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RELIABILITY

ENGINEERI

NG

AVIATION

MAINTENA

NCE AND

MANAGEME

NT

History

In the early days of aviation, the “need” of maintenance was

performed based on the judgment of experienced aircraft maintenance

personnel.

At that time, the scheduled maintenance programmes were not

created to proactively prevention of in-flight failures.

Maintenance at hard time intervals worked fairly well for propeller

driven aircraft that were generally all mechanical and had wear-out

components.

This resulted several hours of maintenance for every hour of flight time

even though the flying machines and onboard systems were simple.

Despite parts on the aircraft were overhauled on a periodic basis as

well as changes were made in either the content or frequency of

scheduled overhauls, FAA realized that scheduled overhaul had

negligible effect on general reliability of engines as in-flight failures

were still excessive and the reliability of certain types of engines

remained low.

The findings led to a new type of maintenance known as the On-

Condition maintenance.

Definitio

ns

Commonly used terms in aircraft maintenance

Maintenance means the performance of tasks

required to ensure the continued airworthiness of

an aircraft, and includes the overhaul,

inspection, replacement, defect

rectification and the embodiment of a

modification or repair.

Repair means the restoration of an

aircraft/aircraft component to an airworthiness

condition to ensure that the aircraft continues

to comply with the design aspects of the

appropriate airworthiness requirements

used for the issuance of the type certificate for

the respective aircraft type, after it has been

damaged or subject to wear.

Overhaul is a major work operation, which

involves dismantling, inspection and replacement

of any necessary parts, reassembly and

complete functional testing to

specifications and renewal of operational

life.

Definitio

ns

Modification means the alteration of an

aircraft/aircraft component inconformity

with an approved standard.

Replacement in relation to any part of any

aircraft or its equipment, includes the removal

and replacement of that part whether or not

by the same part, and whether or not any

work is done on it, but does not include the

removal and replacement of a part which

is designed to be removable solely for

the purpose of enabling another part to

be inspected, repaired, removed or

replaced or cargo to be loaded.

Inspection is any work necessary to

determine the condition of a component,

whether damage or defects exist, or work has

been completed in an approved manner.

Aircraft means any machine that can derive

support in the atmosphere from the reactions

of the

Definitio

ns

Block Hours is hours

measured from the time

aircraft leaves the gate (wheel

chocks removed) to the time

aircraft stops at the

destination gate (wheel chocks

in place)

Flight Hours is the actual

flight time measured from

takeoff (wheels up) to landing

(touching-down).

Flight Cycle is one takeoff

and landing.

Regulatory

Documentati

ons

The regulatory authorities issue numerous documents

related to maintenance of aircraft and their systems. Here are

the more significant documents.

Aviation / Airworthiness Regulations (AR)

These aviation / airworthiness regulations address all

aspects of the aviation field including private, commercial,

and experimental aircraft; airports, navigational aids, air

traffic control, training of pilots, controllers, mechanics, and

other related activities. In the United States, the Federal

Aviation Administration (FAA) issued Federal Aviation

Regulations (FAR).

Advisory Circulars (AC)

An AC is a document issued by the regulatory authorities to

provide assistance to operators on meeting the

requirements of various aviation / airworthiness

regulations. These ACs are not binding as law but are

purely suggestions as to how to comply with other

requirements.

Airworthiness Directives (AD) & Consignes de

Navigabilite (CN)

The AD and CN are substantial regulations issued by the

FAA and EASA respectively, to correct an unsafe condition

that exists in a product (aircraft, aircraft engine, propeller

or appliance) and a condition that is likely to exist or

develop in other similar products.

ATA

Documentation

and Standards

ATA 100

SPECIFICATION

The Air Transport

Association of America

(ATA) standardized

the overall format of

the maintenance

manuals so that all

manufacturers’

documents would be

more compatible.

ATA

Documentation

and Standards

ATA

Documentatio

n and

Standards

An example of the

Chapter

Breakdown is as

follows:

ATA

Documentat

ion and

Standards

The last group of digits (page

block) is the same for all

maintenance manuals.

The page blocks refer to specific

types of information contained in

the airplane maintenance manual.

For example, pages 001 – 099 are

reserved for the description and

operation of the chapter's systems.

Pages 401 – 499 contain

removal/installation procedures for

the various components within the

system or chapter.

Note: The second (section) and

third (subject) groups may vary

from one manufacturer to another

and from one model aircraft to

another of the same manufacturer

because of

differences in the structure of the

systems to which they apply.

ATA

Documentati

on and

Standards

Removal / installation (R/I) procedures are written to provide

detailed, step-by-step instructions on how to remove and

replace a line replaceable unit (LRU), including actions to be

taken prior to removal of LRU such as disconnecting

electrical power, deactivating hydraulic, etc.

Removal / Installation (pages 401-499)

The page block contains procedures for making adjustments

to the systems whenever a component or system has just

been replaced (by an R/I) or during normal maintenance

(scheduled or unscheduled) when such adjustments are

required.

Adjustment / Test (pages 501-599)

The page block covers the zonal inspection activities.

Inspection / Check (pages 601-699)

The page block contains procedures and specifications for

materials to be used for washing, cleaning, and painting the

aircraft.

Cleaning / Painting (pages 701-799)

The page block identifies repairs to structure and aircraft

skin that have been approved by the FAA for operator

accomplishment.

Approved Repairs (pages 801-899)

The page block contains procedures and tasks for items that

are inoperative or degraded at dispatch require maintenance

action prior to the deferral and dispatch.

Dispatch Deviation Guide Procedures

(pages 901-999)

Manufactur

er’s

Documenta

tion

Documentation are provided by the airframe

manufacturers to operators for aircraft

maintenance purpose can either be

customized for the operator to include only

the operator's configuration and equipment,

or generic for all models or all airplanes of a

specific model.

Airplane Maintenance Manual (AMM)



The AMM contains all the basic

information on the operation and

maintenance of the aircraft and its on-

board equipment



Its description and operation (D&O)

section explains how each system and

subsystem works.



Various basic maintenance and servicing

actions such as removal and installation of

LRUs, tests and adjustments performed on

the systems and equipment, and the

replenishing and other servicing tasks are

described in the maintenance sections.

Manufacturer’s

Documentation

Manufactur

er’s

Documenta

tion

Component Maintenance

Manual and Vendor Manual

(CMM / VM)



Components that are installed on

aircraft can be loosely categorized

as seller-furnished equipment (SFE)

and buyer-furnished equipment

(BFE).



SFE are those supplied to the

airframe manufacturer or

purchased by the operator, and are

installed by the airframe

manufacturer before delivery.



BFE are selected and installed by

the operator after delivery. The

CMM