Aircraft Maintenance Programs (Springer Series in Reliability Engineering)

✍ Scribed by David Lapesa Barrera

• Publisher: Springer
• Year: 2022
• Tongue: English
• Leaves: 368
• Edition: 1st ed. 2022
• Category: Library

✦ Synopsis

This book provides the first comprehensive comparison of the Aircraft Maintenance Program (AMP) requirements of the two most widely known aviation regulators: the European Aviation Safety Agency (EASA) and the Federal Aviation Administration (FAA). It offers an in-depth examination of the elements of an AMP, explaining the aircraft accident investigations and events that have originated and modelled the current rules.

By introducing the Triangle of Airworthiness model (Reliability, Quality and Safety), the book enables easier understanding of the processes by which an aircraft and its components are deemed to be in a safe condition for operation from a cost-effective and optimization perspective. The book compares the best practices used by top airlines and compiles a series of tools and techniques to improve the standards of the AMP.

Aircraft maintenance engineers, students in the field of aerospace engineering, and airlines staff, as well as researchers more widely interested in safety, quality, and reliability will benefit from reading this book

✦ Table of Contents

Preamble
Introduction
The Triangle of Airworthiness
Guidance to Navigate Through the Book
Contents
Acronyms
Part I Regulatory Environment
1 ICAO and the Aviation Authorities
1.1 The International Civil Aviation Organization (ICAO)
1.2 The European Union Aviation Safety Agency (EASA)
1.3 The Federal Aviation Administration (FAA)
1.4 Civil Aviation Authorities
1.5 Bilateral Aviation Safety Agreements (BASA)
2 The Story of Airworthiness Approvals and Certifications
2.1 Initial Airworthiness
2.2 Operation
2.3 Continuing Airworthiness
2.4 Maintenance
3 Continuing Airworthiness Management—Organization and AMP Requirements
3.1 EASA: CAMO, CAME and AMP Requirements
3.2 FAA: CAMP, Maintenance Schedule and AMP Requirements
4 Instructions for Continuing Airworthiness (ICA)
4.1 ICA—Design Organizations Responsibilities
4.1.1 ICA—EASA Design Organization—Specifications and Regulations
4.1.2 ICA—FAA Design Organization—Specifications and Regulations
4.1.3 E.U.–U.S. Bilateral Agreement—Design Organization Approvals
Part II Aircraft Maintenance Programs: Content and Management
5 AMP Content and Maintenance Planning Document (MPD)
5.1 AMP Content
5.1.1 General Considerations
5.1.2 AMP Preamble—Procedures
5.1.3 AMP Structure
5.1.4 AMP Revision
5.2 Maintenance Planning Document (MPD)
5.2.1 MPD and AMM/IPC Revision Cycle
5.3 Maintenance Requirement and Task Card
6 AMP Primary Sources
6.1 Maintenance Review Board Report (MRBR)
6.1.1 The International Maintenance Review Board Policy Board (IMRBPB)
6.1.2 The International MRB/MTB Process Standard (IMPS)
6.1.3 Policy and Procedures Handbook (PPH)
6.1.4 Utilization Considerations
6.1.5 The Maintenance Steering Group (MSG)
6.1.6 MSG-3 Analysis Methodology
6.1.7 Issue Paper 44 (IP 44): MRB Evolution/Optmization Guidelines
6.2 Airworthiness Limitations (ALS) and Certification Maintenance Requirements (CMR)
6.2.1 Requirements Derived from Systems Safety Analysis (SSA)
6.2.2 Requirements Derived from the Damage Tolerance and Fatigue Evaluation of the Structure
6.2.3 Examples of ALS Documentation Data Packages
7 AMP Secondary Sources: Aging Aircraft
7.1 Continuing Structural Integrity Program
7.1.1 Supplemental Structural Inspection Program (SSIP)
7.1.2 Corrosion Prevention and Control Program (CPCP)
7.1.3 SSIP/CPCP Implementation
8 AMP Secondary Sources: MCAI, Modifications and Repairs, and Non-mandatory Recommendations
8.1 Mandatory Continuing Airworthiness Information (MCAI)—Airworthiness Directives (AD)
8.2 Modifications and Repairs
8.2.1 Modifications
8.2.2 Repairs
8.2.3 Modifications/Repairs Scheduled Requirements
8.3 Non-mandatory Recommendations
8.3.1 Service Bulletins (SB)
8.3.2 Service Letters (SL)
8.4 Embodiment Policy
9 AMP Secondary Sources: Operational Requirements and Changes to the Operation Type
9.1 Scheduled Requirements Derived from Specific Operation Approvals
9.1.1 Reduced Vertical Separation Minima (RVSM)
9.1.2 Minimum Navigation Performance Specifications (MNPS)
9.1.3 Performance-Based Navigation (PBN): RNAV and RNP
9.1.4 Extended Diversion Time Operations (EDTO)—ETOPS/LROPS
9.1.5 All Weather Operations (AWO)
9.2 Low Utilization Maintenance Program (LUMP)
9.3 Miscellaneous Scheduled Requirements
9.3.1 Preflight Check
9.3.2 Safety/Emergency Equipment
9.3.3 Emergency Locator Transmitter (ELT)
9.3.4 Flight Recorders
9.3.5 Weight and Balance
10 Components Maintenance Program
10.1 Acceptance of Components
10.1.1 Component Authorized Release Certificate
10.1.2 Conformity Documentation/Statement
10.1.3 Suspected Unapproved Parts (SUP)
10.1.4 Organization Responsibilities
10.2 Component Maintenance Manuals (CMM)
10.3 Details of Specific Component Programs
10.3.1 Evacuation Slides
10.3.2 Landing Gear
10.3.3 Powerplant, Thrust Reverser, and Auxiliary Power Unit (APU)
10.4 Aircraft Configuration Management
10.5 Robbery Procedures
10.6 Component Maintenance Program Structure
11 AMP Task Interval Management
11.1 Maintenance Clock
11.1.1 First Accomplishment of Tasks—Starting Point
11.1.2 Repeat Interval
11.1.3 Credit from Accomplishment of a Different Task
11.2 Grace Period (Compliance Time)
11.3 Permitted Variations
11.3.1 Scope of the Permitted Variations
11.3.2 Maximum Permitted Variation
11.3.3 Permitted Variations—Interval Management
11.4 Exceptional Short-Term Extension
11.4.1 Scope of the Exceptional Short-Term Extension
11.4.2 Exceptional Short-Term Extensions—Interval Management
11.5 Task Escalation
11.5.1 Scope of the AMP Task Escalation
12 AMP Evolution/Optimization
12.1 AMP Evolution/Optimization: Assessment of Resources
12.2 AMP Evolution/Optimization Based on MRB Evolution/Optimization (Process Mirror)
13 Maintenance Checks and Bridge Programs
13.1 Maintenance Checks
13.1.1 Types of Maintenance
13.1.2 Maintenance Check Concepts
13.1.3 Task Repackaging
13.2 Bridge Programs
13.2.1 Bridge Program Causes
13.2.2 AMP Bridging Considerations
14 Aircraft Induction
14.1 Aircraft Induction: The AMP Revision
14.2 Aircraft Induction—Documental Review for AMP Compliance
15 Critical Maintenance Tasks/Required Inspection Items
15.1 Critical Maintenance Tasks and Identical Tasks (EASA)
15.2 Required Inspection Items (FAA)
15.3 Dual Maintenance on Extended Diversion Time Operations (EDTO) Significant Systems
15.4 Integration into the AMP
Part III The Reliability Program
16 Reliability Program Regulatory Requirements
16.1 EASA—Reliability Program Requirements
16.2 FAA—Continuing Analysis Surveillance System (CASS)
17 Reliability Program Process
17.1 Sources of the Reliability Program
17.2 Analysis of Reliability Data
17.2.1 Performance Standards
17.2.2 Deviations from Performance Standards
17.3 Reliability Root Cause Analysis (RCA)
17.4 Corrective Actions
18 AMP Task Effectiveness
18.1 AMP Task Effectiveness Analysis
18.1.1 In-Service Data
18.1.2 Analysis
18.1.3 Recommendations
18.1.4 Approval and Implementation
19 Reliability Analysis Results
19.1 Reliability Reports
19.2 Reliability Meetings
Part IV The AMP in the Engineering and Maintenance Organization Context
20 The Engineering and Maintenance Organization
20.1 Aircraft Asset Management
20.2 Engineering Services
20.2.1 Technical Publications
20.2.2 Technical Records
20.2.3 Technical Services
20.2.4 Maintenance Programs
20.2.5 Reliability
20.2.6 Maintenance Planning and Scheduling
20.2.7 IT Systems
20.3 Maintenance
20.3.1 Production Planning and Control
20.3.2 Maintenance Control Center
20.3.3 Line/Base Maintenance
20.3.4 Workshops
20.4 Supply Chain and Material Support
20.4.1 Inventory Control
20.4.2 Procurement
20.4.3 Stores
20.4.4 Component Repairs
20.4.5 Warranty and Insurance
20.5 Oversight Functions: Compliance Monitoring/quality and Safety
20.6 Training
20.7 Others
21 Interface of the Maintenance Program with Other Functions
21.1 Service Level Agreements (SLA)
22 Impact of the AMP Revision on the Organization
Part V Safety Management
23 Hazards and Safety Risks
24 Human Factors
24.1 Human Factors Modeling
24.1.1 The Shell Model
24.1.2 The Pear Model
24.2 The Dirty Dozen
24.2.1 Lack of Communication
24.2.2 Complacency
24.2.3 Lack of Knowledge
24.2.4 Distraction
24.2.5 Lack of Teamwork
24.2.6 Fatigue
24.2.7 Lack of Resources
24.2.8 Pressure
24.2.9 Lack of Assertiveness
24.2.10 Stress
24.2.11 Lack of Awareness
24.2.12 Norms
25 Organizational Factors
25.1 The Reason’s Model (Swiss Cheese Model)
25.2 Case Study: Overdue Airworthiness Directive
26 Safety Programs
26.1 Safety Management Principles
26.2 SMS: EASA and FAA Approaches
26.3 Safety Reporting Systems and Exchange of Information
26.3.1 Types of Safety Reporting Systems
26.3.2 Safety Information Exchange
26.3.3 Safety Data Format
26.4 Safety Culture
Part VI Quality Improvement Tools and Methods
27 Audits
27.1 Regulations and Standards
27.1.1 Regulatory Audit
27.1.2 IATA Operational Safety Audit (IOSA)
27.1.3 ISO 9001:2015 Quality Management Systems
27.2 Preparing for an Audit
28 Problem Solving
28.1 Root Cause Analysis
28.1.1 Five Why Analysis
28.1.2 Cause and Effect Diagram (Fishbone Diagram)
28.1.3 Bow-Tie Diagram
28.1.4 Failure Mode and Effects Analysis (FMEA)
28.2 Reactive Problem-Solving Methodologies
28.2.1 A3 Method
28.2.2 Maintenance Error Decision Aid (MEDA)
29 Continuous Improvement Methodologies and Tools
29.1 Continuous Improvement Methodologies
29.1.1 Lean
29.1.2 Kaizen
29.1.3 Six Sigma
29.1.4 Agile
29.2 Continuous Improvement Tools
29.2.1 Process Mapping
29.2.2 The Re Method: Eliminating Overprocessing Waste
29.2.3 6S Method
29.2.4 Scrumban: Scrum and Kanban
29.2.5 Poka-Yoke
29.2.6 Gemba Walk
29.2.7 Kaizen Events
30 Decision Making
30.1 Business Intelligence (BI)
30.2 Cost–Benefit Analysis
31 Innovation
31.1 Automation
31.1.1 Robotic Process Automation (RPA)
31.1.2 Radio-Frequency Identification (RFID)
31.1.3 Maintenance Automation
31.2 Toward Predictive and Prescriptive Aircraft Maintenance
31.3 Blockchain
Appendix A Introduction to Aircraft Maintenance Program Costs
A.1 Direct Maintenance Cost
A.2 The Cost of an Aircraft Maintenance Program
A.2.1 Use of Cost Indexes
A.2.2 Task Unitary Cost Measurement
A.2.3 Task Cost/Saving Calculations
Appendix B Introduction to Aircraft Accident Investigation
B.1 Investigation Responsibilities
B.2 The Investigation Areas
B.2.1 The Maintenance Investigation
EASA Regulation Codes