COSCAP Seminar

Scheduled Maintenance
Dubai-29th May 2013
Presented by
Christian DELMAS Director Maintenance Programmes Engineering Airbus Customer Services

Introduction

Maintenance Schedule
Development

In Service Experience
Feedback
Data Collection and
analysis

Maintenance Program
Customization

Maintenance Program
Revision

Initial Maintenance
Program Development

Page 2

Who are we?

Customer Services

S
Engineering &
Maintenance
SE
Engineering &
Maintenance Projects

Engineering Support
SEE

Upgrade Services
SEU

Maintenance
Programs &
Services

A/C Embodiment

Technical Data

Operations
SEO

SED

SEM
SEM
Advanced Airline Operations

SEMS

SEME

SEMB

Maintenance
ProgrammesSupport

Maintenance
Programmes
Engineering

Service

Luc COUSIN
Page 3

Christian DELMAS

Bulletins

Maintenance Program Development

Maintenance Schedule
Development

In Service Experience
Feedback
Data Collection and
analysis

Maintenance Program
Customization

Maintenance Program
Revision

Initial Maintenance
Program Development

Page 4

Maintenance Program Development

Regulation Frame Work
Airworthiness standards are not only set for the design of the
aircraft but also for operation and maintenance while in service.

&

&

Regulation(s) :
CS/FAR 25.1529 Instructions for continued airworthiness
Instructions for Continued Airworthiness in accordance with
Appendix H must be prepared.

Economics :
Airline operation needs maintenance instructions to keep level of
safety, reliability and availability at minimum cost.
Page 5

Maintenance Program Development

Scheduled Maintenance Requirements
A group of scheduled tasks to be accomplished at
specified intervals. The objective of these tasks is to
prevent deterioration of the inherent safety and reliability
levels of the aircraft.

Page 6

Maintenance Program Development

Regulations

Structure

Systems

Fuel

EASA/FAR 25-571

EASA/FAR 25-1309 (mainly)

EASA/FAR 25-981

Fatigue Analysis

Safe Life

Safe Life
Airworthiness
Limitation
Items

Page 7

System
Safety Assessment
(pre DSG)
+
Fail safe - Damage
MSG3 Analysis
Tolerance Analysis

Damage Tolerant
Airworthiness
Limitation Items
(ALI)

Certification
Maintenance
Requirements
(CMR)

System
Safety Analysis
(Post DSG)
+
MSG3 Analysis

Fuel Tank
Safety Analysis

System Life Limits

Aging System
Maintenance
(ASM)

Fuel
Airworthiness
Limitations
(FAL)

Maintenance Program Development

Data / Software
JAR 25-1301

Maintenance
FAA AC121-22
EASA MRB Work Instructions / IO11
Maintenance Review Board Team

Maintenance Analysis
(MSG3)

Aircraft Information
System Security
(AISS)
- A380 -

Page 8

Maintenance Review
Board Report

Maintenance Program Development

The MRBR Process
The European Aviation Safety Agency (EASA)
Federal Aviation Administration (FAA)
Transport Canada (TCCA )
regulations
require the A/C Type Certificate holder
to prepare, revise as necessary and submit for approval to the
relevant Airworthiness Authorities
the Initial Minimum Scheduled Maintenance

Requirements
that are applicable to a dedicated Aircraft family.
Page 9

Maintenance Program Development

The MRBR Process
Regulations
mandate establishment of maintenance tasks / requirements
Advisory Materials
propose MRB process / Organization as Means of Compliance

EASA
EC Regul 2042/2003 Annex I = Part M
MRB Work instructions
Ref: IO11 Maintenance Review Board Team
Page 10

FAA
Part 121

AC 121-22

Maintenance Program Development

The Initial scheduled maintenance requirements establishment
requires a collaborative work, in order to combine knowledge
and experience, between :
Customer airlines
Aircraft manufacturer
Regulatory advisors
The final aim is to compile a
Maintenance Review Board (MRB) Report proposal
that is acceptable to the Maintenance Review Board (MRB).
Once approved by the MRB, this proposal becomes the
MRB Report
Page 11

Maintenance Program Development

The MRBR Process
MWG 1

MWG 2

MWG 3
MPP

MRB

ISC
Policies
Procedures
Evolutions for new MRBR rev

MWG 4

MWG 5

MWG 6

ISC: Industry Steering Committee

MWG: Maintenance Working Group
MPP: Maintenance Program Proposal
MRB: Maintenance Review Board

The ISC - owns the MRBR process (policies, targets)

- validates the content of the MRBR and submits to MRB
Page 12

Maintenance Program Development

MRB Process
Type Certificate

1st MSN EIS

M12

M13

1st MSN operational

A/C Production
Last MSN EIS
Last MSN operational life

A/C Devlpt

(5, 6 years)

A/C IN SERVICE > 50 years

MAINTENANCE

Safety + availability & reliability at minimum cost

Page 13

Maintenance Program Development

The Method: MSG-3 Maintenance Steering Group - 3
Written by the Maintenance Steering Group - 3 Task Force
organized under the leadership of the A4A (former ATA).

The MPIG: Maintenance Program Industry Group

4 Major sections
Systems / Powerplant, including components
and APUs
Aircraft structure
Zonal inspections
Lightning / High Intensity Radiated Field
(L / HIRF)
Page 14

Maintenance Program Development

The Method: MSG-3
Airline and manufacturer experience in developing
scheduled maintenance for new aircraft has shown that
more efficient programs can be developed through the use
of logical decision process
MSG-3 is a method to develop maintenance tasks
Objective of the MSG-3 Document
To present a means for developing the scheduled
maintenance tasks and intervals which will be
acceptable to the regulatory authorities, the operators,
and the manufacturers.
Page 15

Maintenance Program Development

The Tool: MSG3
Development of the MSG Methodology

Maintenance
Evaluation and
Program
Development

Airline / Manufacturer
Maintenance Program
Planning Document

MSG-2

MSG-1

Prepared by:
747 Maintenance
Steering Group
Date: July 10, 1968
Aug. 1, 1968
June 1, 1969

Boeing 747

Page 16

Prepared by:
R&M Subcommittee
Air Transport Association
Date: March 25, 1970

Douglas DC-10
Lockheed L-1011

European
Maintenance System
Guide

Airline / Manufacturer
Maintenance Program
Development Document

MSG-3
EMSG
Prepared by:
Association of European
Airlines
Date: July 1972
August 1972
Sept. 1972
February 1973

Prepared by:
MSG-3 Task Force
Air Transport Association
Date: September 30, 1980
March 31, 1988 - Rev.1
Sept. 12, 1993 - Rev.2

A310/A300-600
Airbus A300B2/B4 A318/A319/320/A321
AS/BAe Concorde
A330/A340
VFW 614
B757/767/777

Maintenance Program Development

The Tool: MSG3 - evolutions
ATA MSG-3
Operator/Manufac
turer

ATA MSG-3
Operator/Manufac
turer

Scheduled
Maintenance
Development

Operator/Manufac
turer

Scheduled
Maintenance
Development

Revision
2005.1

Operator/Manufac
turer

Scheduled
Maintenance
Development

Revision
2003.1

Operator/Manufac
turer

Scheduled
Maintenance
Development

Revision
2002.1

Scheduled
Maintenance
Development

Revision
2001.1

ATA MSG-3
ATA MSG-3
ATA MSG-3

Revision 2
(1993)

A380

A400M

ATA MSG-3
Operator/Manufac
turer

A350

Scheduled
Maintenance
Development

XWB

Revision
2007.1
Page 17

Maintenance Program Development

The Tool: MSG3 Policy & Procedures Handbook (PPH)

Relationship of MSG-3 Document and PPH

A350
ATA MSG-3
Operator/Manufacturer
Scheduled
Maintenance
Development

Scheduled
Maintenance
Policy and
Procedures
Handbook

Revision 2007.1

The ATA MSG-3 document no procedures/details necessary for

analysis. Additional guidance on details of analysis procedures
required
Interpretation of rules, interval selection, etc.
Form sheets
Detailed work steps, responsibilities and scheduling

Page 18

Maintenance Program Development

The Tool: MSG3 Policy & Procedures Handbook (PPH)
SCHEDULED MAINTENANCE DEVELOPMENT

Table of contents
Section 1 - Introduction
Section 2 - Organization and administration
Section 3 - Analysis procedure - General
Section 4 - Systems and Powerplant analysis procedure

A3 8 0
POL ICY AND PROCEDURES
H ANDB OOK
For further information about this handbook, please contact:
AIRBUS S.A.S.
Customer Services Directorate
B.P. No. 33, 31707 Blagnac

Cedex, FRANCE

Maintenance Engineering Department

Section 5 - Structure analysis procedure

Section 6 - Zonal and L/HIRF analysis procedure
Section 7 - Type certification interface

REFERENCE: 95A.1689/02
ORIGINAL ISSUE: December 2002

Appendix A : reference documentation

Cover page
Acceptance letter
Record of revisions
History of changes
Table of contents
Page 19

Appendix B : A380 MSG3 Analysis form sheets

Appendix C : Corrosion Rating Tables
Appendix D : Glossary, acronyms and abbreviations
Appendix E : Meeting schedule
Appendix F : Organization
Appendix G : Required data for MWG Report to ISC

Maintenance Program Development

Applicability (e.g A380)

A380-840

9A380-800
A380-860

Aircraft Utilisation Assumptions (e.g A380)

92000 to 6000 FH per year
9360 to 1100 FC per year

These figures are used as a

reference but not as a limit
of validity

FC/year
1200
1000
800
600

Medium / Long Haul routes

A380 PPH
Aircraft utilisation

Routine use of A380 on

short haul routes (higher FC
per year) not covered

assumptions

400
200
1000 2000 4000 3000 5000 7000 6000 8000 9000
Page 20

FH/year

Maintenance Program Development

Interval Frame (example A380)
9Usage parameters versus letter intervals
Flexible concept planning can be optimised according to actual
aircraft operation
Task interval not influenced by planning concerns

9A380 Design Objective

no scheduled maintenance requirement
below 750FH at EIS
Structure Inspections
Initial Inspection /
Environmental

Threshold
12 years

design compatible with no

scheduled maintenance
requirement below 1000FH

Repetitive
Interval
6 years

Deterioration
Fatigue Damage

Page 21

7600 FC
56000FH

3800 FC
28000 FH

Exception may
be granted for
corrosion
sensitive areas

Maintenance Program Development

Before launching the MRB process with the customers, the
TC Holder can call for MRB kick off meetings to:
Present the project
Present the major content of the PPH
Identify any show stopper
Set up an acceptable PPH quality level before presentation to the
customers

The PPH must be approved by the ISC and accepted by the

MRBs before starting the technical activities

Page 22

Maintenance Program Development

The MRBR Process: implementation
The Type Certification Holder calls for the 1st ISC meeting:
Presentation of the project
Major descriptions of Aircraft design & novelties
Validation of the MWGs

Introduction of the manufacturer team

ISC Co Chair assistant
MWG Chairs

Presentation of the MRB team

Presentation the major contents of the PPH
Election of the ISC Chair
Presentation of the macro planning up to 1st MRBR submission
for approval
Page 23

Maintenance Program Development

The MRBR Process: implementation
Before the start of the MWG activities, all the participants must
be trained on
General aircraft features
The MRB Process, the PPH and MSG3 method

The objective is also

Ensure efficient discussions during MWG and ISC meetings
Ensure common understanding of the process and the
objectives by operators, authorities, suppliers

Page 24

Maintenance Program Development

Once the training is completed, the PPH may need to be revised
according to feedback from the Q&A sessions and validated by
the ISC
The detailed MWG activities can start

A350 Planning - 2009

week

44

Training sessions

Page 25

45

46

47

48

49

50

51

52

53

Maintenance Program Development

Based on ISC instructions / PPH and aircraft design maturity the
detailed technical MWG activities can start in the different
MWGs
MWG 1: Hydraulics & Flight Controls
MWG 2 : Environmental
MWG 3 : Power Plant APU
MWG 4 : Avionics
MWG 5 : Structures
MWG 6 : Zonal
MWG 7: Fuel
MWG 8: Landing Gears
MWG 9: Interior

Page 26

Maintenance Program Development

The PPH and the
MSG3 analyses

Systems &
Powerplant

Maintenance
analysis processes

Zonal &
L/HIRF

Structure

The three processes are both complementary and concurrent

Page 27

Maintenance Program Development

The

MWGs / ISC first proceed in selecting the MSIs and

SSIs and Zones on which the detailed analyses will later be

performed. This approach remains very conservative

Page 28

Maintenance Program Development

System / Powerplant MSG3 analyses

Page 29

Maintenance Program Development

System / Powerplant MSG3 analyses
Data Sheet B

Function 1

Functional
Failure A

Function 3

Function 2

Functional
Failure B

Functional
Failure C

Failure
Effect

Failure
Cause 1
Page 30

Failure
Cause 2

Failure
Cause 3

Functional
Failure D

Maintenance Program Development

System / Powerplant MSG3 analyses
Data Sheet B

Function

Page 31

Functional Failure

Failure Effect

Failure Cause

Maintenance Program Development

System / Powerplant MSG3 analyses
Level 1 Analysis

1) failure evident or hidden ?

Yes

No

2) Safety effect ?
Yes

3) add second
failure -->
safety effect ?

No

4) operational or
economic effect ?

Yes
Safety effects

Non-safety effects

Yes

No

Safety effects Operational effects

Economic effects

5
Page 32

No

5, 6, 7, 8 & 9 = FEC
Failure Effect Category

Maintenance Program Development

System / Powerplant MSG3 analyses
Level 2 Analysis
LUBRICATION or SERVICING TASK ?
Task Selection Question 8A

YES
NO

LUBRICATION/SERVICING

FAILURE FINDING CHECK ?

Task Selection Question 8B

YES

OPERATIONAL/VISUAL CHECK

NO

CHECK FOR DEGRADATION ?

Task Selection Question 8C

YES

INSPECTION/FUNCTIONAL CHECK

NO

RESTORATION ?
Task Selection Question 8D
YES
NO

RESTORATION

TASK or TASK COMBINATION ?

DISCARD ?

Task Selection Question 8F

Task Selection Question 8E

YES

DISCARD

NO

TASK/COMBINATION MOST
EFFECTIVE MUST BE DONE

YES
NO
REDESIGN IS MANDATORY

Page 33

Maintenance Program Development

System / Powerplant MSG3 analyses
Level 2 Analysis
Initial Task Interval Selection
Letter interval (e.g. A or C):
former concept (A # FH, C # calendar)
Planning considerations in interval selection
Misleading and conservative

Interval Figure:
Shall answer the question:
How long can I stand with the
failure unfixed or before
detecting degradation?

Answer based on

Usage Parameter:
Unit=f(function degradation or failure mode)

tests and technical analysis,

Vendor Recommendations
Customer or other similar in
service experience

Several parameters possible:

Engineering Judgment.

Technically correct

FH, FC, Calendar

Page 34

Maintenance Program Development

System / Powerplant MSG3 analyses
MSI Analysis Documentation
Administrative Pages
Data Sheet A
Data Sheet B
Level 1 and 2 Analyses

Page 35

for each Functional Failure

Task Summary Sheet
MRBR Interface Sheet
Task Data

Maintenance Program Development

Structure MSG3 analyses

Page 36

Maintenance Program Development

Structure MSG3 analyses

Definitions

AIRCRAFT STRUCTURE
All load carrying structures
wings, fuselage, empennage, engine
mountings, landing gear, flight control
surfaces, and related points of
attachment.
The actuating portions of items such as
landing gear, flight controls, doors, etc. will be
treated as systems components and will be
analysed following the Systems/ Power Plant
Analysis Procedure.
Attachment of the actuators to the airframe will be treated as structure.
Page 37

Maintenance Program Development

Structure MSG3 analyses

Definitions

Primary Structure Element (PSE)

element that contributes significantly to

carrying of flight, ground, or
pressurisation loads, and whose integrity
is essential in maintaining the overall
structural integrity of the airplane.
Structural Significant Item (SSI)

any structural detail, element or

assembly whose failure could affect the
structural integrity necessary for the
safety of the aircraft.
Other Structure

judged not to be a Structural Significant

Item.
Page 38

Maintenance Program Development

Structure MSG3 analyses

Definitions

Non-metallic structure
graphite epoxy (CFRP), boron epoxy, fibreglass (GFRP), aramide
fiber (AFRP such as kevlar epoxy), acrylics,

GLARE
hybrid material
Al Alloy 2024T3 + glass fibre/adhesive
For MSG-3 analysis purposes, it will be treated as Metal.
Page 39

Maintenance Program Development

Structure MSG3 analyses

Definitions

Accidental Damage
caused by contact or impact with an object or influence which is
not part of the aircraft, or by human error during maintenance
practices

Page 40