement department plays a vital role in acquiring technical

resources necessary for the organization's operations. Their focus on vendor
selection, contract management, cost control, and supplier relationships contribute
to the organization's efficiency, cost-effectiveness, and overall success
ii Production maintenance.
The trainees are required to join the maintenance team in the maintenance hangar and
workshop maintenance which is under the supervision of a base maintenance manager
and workshop manager respectively. Th completion takes about 25 days in the hangar
and 15 days in the workshop.
iii Assessment and report compilation.
At precision Air Service the trainees are required to fill the work done in the logbook
and get assessed by the review from the workshop manager and the base maintenance
manager.

2.2 PLACEMENT IN THE ORGANIZATION

The following are the departments in Precision Air Services:
a) Hangar and workshop.

i. Battery room: Deals with battery charging & discharging and storage of aircraft t
battery.
ii. Wheels and brakes room: Deals with storage, maintenance and repair of aircraft
wheels and brakes.
iii. Avionics room: Deals with maintenance of electronics and electrical instruments I
aircraft systems.

iv. Archives/technical library room: Deals with storage of all documentations related to
maintenance of an aircraft. Also updating the maintenance manuals received from
the manufacturer or authorities.

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 v. Technical stores: deals with storage of aircraft components and tools used in repair
and maintenance of an aircraft.
vi. Wheel bay/dark room: deals with storage of wheels and tire covers.
b) Production planning and control.

i. The department forecasts the upcoming maintenance activities and control the life
limited parts of an aircraft.

c) Quality assurance department.

i. Ensures the
ii. Be responsible for ensuring that the Quality Assurance Program is properly
implemented, maintained and continuously reviewed and improved
iii. Develop and implement safety management systems.

2.3 ACTIVIES/DUTIES/TASKS PERFORMED BY THE STUDENT

In the IPT I was assigned and participate to perform the following tasks as specific
procedure from the maintenance manual:
i. Removal of the aileron.
ii. Installation of the aileron.
iii. Inspection of the autopilot actuators, connectors and tension cables.
iv. Corrosion removal and surface restored.
v. Inspection and test of water spray nozzle of the air condition system.
vi. Participated in reduction gearbox borescope inspection.
vii. Removal of the stubborn bolt.
viii. Disassembly and assembly of main wheel.
ix. Lubrication of the MLG and NLG.
x. Riveting of nose landing gear seat.

2.3.1 REMOVAL OF THE AILERON

An aileron is a hinged flight control surface typically located on the wings of an aircraft.
aileron serve a crucial role in controlling the aircrafts roll, which is the rotation of the
aircraft about its longitudinal axis. The motion allows the aircraft to bank or tilt to one
side, enabling it to turn.

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When a pilot moves the control stick to one side, the aileron on that wing moves
downward while the aileron on the opposite wing moves upward. This lift differential
changes the lift and drag characteristics of the wings. The aileron that moves downward
reduces lift on that wing and increases drag, causing that wing to drop or lose altitude.
Conversely the aileron that moves upward and increases lift and reduces drag, causing the
other wing to rise. This differential lift and drag result in the aircraft rolling about its
longitudinal axis. Initiating a turn.
A. SAFETY PRECAUTIONS
i. In the cockpit, put some warning notice to prevent flight controls operation.
ii. put an access platform- wing fuselage position.
iii. Remove the access panel(s) 555 and 655.
B. TOOLS USED
i. Ratchet
ii. Open and closed end spanner
iii. Spatula
iv. Speeder
v. Socket
vi. Bit holder
vii. Bit
viii. Dog bone
ix. Rigging pins
x. Screw driver

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 Tools assembly for removal of bolts on the access panels.

Figure 2.1: speeder, bit and bit holder

C. PROCEDURES TO ACCOMPLISH TASK
i. Rigging of the aileron control.
ii. Removal of the electrical wiring.
iii. Removal of position transmitter rod and the aileron input rod.
iv. Removal of the aileron.
In the last procedure of removing the aileron the following were adhered:
i. Recording the position of the bolts.
ii. Recording the position of the bonding leads on the aileron attachment points
iii. Disconnect the aileron from the center attachment point.
iv. Disconnect the aileron from outer fittings.
v. Lastly remove the aileron.

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The location of work areas is shown in the figure below.

Figure2.2: Description of the aileron assembly

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2.3.2 REDUCTION GEARBOX BORESCOPE INSPECTION

Borescope is a flexible optical instrument equipped with a camera and lighting system at
the tip. Borescope inspection is a non-destructive testing procedure to access the internal
condition of the gear box without need for disassembly. This inspection is crucial for
ensuring the reliability and safety of mechanical system of an engine. The examined areas
are gears, shafts and bearings. The inspected defects that might occur are foreign object
debris, cracks and gear tooth wear.
A. SAFETY PRECAUTIONS
i. Clean the opening to where the fiberscope is inserted.
ii. Caution: to avoid damage, withdraw fiberscope from gear box before turning a
propeller.
iii. Use only approved fiberscope (PWC34910-102) for inspection of the second stage
reduction spur gear teeth.
iv. Do not use the steel braided fiberscope.
v. Be careful when you put the fiberscope to prevent damage or scratch to the bearing
race.

B. TOOLS USED
i. Borescope
ii. Dog bone spanner
iii. Ratchet
iv. Open end and closed end spanner
v. Socket
vi. flat

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The pictorial representation of tools used are shown in the picture below.

Figure 2.3: Tools used

C. PROCEDURES TO ACCOMPLISH THE TASK
i. Remove the bolts, washers and the cap
ii. Secure borescope eyepiece to holding fixture and connect light source.
iii. If necessary, clean fiberscope, using a lint-free cloth.
iv. Slowly insert the fiberscope into a gearbox in the port.
v. Inspect the teeth on layshaft pinion gear for damage.
vi. Withdraw fiberscope into a gearbox and turn the propeller shaft 5 degrees
vii. Repeat steps (iv), (v) and (vi) until all teeth have been inspected.

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viii. Install the cap, washers, and bolts respectively torque bolts 36 to 40lb.in

Figure 2.4: Left and right view of RGB

Figure 2.5: Gear arrangement of RGB

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2.3.4 REMOVAL OF CORROSION AND SURFACE RESTORED OF SERVICE
DOOR ASSEMBLY
Corrosion removal involves elimination of existing corrosion products from a material´s
surface and surface restoration aim to protect, refinish, or improve the appearance and
functionality of the treated material or structure. It involves painting and coating. The
corrosion removal and surface restoration are essential for maintaining the structural
integrity, safety of various components and structures that are susceptible to corrosion.
The type of corrosion found on the work piece is pitting corrosion which is due to expose
to moisture condition from the service room (toilet).
A. SAFETY PRECAUTIONS
i. Avoid prolonged breathing of solvent or acid.
ii. Mix all chemicals per the instruction.
iii. Avoid prolonged or repeated contact with skin and the solvent. Rubber gloves should
be worn.
iv. Wash any paint stripper, or conversion material immediately from body.
v. Materials splashed into exes should be properly flushed with water and medical aid
obtained immediately.

B. TOOLS AND MATERIALS USED

i. Abrasive paper and mats (scrapers, abrasive wool or wire brushes).
ii. Rotary file.
iii. Primer.
iv. Alodine.
v. Paint.
vi. Rags.

C. PROCEDURES TO ACCMPLISH THE TASK

i. Cleaning and stripping of the corroded area (isopropyl alcohol).
ii. Removing as much as practicable.
iii. Neutralizing any residual materials remaining in pits.
iv. Surface preparation, smoothing the surface to remove any remaining rough spots or
irregularities.

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 v. Applying the protective coatings such as paint, primer for surface restoration.
The workpiece for corrosion removal and surface restoration is shown below.

The picture of a service door assembly which is covers the draining part of the toilet
waste.

Figure 2.6: Service door assembly

2.3.5 RIVETTING OF NOSE LANDING GEAR SEAT
Riveting is a mechanical joining process that involves fastening two or more components
together by using a rivet. Rivet is a cylindrical metal pin with a head on one end. Riveting
done on the new nose landing gear seat using the squeezing method.
A. SAFTEY PRECAUTIONS
i. Wearing goggles.
ii. When using the drill and the drill machine should not be direction of a co-worker or
any other person.
iii. The workpiece should be hold tight to the bench.

B. TOOLS USED
i. Rivet squeezer.
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 ii. Solid rivets.
iii. Crackle pins.
iv. Crackle pin holder.
v. Rivet cutter.
vi. Drill and drill machine.

C. PROCEDURES TO ACCOMPLISH THE TASK

i. hold tight the workpiece to the bench.
ii. Enlarge the rivet holes in respondents´ to the diameter of the rivet using the drill and
the drill machine.
iii. Align the landing gear seat assembly using the crackle pins.
iv. Cut the rivet the correct size using the rivet cutter.
v. Remove either of the crackle pins using the crackle pin holder and insert the rivet in
the hole.
vi. Squeeze the rivet till the rivet shop head is formed.
vii. Inspect the rivet if is correct riveted.

Figure 2.7: Tools and a workpiece

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2.4 EXPECTATIONS FROM INDUSTRIAL PRACTICAL TRAAINING (IPT)
Precision Air service fulfilled my expectations as follows:
i. Identification of aircraft systems and operation.
ii. Developing a team building skills.
iii. Understanding the flight controls operation through visualization.
iv. Reading and interpretation of aircraft maintenance manual.

2.5 WORK ENVIROMENT

Precision air hangar can accommodate 5 aircraft of ATR 42 and ATR 72 type. It is well
ventilated and light that support the working during the day and night. It´s equipped with
tools that facilitate to perform different tasks at a time and the supportive departments the
enhance the task to be done in a safe manner.
Appreciation to the Precision Air team for their supportive, collaborative culture during
the interaction with the trainees and other members. It is a good place for practical
training and theory learning and expanding experience of the career.

2.6 CHALLENGES FACED

Challenges in the completion of Industrial Practical Training are follows:

i. Delay of components to replace the unserviceable one due to store procedures.

ii. Lack of chance to participate in some activities, due to underrating of some senior
example working with Engine.
iii. Urgent requirement of the tools to perform a task.
2.7 SOLUTIONS TO THE PROBLEMS FACED
i. The store staff is alerted and informed early to prepare the component through the
ALKYM system.
ii. Rotation of working area of personnel.
iii. Clear description of the task and prepare the required tools to accomplish the task
2.8 NEW SKILLS/ LESSON LEARNT
The following are the new things that I learned in this field.

i) Identification of aircraft systems and their operation.

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 ii) Reading and interpretation of aircraft maintenance manual to
perform a task.

iii) Handling and identifying tools, materials and

equipment.

iv)Team handling.

v) For any inconvenience should be reported early to responsible

personnel.

vi) Workers should be given enough rest time after performing a

heavy duty, so as to minimize errors in doing another task.

vii) The serviceable and unserviceable components or tools

should be well identified by a tag.

viii) In performance of task there should be a leader to

overlook the safety of job.

2.9 OUTCOMES FROM THE IPT

The training obtained from the Precision Air services has greatly impacted to my career in
different spheres to act and being the aircraft maintenance technician/engineer. Some of
the outcome after joining the training are follows:
i. Awareness of the social, cultural and environmental responsibility as trainee,
technician, engineer and manager.
ii. Understanding the power of teamwork in task completion.
iii. Ability to handle and identify tools used if performing some tasks.
iv. Awareness of aviation authorities.
v. Capability of reading the maintenance manual procedures to perform a task.

2.10 GAPS BETWEEN THEORY AND PRACTICAL

i. Application of knowledge.
Theoretical knowledge may not always translate directly into practical skills.
Understanding the concept in theory doesn’t guarantee the ability to apply it
effectively in real tasks

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 ii. Contextual difference.
The real works is diverse and dynamic. What works in one context or theory
might not effective or applicable in another due to variation in circumstances.
iii. Changing environment.
The gap can widen when theory lags behind rapidly evolving practical
environments, in aviation industry.
iv. Education and training.
The way theory is taught and learned may not always prepare students for
practical challenges, leading to a gap in their ability to apply knowledge
effectively.

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 CHAPTER THREE
3.0 CONCLUSION AND RECOMMENDATIONS
3.1 CONCLUSION
The Industrial Practical training is very helpful to gain experience and what is learnt
theoretically when at the university, as exposes a student to the real industry of what is dealing
with his/her career and facilitates fast understanding of system operations of an aircraft. As an
individual participate to perform tasks that involve different systems of an aircraft. this makes
a person to learn new thing at a short period of time in a long run. This report is in detail of
what I performed and participated during Industrial practical Training conducted at the
Precision Air Service.
3.2 RECOMMENDATIONS
i. Precision air services is an interactive place for an individual (trainee) to acquire skills
and knowledge pertaining aircraft
ii. There are should be task assigned to student to perform and evaluated when at the
university.
iii. Teaching model should involve the interactive with the actual system, or component
instead of learning only theoretically and wait for IPT.

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 REFERENCES

i. https://www.precisionairtz.com/en/about-us/history

ii. Harry A. Kinson, PhD & Donley R.R (2004), .Aviation management 1st edition. McGraw
Hill Inc. Us

iii. EASA Part 66 Cat. B1 Module 7; Maintenance Practices Volume 1, Europe department of
transportation, European aviation safety agency

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 APPENDICES
Appendix 1: Typical aircraft used by Precision Air services

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Appendix 2: Propeller shaft

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Appendix 3: Water spray nozzle and general inspection of ACS

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Appendix 4: Job instruction card for removal of aileron

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Appendix 5: Job instruction card for installation of the aileron.

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Appendix 6: job instruction card for schedule inspection of Auto Pilot (AP) actuators,
connectors and cables.

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Appendix 7: job instruction card of installation of the flashlight.

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Appendix 08: Top view of the reduction Gearbox.

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