W ELCOME

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MAINTENANCE ORGANIZATION
AND PRACTICES

ASHVIRGINS
AEROMECH INST.
 Objectives
a. State the purpose and general structure of parts
catalogues
b. list the general range of documentation usually
accompanying an aircraft on delivery
c. list the documents contained in the set of aircraft
records
d. Describe the most important forms and documents used
for recording maintenance and inspection activities

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 POSSIBLE QUESTION AREAS

– aircraft weight and balance

– Airworthiness Directives (AD)
– Service Bulletins (SB)
– Alert Servicing Bulletin
– aircraft maintenance
– airline's Required Inspection Item (RIIs)?
– Structural Repair Manual

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 Aircraft Maintenance

 Is the performance of the tasks require to ensure the

continuing airworthiness of an aircraft or aircraft
parts. It include
 overhauling
 Inspection
 Replacement
 Defect rectification
 Modifications
 And all this must be done with airworthiness
directives and repairs.
Wikipedia. com
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 So

Maintenance?
a. all activities necessary for retaining an item or equipment
in serviceable (operating) condition.
b. It also includes all activities involved in restoring
items/equipment to a serviceable condition.

 In general, they have been subdivided into

• preventive
• corrective maintenance methods.

 An activity which remains an indispensable part of

maintenance is inspection.

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 Preventive
’ maintenance

This maintenance is performed at defined intervals to

retain item in serviceable condition by:

a. Cleaning
b. Systematic inspection
c. Detection
d. replacement of wearing parts
e. Adjustment
f. Calibration etc.

 Equivalent terms are ’scheduled’ or ’routine

maintenance’.
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 Corrective
’ maintenance

 Is a maintenance performed to restore an item to

satisfactory condition by providing correction of
a known or suspected malfunction and/or defect.

o Equivalent terms are ’unscheduled’ or ’non-routine

maintenance

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 Basic. Concepts

 Basically, the following maintenance

concepts are known:
a. Scheduled overhaul
b. On condition
c. Spectrum analysis
d. Condition monitoring
e. Fly to fault.

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 Scheduled Overhaul

 Scheduled overhaul has become a common practice

since the early years of aviation.

 Its philosophy is that every functional part requires overhaul

on a fixed schedule to ensure the highest possible level of
safety.

 This requires that the aircraft must be grounded

periodically.
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Advantages Scheduled Overhaul
a. Easy planning of the work to be done.
b. Continuous, steadily balanced work load through the
maintenance line.

Disadvantages
c. Very high maintenance work loads resulting in a long time the
aircraft has to be grounded.
d. Unnecessary work is done on components which might
sometimes even show an increased failure rate afterwards.
e. The pattern of serviceability aimed at by the manufacturer may
be distorted.
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 On Condition

As aircraft engineering technology had advanced and

more accurate test equipment had been developed, the
concept of ’on-condition maintenance’ was introduced
in the early 1950s.

 Its philosophy is that the operability of components is

determined by physical tests and measurements at set
intervals.

The results determine the necessary degree of

maintenance
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advantages On Condition
 considerably reduced time on ground caused by maintenance
 Increased cost effectiveness.

Disadvantages
 Very high costs for the test equipment
 More difficult work planning because the system must allow for the
tests.

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 Spectrum Analysis

 This is the results gathered by the ’on-condition’ method.

 lt was developed by Rolls Royce in the 1950s.
 lt proved to be extremely useful in planning and
recording an engine’s unserviceability.
 Backed up by modern computers today it is the most
important system used by aircraft engine manufacturers.

 Its philosophy is that by analyzing the engine oil it is possible to detect

wear pattern of all moving components and to plan the necessary
maintenance or overhaul accordingly.

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Advantages Spectrum Analysis
a. Unnecessary stripping of the engines for component examination is
avoided
b. Preventive maintenance is pin-pointed
c. Maintenance and overhaul are much more predictable and the necessary
times can be planned more accurately.

Disadvantages Spectrum Analysis

d. Highly complex test equipment to perform the analysis
e. Suitably trained personnel to interpret the information obtained.

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 Condition Monitoring

 The conception of condition monitoring is a progressive

improvement of ’on condition’ maintenance.
 lt involves computerized analysis of malfunctions.
 lt was developed and first introduced by BOEING AIRCRAFT
CORP. in the early 1960s.

 Its philosophy is that in condition monitoring a malfunction is allowed to

occur.
 Then an extensive analysis is carried out to determine the exact
preventive maintenance necessary to avoid a repetition of that
malfunction.

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 Advantages Condition Monitoring

a. Very detailed preventive maintenance requirements can be scheduled

b. Cost effectiveness is maximized.

Disadvantages Condition Monitoring

c. A malfunction is allowed to occur

d. Work planning is difficult to be assessed

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 FIy to Fault

 lt has been used since the dawn of the industrial

revolution but obviously in the field of aviation it is
strictly limited to non-critical components, i.e.
components which do not affect flight safety.

 The concept of ’fly to fault’ is that a component is

operated until it malfunctions or breaks down.

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 Advantages FIy to Fault
a. Never at all preventive maintenance
b. Maximum use of components
c. The possibility of accurately defining the component’s
reliability.

 Disadvantages FIy to Fault

a. The work load can hardly be planned
b. Spares for all components which might break down have to
be stored
c. The concept’s limited application to aviation engineering.

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 Maintenance Activities

There are 3 types of maintenance activities:

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 Maintenance carried out at specified periods of time regardless of the item’s
condition at that time.

 The maintenance activity may be periodic:

a. Overhaul
b. Bearing change
c. Repaint
d. Calibration
e. lubrication, etc.

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 Periodic examinations, mostly at specified periods of time, but sometimes
on an ’opportunity’ basis.

 (when an item has been removed for better access) to

determine not only the extent of deterioration but also
whether the deterioration is still within its specified
limits.

 These activities originate from the on-condition process.

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  Actions implemented in response to the analysis of condition clues based
on the monitoring during flight, in the workshop and on other types of
information sources.

 These activities originate from the condition-

monitoring maintenance process.

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 Documentation Breakdown

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 The set of documentation that accompanies an aircraft on
first delivery is very large.
 It is normally divided into a series of publications similar to
standard books of reference.
 The set of publications normally comprises:

 Maintenance manual
 Repair and overhaul manual
 Illustrated parts catalogue
 Ground support equipment
 Vendor’s manual(s).

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 AMM : Aircraft Maintenance Manual

– Basic information on the operation and maintenance of the

aircraft and its on-board equipment.

• Description and operation of each system

• Basic maintenance and servicing actions
• Functional tests and operational tests
• Adjustments
• Replenishing of various fluids
• Other servicing tasks

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 Documentation Standard ATA

ATA Spec 100

Air Transport Association of America (ATA) standardized the
overall format of the maintenance manuals

Each system type was assigned a chapter number. For

example,
• Hydraulic systems are in ATA Chapter 29
• Radio equipment is ATA Chapter 23
• Fuel system is ATA Chapter 28
Chapters referring to the aircraft’s systems
 Sections referring to the sub-systems
 Subjects referring to units.

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 ATA Spec 100

Format

 The fuel cells are covered in

chapter 28 ’Fuel System’

 section 28-10 Storage System

 subject 28-10-01 ’Fuel Cells’

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 Illustrated Parts Catalogues

 A parts catalogue is published by manufacturers to assist the

aircraft operator

 In the procurement of spares and other materials required for servicing,

maintenance, repair or overhaul of the entire aircraft or any of its systems.

 Lists and location diagrams of all parts used on the aircraft model.

 Information on part numbers, vendors, interchangeability of parts

 These catalogues are normally known as either

 Illustrated parts catalogues (IPC) or

 Illustrated parts listings (IPL).
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 Air Operator’s Documentation

 What is an Air Operator ?

 Air operator or Aircraft operator” means any person who provides

the service of transport of goods or passengers by aircraft;

 What is an Air Operator Certificate?

 A Certificate authorizing as operator to carry out specified air

transport operation.

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 Aircraft Records

 By appropriate regulations, every operating aircraft is required to

have certain records available.
 It is the responsibility of a repair station to supply and maintain
records when:

a. Inspections
b. Repairs
c. Alterations have been performed on airframes, power plants, propellers,
helicopter rotors or appliances.

 It is the responsibility of the owner or operator of an aircraft to

ensure that all required records are kept up-to-date.

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Set of Aircraft Records Usually Includes

 An operator’s (or: owner’s manual)

 weight-and-balance data
 A log-book for maintenance records and flight records
 The airworthiness certificate
 The registration certificate
 The ownership certificate
 A copy of the type certificate data sheet
 Copies of major repair and alteration forms.

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 Operator’s Manual

 An operator’s (or: owner’s) manual is supplied by the

manufacturer:

 to assure that the owner (or operator) of the aircraft gets all
necessary information regarding the operation of the aircraft.

 The manual of a particular aircraft may include all

information in one booklet, others may be provided in
separate books.

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 Weight-and-Balance Data

• For safe operation of an aircraft the location of the CG must

be in such a position that the aircraft is not excessively nose-
heavy or tail-heavy.
• Therefore accurate information on the CG location must be
maintained.
• The aircraft records must show that the EWCG (if specified) is
within the prescribed limits. Loading information must be
such that the operator can easily determine that under the
’loaded’ condition of the aircraft the CG will be maintained
within the ’safe operating’ range.

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 Whenever the airframe manufacturer or the engine manufacturer have modifications or
suggestions for improving maintenance and/or servicing, they will issue appropriate
paperwork to the affected airlines.

SB : Service Bulletins

A service bulletin (SB) is usually a modification of a system that will

provide improved safety or operation of a system and includes a
detailed description of the work and parts required.

SL : Service Letter

A service letter (SL) usually provides information to improve
maintenance actions without equipment modification.

MT : Maintenance Tip

The maintenance tip is a suggestion for maintenance personnel to
assist in their work or improve conditions.
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Information needed to effect certain repairs of the
aircraft structure.

Repairs are simple and are approved by the FAA for

operator completion.

Other structural repairs must be done by the

airframe manufacturer or some other FAA
designated repair facility.

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List of maintenance and servicing tasks to be
performed on the aircraft.

All items of the MRB report along with other

information.

Certification maintenance requirements (CMRs)

Tasks, which were developed by the MSG process

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 Inspections

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  Many inspections are necessary in order to keep any aircraft in proper
operating condition and to avoid the possibility of failure during
operation.

 Manufacturers often include inspection charts in their aircraft

maintenance manuals

 to specify the intervals of time for each inspection and the parts and
systems to be inspected.

 The use of these charts usually ensures

 adequate inspection of the aircraft to provide safe operation.

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 Daily
 Pre-,Through
 Post-flight Inspections
 Walk-round Inspections

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International aviation regulations require that certain inspections
are carried out for operating aircraft.

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 Annual Inspections

 Every certified aircraft must have had an annual inspection

within the 12 months preceding any flight.
 An annual inspection is a complete examination of every
accessible part of the aircraft, including:

a. Engine accessories
b. Electrical accessories
c. Hydraulic systems
d. Fuel systems,
e. Engine components and all other parts that could become
defective.

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 100-h Inspections
 The 100-h inspection is similar to the annual inspection.

 It is required for any aircraft operated for hire after every 100
hours of operation.

 Certified airframe and powerplant technicians are authorized to

carry out a 100-h inspection and to return the aircraft to service.

 Inspecting personnel are to record the results in the aircraft and

powerplant log-books, sign the entries and record their
certificate number.

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 Inspection Authorization

 A certified airframe and powerplant technician holding an

inspection authorization rating (IA) issued by the national
aviation authority may carry out the annual inspection.

 Upon completion of such an inspection, the inspector records

the details of the inspection in

 the aircraft log-book including a description of all maintenance and

repair work carried out during the inspection.

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 Questi ons …???

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