28 August 2015 Aircraft Maintenance Module1 Aircraft Maintenance Management Module MRO- Base...

April 21, 2023 Aircraft Maintenance Module 1

Aircraft Maintenance Management Module

MRO- Base Maintenance Activity and Safety

Management

Base Maintenance features

Base Maintenance is responsible for conducting aircraft major scheduled maintenance inspections, incorporation of service bulletins and modifications, aircraft reconfigurations and major structural modifications.

All bays are air conditioned and access is via four electrically driven main doors for each bay, with a vertical door for the tail access into each bay.

All the aircraft main servicing areas within the hangar bays are protected by an automatic fire detection and suppression system. This system consists of automatic

foam dispensing cannons and a roof deluge system. Hand operated foam lines are also fitted.


Component lifting capability is via three roof cranes (2 ton, 5 ton and 15 ton), all of which can traverse the full width of the bays.

Automated maintenance docking systems equipped with services to provide air conditioning, power, and air are available in bays A and B, bay C and D will contain a larger dock capable to accommodate A380 aircraft.

To the rear of all bays are hanger management and planning offices, tool stores and toilet facilities. Above this area is a mezzanine floor with open areas to each side of

the aircraft nose used to store removed aircraft seats during major servicing. Engineer and Mechanic crew locker rooms are also on this floor.


Each hangar has its own secure tool store area. This area is used for storage of tools and equipment and

contains shelves and racking for these items. A First aid center and restaurant is provided for the use of

all staff within the main complex. On both the ground and first floor, to the rear of all servicing bays, runs a 16 meter service corridor which provides access to all hanger bays on one side and to workshops and stores on the other.


Base Maintenance (Responsibilities)

Base Heavy Maintenance is responsible to ensure that scheduled heavy maintenance be conducted in an efficient, safe and to the highest possible standards.

The responsibility mainly includes performing 'C' and 'D' checks, major modifications, configuration changes, IFE upgrades and major equipment/system installations. The responsibility will be to carry out such activities on the company current and future fleet types.

Hangars A, B and C are under the responsibility of one Manager, whilst hangars D and E are under the responsibility of the second Manager.


Base Maintenance Safety procedures for new staff It is required that a new staff member is introduced in the

working environment in the airport and make him aware of the system and procedures in place to safeguard his own Safety and the safe use of all the relevant equipment he will be dealing with.

The new staff member should review as part of his introduction into the airport/ramp working environment. The staff should undergo the company induction course.

After the formal introduction with his designated supervisor, the designated supervisor should carryout a safety awareness familiarization to the working environment that the new staff member will be carrying out his duties.April 21, 2023 Aircraft Maintenance Module 6

Base Maintenance Safety procedures for new staff cont’d The designated supervisor should take the staff into a tour

of the main base facilities and familiarize him with the safety equipment available and review with him all the relevant procedures.

The designated supervisor should take the staff to stores and assist him with the issue of his own personal safety protection equipment and review with him their use and when they should be used.

The designated supervisor should introduce the staff to the designated first aid certified staff and explain their function.


Base Maintenance Safety procedures for new staff cont’d The designated supervisor should carry out a tour of the

hangers including all the shops, restrooms, lockers, production planning area and point out all the relevant system in place and their use.

The designated supervisor should carry out a walk around of each aircraft type, with the new member of the staff, highlighting all the potential hazardous areas. This should include but not be limited to main entry doors, flight control surfaces and landing gear doors.

The designated supervisor should brief him about the hanger fire detection system and their activation and deactivation procedures, when, where and how to carry out the activation/deactivation procedures .


Base Maintenance Safety procedures for new staff cont’d The designated supervisor should introduce him to the

Learning Resource Centre, its advantage and a brief summary of the courses he can study.

The ATS coordinator should arrange all the relevant documentation for obtaining and Airport driving permit ADP. After the granting of the permit he should review and explaining detail the procedure for use of the vehicle and access equipment at his disposal.

The designated supervisor should arrange a course for him in the PPC system. The designated supervisor should then sign-off a checklist which covers his introduction to Base Maintenance and filed in the individual staff file.


Base Maintenance Safety procedures for new staff cont’d After completion of all of the above training the new staff

member should be assigned with his designated supervisor for a period of a month, for review his compliance with all the relevant procedures. A report should be made by the designated supervisor to the Base Maintenance Shift Manager for competency and compliance to the procedures in place or for any corrective action required.

After receiving the above mentioned safety awareness familiarization and a satisfactory report from his designated supervisor the new staff member should be allocated to work independently and undertake tasks with no supervision.


General Base Maintenance workspace rules Report unsafe conditions to your immediate supervisor. Promptly report all accidents/injuries/incidents to your

immediate supervisor. Raise ESR where applicable. Use eye and face protection where there is danger from

flying objects or Particles, (such as when grinding, chipping, burning and welding, etc.) or from Hazardous chemical splashes.

Dress properly. Wear appropriate work clothes, gloves, and shoes or boots.

Loose clothing and jewelry shall not be worn.


General Base Maintenance workspace rules cont’d Operate machines or other equipment only when all safety

devices are in place and in proper operating conditions. Keep all equipment in safe working condition. Never use

defective tools or equipment. Report any defective tools or equipment to immediate

supervisor Properly care for and be responsible for all Personal

Protective Equipment (PPE). Wear or use any such PPE when required Lockout / tag out or disconnect power on any equipment or

machines before any maintenance, unjamming, and adjustments are made.


General Base Maintenance workspace rules cont’d Do not leave materials in aisles walkways, stairways, work

areas, or other points of egress Training on equipment is required prior to unsupervised

operation. Compliance with all established rules/regulations and

procedures is required.


Maintenance Safety

When no medical facility is reasonably accessible (time and distance) to the workplace, a person who has a valid certificate of first aid training to render first aid and first aid supplies will be available at the workplace

Employees exposed to noise levels above permissible noise level must use hearing protection as required.

Employees exposed to harmful gases, fumes, dust, and similar airborne hazards will be furnished protection through proper ventilation or personal respiratory equipment.


Maintenance Safety, cont’d PPE must be worn as required for each job in all

operations where there is an exposure to hazardous conditions.

Safety glasses, goggles, or face shields will be worn in those areas where there is a reasonable probability of injury to the eye from flying particles molten metal, chemicals/acids, or light radiation, or other eye hazards

Appropriate hand protection is required when hands are exposed to severe cuts/abrasions, chemical/thermal burns, or chemical absorption.

Appropriate aprons and goggles will be used when necessary for protection against acids and other chemicals which could injure employees.April 21, 2023 Aircraft Maintenance Module 15

Maintenance Safety, cont’d

Respiratory equipment in many cases is needed for protection against toxic and hazardous fumes/dusts. Only approved equipment will be used.

The use of safety harnesses, and lanyards are required when working more than ten feet above a floor or ground level and there are no guardrails or other form of fall protection. Each employee will be on a separate safety line, and this line will be adjusted so that the employee cannot fall more than six feet.

Clear, clean and accessible space will be kept around electrical equipment and distribution boxes. This includes: drill press, floor shear, pan brake, and all tables and cabinets in use.April 21, 2023 Aircraft Maintenance Module 16

Personnel Safety

Before any work or maintenance is performed on any machine, equipment, tool, or electrical system, they will be made totally safe before work starts by removing any source of energy or power to them, such as electrical, air/hydraulic pressure, spring/stored energy, or thermal (heat/cold).

The Lockout/Tag out Requirement provides for a safe method of working on, near, or in machinery or equipment that can cause serious injury. This program will be used by all employees to ensure that the machine or equipment is stopped, isolated from all potentially hazardous energy sources,


Personnel Safety cont’d

and locked out before employees perform any servicing or maintenance where the unexpected energizing or start-up of the machine or equipment, or release of stored energy, could cause injury.

Live electrical parts shall be guarded against accidental contact by cabinets, enclosures, location, or guarding. Open circuit breaker openings or knock out holes in fuse panels, broken receptacles/switches, missing covering plates, etc. will be reported to supervisors for repair or replacement.


Electrical Safety Circuit breakers, switch boxes, etc. will be legibly marked

to indicate its purpose. All extension cords and electric powered tools (except double insulated) will be grounded. Ground prongs will not be removed. Electric wiring/cords entering/exiting any panel/control/junction box will be secured with clamps or appropriate strain relief device.

Extension cords and other flexible cords will not be used in lieu of permanent wiring and receptacles. Cords will not be run through holes in or around doors, walls, windows, nor will they be fastened to walls, poles, equipment, etc.

All auxiliary lighting equip used on and around A/C, hangars must be of approved type


Compressed Gas Cylinders Safety

All gas cylinders shall have their contents clearly marked on the outside of each cylinder.

Cylinders must be transported, stored, and secured in an upright position, unless approved by the Eng. Facilities. They will never be left laying on the ground or floor, nor used as rollers or supports.

Cylinder valves must be protected with caps and valves closed to regulators when not in use.

Oxygen cylinders and fittings will be kept away from oil or grease. Oxygen cylinders will be stored at least 20 feet from any fuel gas cylinder, or separated by a fire barrier at least five feet high.


Ladders safety

When cylinders are hoisted, they will be secured in a cradle, sling-board, or pallet. Valve protection caps will not be used for lifting cylinders from one vertical level to another.

Ladders will be inspected prior to each use to identify any unsafe conditions. Those ladders, which have developed defects, will be removed from service, and repaired or replaced. They will be tagged or marked as such.

Portable ladders will be placed as to prevent slipping, or if used on other than stable, level, and dry surfaces, will be tied off or held.


A simple rule for setting up a ladder at the proper angle is to place the base from the vertical wall equal to one fourth of the working length of the ladder.

The top of a step ladder will not be used as a step. Only one person will be on a ladder at a time.


Flammables Safey Only approved safety cans, original containers, or portable tanks

will be used to store flammable liquids. All Flammable or Combustible Liquids will be stored in the

approved storage area in Hangars. No more than 5 gal. of any Flammable or Combustible Liquid may be portably transported at any time. Exceptions: De-fueling cart, 35gal. or approved 55gal. drums.

Above ground storage tanks will be separated from each other by a minimum of three feet or 1/6 the sum of their diameters. Dikes or drainage to prevent accidental discharge from reaching adjoining property or waterways will be provided.

At no time will any size quantity portable container be left unattended away from its designated storage area.


Hoist Operations Safety

Hoists to be inspected prior to each use/during use to make sure it is in safe operation condition.

A monthly inspection of hooks, and hoist chains will be made and a certification record to include date, inspector signature, and hook identifier (its purposeful use) will be maintained with supervisor’s safety inspection criteria

Job or shop hooks or other makeshift fasteners using bolts, wire, etc. will not be used

No item will be hoisted without knowing the load rating capability of the hoist and/or any attaching devices (i.e. chains, ropes, hooks etc.).


Welding Safety Combustible material will be cleared for a radius of 35 feet

from the area around cutting or welding operations. If the combustible material cannot be cleared or the work cannot be moved, then the welding/cutting will not be done.

Welding helmets and goggles will be worn for eye protection and to prevent flash burns.

Eye protection will be worn to guard against slag while chipping, grinding and dressing of welds.

Welding screens will be used and in proper position to protect nearby workers from welding rays.

Cables, leads, hoses, and connections will be placed so that there are no fire or tripping hazards. Cables will not be wrapped around the welder’s body.April 21, 2023 Aircraft Maintenance Module 25

Tools Safety Hand tools with broken/cracked handles, mushroomed

heads, or other defects will not be used. Files will have handles installed.

Take special precautions when using power tools. Defective tools will be removed from service.

Power tools will be turned off and motion stopped before setting tool down

Tools will be disconnected from power source before changing drill bits, blades or attempting to repair or adjust. Never leave a running tool. Never lay down an air tool on a toolbox or table while attached to the air source. If the tool is to remain attached to an air source during intermittent use, use the provided tool storage hooks.April 21, 2023 Aircraft Maintenance Module 26

Portable abrasive side-winder grinders will have guards installed covering the upper and back portions of the abrasive wheel. Wheel speed ratings will never be less than the grinder RPM speed.

Air compressor receivers will be drained frequently to prevent buildup of water in the tank.

Compressed air will not be used for cleaning purposes except when pressure is reduced to less than 30PSI by regulating or use of a safety nozzle, and then only with effective chip guarding and proper PPE. Any employee-furnished tools of any nature must meet all Safety requirements.


Fall Safety protection

All open sided floors and platforms four feet or more above adjacent floor/ground levels will be guarded by a standard railing (top and mid rail, toe board (if required).

All stairways of four or more risers will be guarded by a handrail, or stair rails on the open side. Handrails or stair rails will be provided on both sides if the stairs are more than 44 inches wide.

When a hole or floor opening is created during a work activity, a cover or a barricade must be installed immediately.


Scaffolding Safety

Scaffold platforms more than ten feet above the ground, floor, or lower level will have standard guardrails (consisting of a top rail, mid rail, and a toe board) installed on all open sides and ends of platforms.

Mobile scaffolds will be erected no more than a maximum height of four times their minimum base dimension.

Scaffolds will not be overloaded beyond their design loadings.


Personnel Safety

Only personnel trained and approved in the operation& safety procedures of the Mechanical Scissor Lift are eligible to operate these Units

Use of Mobile phones in areas classified as hazardous is prohibited.

Prescribed safety recommendations are to be followed at all times when handling Hazardous materials , Waste, Components contaminated with waste, Particulate Filters (e.g Cabin Re-circ filter) and any component suspected of viral or bacterial contamination.


28 August 2015 Aircraft Maintenance Module1 Aircraft Maintenance Management Module MRO- Base...

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