Chapter 8 Engineering

Facultad de Ingeniería y Ciencias Básicas

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 Introduction
• There is discussion in the aviation industry about whether or not an airline needs an engineering
component. In former times, airlines were instrumental in determining what they wanted in terms of
aircraft size, range, and operating systems.
• The airlines would establish specifications and present these to the various airframe manufacturers who
would then compete for the contract and ultimately produce the final product.

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 Engineering definition
Engineering is defined by the Engineers Council for Professional Development as the

“profession in which a knowledge of the mathematical and natural sciences gained by study, experience,
and practice is applied with judgment to develop ways to utilize economically the materials and forces of
nature for the benefit of mankind.”

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 Airline engineering department
• Made up of the more experienced people of the maintenance organization. They must be
knowledgeable of the total maintenance operation as well as the airline and regulatory
requirements.
• There would be engineering staff for each type of equipment: avionics, electrical, hydraulic,
pneumatic, power plant (engines and APU), structures, and mechanical systems. Avionics may even
be divided into communications and navigation systems; and mechanical systems into flight
controls, hydraulics, etc.
• This distribution of specialties is determined, for the most part, by the size of the airline.

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 Mechanics and Engineers

Engineers and mechanics are trained differently, and each approaches problems in
different ways. While the mechanic’s approach is somewhat reactive, the engineer’s
approach is more proactive. But, it takes both disciplines to run an effective engineering
operation at an airline.

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 Mechanics
• Mechanics and technicians study the practical aspects
of aviation systems and equipment, they may specialize
in:
o avionics systems:
 electrical
 Electronic
 Communication
 computer
o mechanical systems:
 Hydraulics
 Pneumatics
 flight controls
 structures

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Maintenance & Engineering Organizational Chart
• Engineers are trained in the basics of science and engineering (mathematics, chemistry, physics, etc.); in the
techniques of inductive and deductive reasoning; as well as in the areas of statistical analysis, problem
solving, and systems engineering.
• Engineers also specialize in one particular engineering discipline—civil, electrical, mechanical, aeronautical,
structural. Seldom do engineers spread themselves over the gamut of aviation disciplines.

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 Engineering Department Functions

• The engineering department provides preparation, study, and analysis of various aspects of the
maintenance operation.
• Evaluate maintenance requirements and establish the maintenance program for the airline.
• Suggested modifications of aircraft systems for possible incorporation into the fleet and
provide technical assistance to maintenance.
• Prepares the units for handling new equipment and facilities and provides assistance, where
needed, in all other aspects of maintenance.

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Development of the maintenance program

The initial maintenance program is a generalized program and must be tailored

to the individual operator from the very beginning. The manufacturer produces
the FAA approved

Engineering department in the Development of the maintenance program:

Is the responsibility for selecting the tasks to be done, for packaging the tasks
into workable check packages, and ensuring that all task limits are met (time,
cycles, etc.)

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 Develop technical policies
and procedures manual for M&E

THIS DOCUMENT identifies:

• the organizational structure
• information on duties and responsibilities of key personnel
and key organizations
• maps and layouts of the airline’s facilities.
• Descriptions of how work is to be carried out

Engineering is responsible for developing this document with

inputs from the other M&E units.

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 Evaluate changes in
the maintenance program

• Add or take away Individual tasks that may be ineffective or less than adequate.
• shorten or extend the intervals between repetitive tasks to improve the overall performance or
reduce in-service failures of a system or component.
This adjustment of the maintenance program is the job of the engineering staff. Data collection by
the reliability organization and analysis of the problem by engineering are necessary to carry out this
function.

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 Evaluate changes in aircraft
or system configuration
Engineering will, however, be required to provide the information needed by maintenance to
accomplish the modification regardless of whether it is an AD, SB, or SL. This will be accomplished by
engineering order (EO) .
• These modifications are issued as service bulletins (SBs) or service letters (SLs)
• If a safety or airworthiness issue is involved, the modification may be issued by the FAA as an
airworthiness directive (AD).
• Since service bulletins and service letters are not FAA requirements, the airline has the option to
incorporate or ignore the modification.
• Airworthiness directives are mandatory, so there is no need for engineering to evaluate the
change.

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Evaluation of new aircraft added to the fleet

Engineering will be required to provide the information needed for take decisions such as:
• Chose the best new equipment for the airline.
 Aircraft
 Engine modifications
 Structural modifications
 Avionics modifications
• Selection of the best maintenance equipment to accomplish given work.

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Example of engineering department decision
The question is to chose between the Boeing 767 and the Airbus A330.
 What engines are available for these models?
This is important because:
• There may be a need for additional maintenance and test facilities for these new engines.
• The cost and the feasibility of this is very important.
• Training needs for engine mechanics
 What is the range of these airplanes?
This is important because:
• The airline need to position their own line personnel at outstations
• outstation personnel must to handle these new airplanes
• Additional training for the new personnel required
 What new technology is included in these new models?
This is important because:
• To recognize if the skills of the current maintenance and engineering staff sufficient to
maintain these airplanes
• Will this involve extensive training or “differences training”
 Based on current knowledge of the maintenance programs for these two airplane models, will
the scheduled checks be compatible with current schedules available on the fleet
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Example of engineering department decision
The question is to chose between the Boeing 767 and the Airbus A330.
 Will additional ground support equipment (GSE) be needed for these new airplanes?
This is important because:
• Additional cost for the airliner
 Will the existing hangars be suitable for these airplanes?
This is important because:
• modified or build a new hangar
 What will be the increased need for parts and parts storage at the home base and at outstations
to support the new airplanes?
This is important because:
• This could involve a considerable amount of financial investment for parts not common to
the existing fleet.
 What is the industry experience on these two models relative to maintenance support?

“These and other questions must be considered by the engineering department, with inputs from
other units within M&E, prior to the decision as to which airplane should be purchased.”

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Evaluation of used aircraft to be added to the fleet
• the current configuration of the airplane,
• check the maintenance program schedule that the current operator is using; status of
modifications (ADs and SBs).
• If this affect training, maintenance support, material support, outstation activities.
• modification and configuration standards that must be met by the operator
• Configuration that the airplane should be in at termination of the leasing case

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 Development of new facilities for M&E
It is necessary for the airline to build new facilities or expand existing ones to support new
equipment, airline expansion, or modernization efforts.

This would include such as:

• projects
• Hangars
• engine test facilities
• component shops
• storage facilities
• types of equipment
• storage for special parts.

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 Issuance of engineering orders
will be issued on an engineering order developed by engineering,
with inputs from appropriate work centers, to define:
• the scope of the job
• schedule the work
• Work performed as a result of
 SBs,
 SLs,
 Ads
• work resulting from evaluation of problems defined by
reliability investigations or QC reports.

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 Provide assistance in troubleshooting
difficult problems
When the problem eludes the mechanic’s expertise, assistance is available from engineering to get
to the bottom of the problem. This assistance can be given to line, hangar, and shop people, as well
as vendors handling warranty claims or working on contract..

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 Other engineering functions

They are considered the technical experts of the organization and are available to lend technical in
the airline needing such assistance.

Engineering can also provide :

• expertise to training
• material
• the technical library
• Help any other M&E organization

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 Engineering Order Preparation
It initiates an engineering order for any work not included in the standard maintenance program plans as established
by the Ops Specs.
The following eight steps generalize the EO creation :
1. A decision is made to do work based on one of the following:
• reliability program alert an AD, SB and SL
• fleet campaign.
• work force requirement
2. Engineering analyzes the work requirements:
• troubleshoot or investigate the problem to determine scope and needs; analyze AD, SB, SL, etc. if applicable
for time, personnel, etc. requirements.
3. Determine the approach to follow:
• incorporate work into PP&C check or other scheduled or unscheduled maintenance activity
• schedule other corrective action as necessary
• issue EO as required.
4. Identify the needs for schedule and performance of the work: engineering studies, plans, etc.
• the need for special skills if any (in-house or contract);
• the need for parts and supplies (on hand or order, consider lead time for delivery);
• determine need and availability for special tools and/or test equipment needed.
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 Engineering Order Preparation
5. Identify work required:
• personnel (maintenance, engineering, contract, etc.)
• facilities (hangar space, GSE, etc.)
• time requirements for work to be done.
6. Call a coordinating meeting to finalize EO (if necessary):
• all organizations involved in the work
• coordinate and resolve difficulties.
7. Issue engineering order:
• PP&C will plan work and monitor execution
• EO may go directly to material, training, etc. as necessary.
8. Engineering closes EO when all work is completed:
• notification comes from each work center involved in the particular EO
• EO remains open,
• PP&C schedules each aircraft for incorporation;
• engineering closes EO when fleet is complete.

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GRACIAS

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