Maintenance Schedule Development - COSCAP-GS · PDF fileMaintenance Schedule Development...
Transcript of Maintenance Schedule Development - COSCAP-GS · PDF fileMaintenance Schedule Development...
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MSG3Analyses
MRBReport
MPD
ALS Part 4
ASMDocument
ALS Part 2
DT-ALIDocument
ALS Part 3
CMRDocument
System Safety
Analysis(SSA)
ALS Part 5
FALDocument
Damage TolerantAnalysis
+Full Scale Fatigue
Test results
EASA Certification Approved
Maintenance Schedule Development
OMP
Approved by local AA
Airlinetasks
National Requirements
Manufacturer Operator
A/C configuration
Customization
Planning Mtce Checks
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MaintenanceProgram
Operational parameters (FH/YE, FH/FC)
Maintenance concept :• block (basic)
• semi equalized• fully equalized
Check intervals
Maintenance Program
Customization
MPDVendor requirements
National requirements Specific A/L requirements
Scheduled maintenance engineering process
MPD: Maintenance Planning Document
MIS: Maintenance Information System Work-package, Task / Job Cards
Production
Do
Maintenance
Do Maintenance
Part 145 organisation
Maintenance Schedule developmentSchedule maintenance process
PrepareMaintenance
Part M organisation
Packaging
definition
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Maintenance Concept Definition
Work Packages
Aircraft utilization
- Seasonality/Charter- Low Aircraft Utilization- Long or Short Haul- Scheduled- Freighter
Fleet Age
- Structural Items Threshold- Additional ageing program- Fatigue Structural findings
Aircraft Ground Time -Airlines Policies
- Return to main base - Night stop- Outstation capability
Manpower Skills and availability- Task Man-hour - Access Man-hour - Preparation Man-hour
Fleet Size- Facilities- Manpower- Materials- Maintenance Planning
Maintenance Schedule Development
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« Block concept »Tasks grouped by interval families and performed close to their deadline.
Maintenance workload and ground time per event could vary significantly
Several concepts could be possible :
« Equalized concept »Tasks grouped in order to fit with predefined maintenance ground times.
Event manpower load and maintenance ground time are balanced
« On Demand concept »Tasks not grouped in order to optimize predefined maintenance interval. Next due
managed task by task.
Event manpower load and maintenance ground time are flexible according to the Work Package selected
Maintenance Schedule DevelopmentMaintenance Programme Packaging Concepts
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1A Package2A Package4A Package
1C Package2C Package4C Package
Number of M/H
Maintenance
Events
Block concept principles:Block checks clearly identified at fixed intervals + 100% interval useThe workload of each block check varies – maintenance is done during the block checks as it becomes due
Maintenance Schedule Development“Block” Concept
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0
100
200
300
400
500
600
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
2A 50%
4A 25%
“A and OOP tasks equalized on A events, C and Structure tasks stay as Block”
Maintenance Schedule Development“Semi-Equalized” Concept (A & Multiples Equalized)
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“A and OOP tasks equalized on A events, C and Structure tasks stay as Block”
Maintenance Schedule Development“Semi-Equalized” Concept (A & Multiples Equalized)
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0
100
200
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600
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
2C 50%
“A and OOP tasks equalized on A events, C tasks equalized on C events and Structure tasks stay as Block”
Maintenance Schedule Development“Semi-Equalized” Concept (A, C & Multiples Equalized)
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“A and OOP tasks equalized on A events, C tasks equalized on C events and Structure tasks stay as Block”
Maintenance Schedule Development“Semi-Equalized” Concept (A, C & Multiples Equalized)
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0
100
200
300
400
500
600
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1C 12.5%
2C 6.25% +
“A, OOP and C tasks equalized on a A events except Structure tasks (stay as Block)”
Maintenance Schedule Development“Fully-Equalized” Concept (A, C & Multiples Equalized)
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“A, OOP and C tasks equalized on a A events except Structure tasks (stay as Block)”
Maintenance Schedule Development“Fully-Equalized” Concept (A, C & Multiples Equalized)
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“On Demand” concept principlesTasks managed on a case by case basis in order to optimise the maintenance program according to various operator parameters .
0
100
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Maintenance Schedule Development“On Demand” Concept
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Pros
Less investments as fewer maintenance stations (spares / tools / consumables / Accessing / Docking / Tooling)
Maintenance task interval utilization optimized
Lower risk for additional ground times (AD, Mods, Repairs, …)
More time for defects rectifications
Cons
Unbalanced manpower load over the checks
Premature planning of Out of Phase and Time Controlled Items
Maintenance Schedule Development“Block” Concept – Pros & Cons
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Pros
Better Aircraft availability & better operational flexibility
Even Maintenance Ground Time
Even Manpower load
Better interval utilization for Out of Phase and Time Controlled Items
Cons
More investments as more maintenance Stations (spares / tools / consumables / Accessing / Docking / Tooling)
Repetitive access opening/closing
Increase of non-routine items on ageing aircraft affect expected maintenance ground time
More stringent monitoring and correction of arising defects
Maintenance Schedule Development“Equalized” Concept – Pros & Cons
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Pros
Better operational flexibility due to less down time
Better A/C availability
Optimized to fit operator needs
Better interval utilization for Out of Phase and Time Controlled Items
Takes real benefits of Interval Evolutions (coming from MPD or from Airline)
Cons
High Planning complexity
Accurate A/C utilization & routes known in advance
MIS availability mandatory
Large line maintenance capacities
More investments as more maintenance Stations (spares / tools / consumables / Accessing / Docking / Tooling)
Maintenance Schedule Development“On Demand” Concept – Pros & Cons
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1932 FH/YE – 2.5 FH/FCA320 LOW UTILIZATION:
A320 HIGH UTILIZATION: 4500 FH/YE - 2 FH/FC
Maintenance Schedule DevelopmentPlanning Example 1 : Effect of A/C utilization
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7500FH Maintenance
Check45%drop outs 22%drop outs
6000FH Maintenance
CheckOR
30Mo Maintenance Check
54%drop outs
2%drop outs
24Mo Maintenance Check
Maintenance Schedule DevelopmentCommunication on Maintenance Checks: Special Attention !
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Maintenance Programs Approved by local Airworthiness Authorities
Contains customized approved and non-approved maintenance requirement sources
Contains as well Customer specific tasks, Vendor requirements and local Airworthiness requirements
Maintenance ScheduleBased on Operator Maintenance concept
Flexible to cope with Operator policy and operational constraints
Maintenance Schedule DevelopmentConclusions
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Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
In Service Experience Feedback
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In Service experience collection and analysis is required in the frame of “Continued Airworthiness” (EASA Part M AMC 302 & FAA AC N°120-17A)
In Service Experience Feedback
Safety First
At operator’s level
Keep OMP up to date according to fleet in service experience feedback
Optimize maintenance costs and aircraft availability
At Manufacturer’s level
Keep ICAs up to date according to fleet in service experience feedback
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Reliability Control program :
Is used to monitor the effectiveness of the Maintenance Program
Is an essential Quality System process
Contribute to the optimization of maintenance costs (scheduled / unscheduled)
Reliability program is imposed by the Regulatory Authorities, which require an Operator to establish a program for continuing analysis & surveillance of its operations.
In Service Experience Feedback
Reliability Control Program
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In Service Experience Feedback
Reliability Control Program
•Fulfill the authorities requirementsReliability reports
•Contribute to the Maintenance & Engineering missionInvestigate deficiencies affecting aircraft operationsDefine & implement required improvementsEnsure continuous airworthiness through the monitoring of the effectiveness of the maintenance program
•Minimize operating costsSchedule disruptionsScheduled Maintenance task interval adjustmentSound evaluations for implementation of modifications
•Provide the Airline Management with a performance measurement tool
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In Service Experience Feedback
Performance Measurement & Reporting
$
Analysis
Corrective Actions &
Decision Making
Actions&
Follow-Up
Data Collection
Supplier Manufacturer
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In Service Experience Feedback
Data Collection
Data collected from different sources:
•Aircraft log book & On-Board Maintenance System
•Operational interruptions
•Technical incidents
•MaintenanceMaintenance complaintsRemoval dataDeferred defectsCheck findings
Workshops Shop findings
Efficient data collection means •reduced workload•Better quality of information•Information easier to use (standards, coded data)
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In Service Experience Feedback
•Collected data usually computed into rates to help assessment
•Performance measurement compared to:
• trends
•Targets
•alerts levels
Performance Measurement & Reporting
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$
Analysis
In Service Experience Feedback
•Analysis triggered when:
•Alert level is reached
•Trend is not as expected
•Objectives are not met
•Objective:
•identify & confirm root causes of the issue
•Propose recovery actions
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In Service Experience Feedback
Corrective Actions &
Decision Making
Proposed corrective actions: technical, process or organization
•Technical•Modifications•Maintenance program changes
•Processes•Maintenance practices•Training
•Organizational•Provisioning review•Equipment and tools management
Quality assurance / control
Engineering / technical services
Maintenance (line, hangar, shop) Material
Planning
Fleet Management
•Proposals documented in detailed reports used forReliability Control Board meetings
Actions&
Follow-Up
•Follow up to• Validate solutions or re adjust as soon as possible•Learn from experience
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In Service Experience Feedback
The MRB Report represents the initial maintenance program
Maintenance Checks
Initial MRBR intervals are often conservative
Operator can adjust tasks and intervals according to their own experience
Analysis of maintenance check results is associated to the Reliability Control Program
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Data shared in real time
MRBR
Updates
Unique Airbus Data collection Template
(with CPCP)
« XML Format, No volume limitations »
Customized studies -
Benchmarking
Data Collection on an “On-Going” Basis
DatabaseAirlines
In Service Experience Feedback
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In Service Experience Feedback
Maintenance Checks – Data Collection
MPD task reference
Nber of Months
(ONLY NUMBER)
Nber of FH(ONLY
NUMBER)
Nber of FC(ONLY
NUMBER)
Date at inspection(ONLY DATE
FORMAT)
FH(ONLY
NUMBER)
FC(ONLY
NUMBER)
Previous inspection(Aircraft Status at previous inspection)
Actual interval(interval since the previous inspection)
Mandatory
Actual interval
information
Finding?(Y/N)
Details of finding(e.g corrosion Level, component/element which failed and how
did it fail, possible reasons for defect)
Type of Findings Associated Corrective Action
Task Result(to be filled if finding found during the task accomplishment)
Task findings / nil findings and
corrective actions
Assistance: [email protected]
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Operator A300 A300-600 A310 A320 fam. A330 A340XXX >> >> >>
In Service Experience Feedback
Benchmark my finding rates with IDOLS for Scheduled Maintenance
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In Service Experience Feedback
Operator A300 A300-600 A310 A320 fam. A330 A340XXX >> >> >>
Benchmark my finding rates with IDOLS for Scheduled Maintenance
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Examples of benchmarking queries: Benchmarking “Finding Rates”, Operator vs. Fleet for a list of tasks selected.
Benchmarking ”Finding Rates”, 3 groups based on A/C age (e.g. 0-10, 10-15 and >15) for a list of tasks.
In Service Experience Feedback
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