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Aviation Maintenance Management Harry A. Kinnison, Ph.D. McGraw-Hill New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto
Aviation Maintenance Management
Harry A. Kinnison, Ph.D.
McGraw-Hill New York Chicago San Francisco Lisbon London Madrid
Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto
Contents
List of Figures xiii List of Tables xv Preface xvii Introduction xix
Part I: Fundamentals of Maintenance 1
Chapter 1. Why We Have to Do Maintenance 3
Thermodynamics Revisited 3 A Saw Blade Has Width 4 The Role of the Engineer 4 The Role of the Mechanic 5 Two Types of Maintenance 5 Reliability 7 Redesign 7 Failure Rate Patterns 9 Other Maintenance Considerations 11 Establishing a Maintenance Program 13
Chapter 2. Development of Maintenance Programs 15
Introduction 15 The Maintenance Steering Group (MSG) Approach 16 Process-Oriented Maintenance 18 Task-Oriented Maintenance 22 The Current MSG Process—MSG-3 24 The Maintenance Program Documents 28 Maintenance Intervals Defined 29 Changing Basic Maintenance Intervals 30
Chapter 3. Definitions, Goals, and Objectives 33
Definitions of Important Terms 33 Maintenance 34
Inherent Reliability 36 Mechanics, Technicians, Maintainers, Engineers 36 Word Pairs Used in Aviation 36 Goals and Objectives of Maintenance 39 Maintenance Program Content 41 Discussion of the Five Objectives 41 Summary 44
Chapter 4. Aviation Industry Certification Requirements 45
Introduction 45 Aircraft Certification 45 Delivery Inspection 49 Operator Certification 53 Certification of Personnel 54 Aviation Industry Interaction 54
Chapter 5. Documentation for Maintenance 57
Types of Documentation 57 Manufacturer's Documentation 58 Regulatory Documentation 62 Airline Generated Documentation 63 ATA Document Standards 66 A Closer Look at the TPPM 70
Chapter 6. Requirements for a Maintenance Program 75
Objectives of a Maintenance Program 75 Aviation Maintenance Program Outlined (AC 120-16D) 75 Summary of FAA Requirements 81 Additional Maintenance Program Requirements 82 Summary 84
Chapter 7. The Maintenance and Engineering Organization 85
Organization of Maintenance and Engineering 85 Organizational Structure 85 The M&E Organizational Chart 87 General Groupings 87 Manager Level Functions—Technical Services Directorate 88 Manager Level Functions—Aircraft Maintenance Directorate 90 Manager Level Functions—Overhaul Shops Directorate 91 Manager Level Functions—Materiel Directorate 92 Manager Level Functions—Maintenance Program
Evaluation Directorate 93 Summary of Management Levels 94 Organizational Structure and the TPPM 94 Variations from the Typical Organization 95
Contents ix
Part II: Technical Services 97
Chapter 8. Engineering 99
Introduction 99 Makeup of Engineering 100 Mechanics and Engineers 101 Engineering Department Functions 103 Engineering Order Preparation 108
Chapter 9. Production Planning and Control 111
Introduction 111 Forecasting 113 Production Planning 113 Production Control 121 Feedback for Planning 122 Organization of PP&C 123
Chapter 10. Technical Publications 125
Introduction 125 Functions of Technical Publications 125 Airline Libraries 126 Control of Publications 127 Document Distribution 128
Chapter 11. Technical Training 129
Introduction 129 Organization 130 Training for Aviation Maintenance 131 Maintenance Resources Management 132 Airframe Manufacturer's Training Courses 133 Other Airline Training Courses 133
Chapter 12. Computer Support 135
What Is a Computer? 135 . Airline Uses of Computers 136
Computer Program Modules 138 Selecting a Computer System 138
Part III: Maintenance and Materiel Support 141
Chapter 13. Line Maintenance (on-Aircraft) 143
Makeup of Line Maintenance 143 Functions that Control Maintenance 144 Maintenance Control Center Responsibilities 145
Line Maintenance Operations—General 147 Aircraft Logbook 148 Ramp and Terminal Operations 149 Other Line Maintenance Activities 150 Line Station Activities 151 Maintenance Crew Skill Requirements 152 Morning Meeting 153
Chapter 14. Hangar Maintenance (on-Aircraft) 155
Introduction 155 Organization of Hangar Maintenance 156 Problem Areas in Hangar Maintenance 157 Maintenance Support Shops 159 Ground Support Equipment 159 Hangar Maintenance Activity—A Typical "C" Check 162
Chapter 15. Maintenance Overhaul Shops (off-Aircraft) 165
Organization of Overhaul Shops 165 Types of Shops 165 Operation of Overhaul Shops 167 Shop Data Collection 168
Chapter 16. Materiel Support 169
Organization and Function of Materiel 169 The Materiel Directorate 170 M&E Support Functions of Materiel 171 Other Materiel Functions 176
Part IV: Oversight Functions 179
Chapter 17. Quality Assurance 181
Requirement for Quality Assurance (QA) 181 Quality Audits 182 ISO 9000 Quality Standard 186 Technical Records 188 Other Functions of QA 190
Chapter 18. Quality Control 191
Introduction 191 Quality Control Organization 191 FAA and JAA Differences 192 QC Inspector Qualifications 193 Basic Inspection Policies 194 Other QC Activities 195
Contents xi
Chapter 19. Reliability 201
Introduction 201 Types of Reliability 202 A Definition of Reliability 206 A Reliability Program 206 Elements of a Reliability Program 206 Other Functions of the Reliability Program 217 Administration and Management of the Reliability Program 217
Chapter 20. Maintenance Safety 221
Industrial Safety 221 Safety Regulations 221 Maintenance Safety Program 223 General Responsibilities for Safety 223 General Safety Rules 225 Accident and Injury Reporting 227
PartV: Appendixes 229
Appendix A. Systems Engineering 231
Introduction 231 Systematic versus Systems Approach 231 Systems Engineering 232 Definitions 233 System Interface Control 235 System Optimization 236 An Example of a System—The "Onion Layered" Structure 236 Summary 238
Appendix B. Human Factors in Maintenance 239
Background 239 Basic Definitions 240 Human Factors and Systems Engineering 240 Goals of the System versus Goals of the User 241 Designing for the Human Interface 242 Human Factors in Maintenance 242 Human Factors Responsibilities 243 Safety 244 Summary 244
Appendix С The Art and Science of Troubleshooting 245
Introduction 245 Three Levels of Troubleshooting 246 Knowledge of Malfunctions 247 Knowledge is Power 250
Building Your Own Knowledge Base 252 Understanding the Sequence of Events 253 Eight Basic Concepts of Troubleshooting 254 Summary 257
Appendix D. Investigation of Reliability Aierts 259
Introduction 259 A Review of Reliability 259 Alert Investigation—A Cross-Functional Activity 260 Zeroing in on the Problem 261 About the Alert Analysis Flow Charts 262
Appendix E. Extended Range Operations (ETOPS) 273
Introduction 273 Background 273 Deviation from the 60-Minute Rule 275 ETOPS Maintenance versus Conventional Maintenance 277 ETOPS for non-ETOPS Airplanes 278 Summary 279
Appendix F. Glossary 281
Index 291
