MRO- Maintenance, Repair & Overhaul

MRO- Maintenance, MRO- Maintenance, Repair & OverhaulRepair & OverhaulAll actions which have the objective of

retaining or restoring an item in or to a state in which it can perform its required function.

The actions include the combination of all technical and corresponding administrative,

managerial, and supervision actions.

MRO- Maintenance, Repair & OverhaulMRO- Maintenance, Repair & Overhaul

Aircraft MROAircraft MRO is the overhaul, repair, inspection or is the overhaul, repair, inspection or modification of an aircraft or aircraft componentmodification of an aircraft or aircraft component

Maintenance includes the installation or removal of a Maintenance includes the installation or removal of a component from an aircraft or aircraft subassembly, but component from an aircraft or aircraft subassembly, but does does notnot include: include: Elementary work, such as spark plugs, checking cylinder compression, Elementary work, such as spark plugs, checking cylinder compression,

etcetc Servicing, such as refueling, washing windowsServicing, such as refueling, washing windows Any work done on an aircraft or aircraft component as part of the Any work done on an aircraft or aircraft component as part of the

manufacturing process, prior to issue of a certificate of airworthiness manufacturing process, prior to issue of a certificate of airworthiness or other certification documentor other certification document

Regulation of Maintenance

JAA - Joint Aviation AuthoritiesJAR - Joint Aviation Requirements JAR-OPS 1 & 3 issued in May 1995 JAR-OPS 1 - Aeroplanes JAR-OPS 3 - Helicopters

Applicability, i.a.w. JAR-OPS 1 & 3 Subpart A: Civil aeroplanes in commercial air transportation Operators whose principal place of business is in a JAA Member State

JAR-OPS 1 & 3 Subpart M: Subpart M defines the aircraft maintenance requirements as viewed from the

perspective of the Airline OperatorAirline Operator Subparts B and C also define maintenance related requirements

Responsibilities of Airline Operators

An Airline Operator shall ensure the airworthiness of the aeroplane and the serviceability of both the operational and emergency equipment, being responsible to perform and / or control the following.

Defect rectification to an approved standard

Preflight inspection Maintenance i.a.w. maintenance programme

Effectiveness analysis

Airworthiness Directives (ADs)

Modifications and its policy

Life limits and expiry dates

These requirements must be performed in accordance with procedures acceptable to the Authority


The airworthy condition of the aeroplane, even if the Airline Operator does not perform any maintenance

Managing a maintenance programme (what maintenance is required, when to perform it, by whom and to what standard) and getting Authority approval

Amending the maintenance programme and getting Authority approval Maintaining adequate knowledge of the design status of the aeroplane Establishing a policy, and work to that policy, to assess non-mandatory

information such as certain Service Bulletins, Service Letters, etc. Analysing the effectiveness of the maintenance programme, with regard to

spares, established defects, malfunctions and damage Providing a clear work order to the JAR-145 maintenance organization Checking the subcontracted work at the maintenance facilities

The airworthy condition of the aeroplane, even if the Airline Operator does not perform any maintenance

Managing a maintenance programme (what maintenance is required, when to perform it, by whom and to what standard) and getting Authority approval

Amending the maintenance programme and getting Authority approval Maintaining adequate knowledge of the design status of the aeroplane Establishing a policy, and work to that policy, to assess non-mandatory

information such as certain Service Bulletins, Service Letters, etc. Analysing the effectiveness of the maintenance programme, with regard to

spares, established defects, malfunctions and damage Providing a clear work order to the JAR-145 maintenance organization Checking the subcontracted work at the maintenance facilities

The Airline Operator is therefore responsible for:


An Airline Operator shall establish and maintain a Quality System in accordance with JAR-OPS 1.035 (Subpart B).

An Airline Operator shall therefore establish a Quality System and designate a Quality Manager, acceptable to the Authority.

The Quality System must at least monitor:

The Quality System may be combined with JAR-145 Quality System.

Compliance with approved procedures, ref. JAR-OPS 1.035(a)Feedback system to the Accountable Manager, ref. JAR-OPS 1.035(a)Quality Assurance Programme, ref. JAR-OPS 1.035(b)JAR-OPS 1.890 activities i.a.w. accepted procedures, ref. JAR-OPS 1.900(a)(1)Contracted maintenance i.a.w. the contract, ref. JAR-OPS 1.900(a)(2)Continued compliance with Subpart M, ref. JAR-OPS 1.900(a)(3)

Types of MaintenanceTypes of Maintenance Each airline develops its own program, based on Each airline develops its own program, based on

manufacturer’s planning documents, but includes manufacturer’s planning documents, but includes adjustments for the airline’s own operationsadjustments for the airline’s own operations

Each aircrafts requires different operators and Each aircrafts requires different operators and programsprograms

BUT, aircraft of the same number of routine BUT, aircraft of the same number of routine maintenance hours during the program cyclemaintenance hours during the program cycle

Maintenance of aircraft usually categorized into Maintenance of aircraft usually categorized into Product type (airframe, engine and components)Product type (airframe, engine and components) Timing and purpose of workTiming and purpose of work

Then, resulted into 4 categoriesThen, resulted into 4 categories Routine scheduled maintenanceRoutine scheduled maintenance Non-routine maintenanceNon-routine maintenance RefurbishmentsRefurbishments ModificationsModifications

MRO- Maintenance, Repair & OverhaulMRO- Maintenance, Repair & Overhaul

Routine scheduled maintenanceRoutine scheduled maintenance

Includes airframe and engine checksIncludes airframe and engine checks The most elementary is visual inspection of the The most elementary is visual inspection of the

aircraft before flight- ‘walk-around’aircraft before flight- ‘walk-around’ To ensure there are no leaks, missing rivets or cracksTo ensure there are no leaks, missing rivets or cracks Types of checks-In GradesTypes of checks-In Grades

OvernightOvernight A-CheckA-Check

B-checkB-check C-checkC-check D-CheckD-Check

Overnight: Operate 1 to 1.5 hrs. inspection (End of Overnight: Operate 1 to 1.5 hrs. inspection (End of working day) to ensure the plane operating in working day) to ensure the plane operating in according to OEM ‘s (Original Equipment according to OEM ‘s (Original Equipment Manufacturer) minimum listManufacturer) minimum list

In, example installation of telephones and other In, example installation of telephones and other devicesdevices

10


A-Check: Done after 125flight hours (2-3 weeks)A-Check: Done after 125flight hours (2-3 weeks) An amplified preflight visual inspection of plane's power An amplified preflight visual inspection of plane's power

plants, avionics and accessories plants, avionics and accessories B-Check: Done approximately after 175 flight hours B-Check: Done approximately after 175 flight hours

(3 to 4 months)(3 to 4 months) An open inspection for preventive maintenance (exterior An open inspection for preventive maintenance (exterior

wash, engine oil)wash, engine oil) Oils filters are removed and checked, parts are lubricated Oils filters are removed and checked, parts are lubricated

and carefully examinedand carefully examined


C-check: Carried out approximately for every 3000 C-check: Carried out approximately for every 3000 flight hours (15 months)flight hours (15 months) Incorporates both A and B checks Incorporates both A and B checks Components are repaired, Components are repaired, Flights controls are calibratedFlights controls are calibrated Major internal mechanism are testedMajor internal mechanism are tested Other tests include minor structural inspections, Other tests include minor structural inspections,

compressor, flight control rigging tests, engine, compressor compressor, flight control rigging tests, engine, compressor washes, aircraft appearance maintenance, and post-check washes, aircraft appearance maintenance, and post-check flight testsflight tests


D-Check: The most intensive, approximately 20, 000 D-Check: The most intensive, approximately 20, 000 flights hours (6-8 years)flights hours (6-8 years) Cabin interiors (including seats, galleys, lavatories, cockpit, Cabin interiors (including seats, galleys, lavatories, cockpit,

furnishings, headliners and sidewalls) are removed to furnishings, headliners and sidewalls) are removed to enable careful structural inspectionsenable careful structural inspections

Flights controls are examined and the fuel system is Flights controls are examined and the fuel system is probed for leaks and cracksprobed for leaks and cracks

The aircraft is stripped to its shell and rebuilt to return it to The aircraft is stripped to its shell and rebuilt to return it to its original conits original con


MRO activitiesMRO activities


Engine Compressor washesEngine Compressor washes

flight control rigging testsflight control rigging tests

Engine Maintenance

JT8D at TAP Maintenance & Engineering Engine Overhaul Shop

CFM56-5B and CFM56-5C at TAP Maintenance & Engineering C-Check Hangar

I must leave this shop in full airworthy condition !

I must leave this shop in full airworthy condition !

TAT and profit margin considerations shall never impair quality !

TAT and profit margin considerations shall never impair quality !

Engine MRO Providers

OEMOEM Original Equipment Original Equipment Manufacturers (own facilities or Manufacturers (own facilities or acquired shops)acquired shops)ex: GE, Snecma, P&W, RR, etc.

AirlinesAirlines Airline Engine Shops (integrated Airline Engine Shops (integrated or independent from airline)or independent from airline)ex: TAP M&E, KLM E&M, Lufthansa

Technik, Air France Industries, etc.

IndependentsIndependents Independent Engine ShopsIndependent Engine Shopsex: MTU, Fiat Avio, IAI, etc.

Non-routine Maintenance Non-routine Maintenance

Done due to unforeseen event such as accident.Done due to unforeseen event such as accident. An example of the first engine damage due to bird An example of the first engine damage due to bird

ingestion or an airframe dented by a catering truckingestion or an airframe dented by a catering truck Done also for an aging aircraftDone also for an aging aircraft

RefurbishmentsRefurbishments

Any form of upgrading of cleaning, brighting, or Any form of upgrading of cleaning, brighting, or making it fresh again.making it fresh again.

To renovate and upgrade the aircraft To renovate and upgrade the aircraft For example: Cabin upgrades and exterior paintingFor example: Cabin upgrades and exterior painting

ModificationsModifications

Any form of small alteration, adjustment, or Any form of small alteration, adjustment, or limitation to fulfill the aircraft’s owner.limitation to fulfill the aircraft’s owner.

Most modifications are carried out within the interior Most modifications are carried out within the interior design, not much on the airframe and engine.design, not much on the airframe and engine.

For example: Installation of karaoke, PS3 and various For example: Installation of karaoke, PS3 and various kind of entertainment in the cabinkind of entertainment in the cabin

Overhaul of airframesOverhaul of airframes A plan where a series of seven minor overhauls and A plan where a series of seven minor overhauls and

one major check were conducted on aircraftone major check were conducted on aircraft The major overhaul was designed to rework the The major overhaul was designed to rework the

airplane to a like-new condition-to fit the bits and airplane to a like-new condition-to fit the bits and pieces back together to the exactness of current pieces back together to the exactness of current manufacturing tolerancesmanufacturing tolerances

Overhaul of engines and other componentsOverhaul of engines and other components

Components are brought in when either operating Components are brought in when either operating time/ condition requires ittime/ condition requires it

The overhaul returns them to specifications laid The overhaul returns them to specifications laid down by engineering and manufacturerdown by engineering and manufacturer

BUT when practical, engine changes are made BUT when practical, engine changes are made during maintenance checks or airframe overhaulsduring maintenance checks or airframe overhauls

Contract MaintenanceContract MaintenanceWhen?When? When the airline do not have the personnel and equipment to When the airline do not have the personnel and equipment to

perform maintenanceperform maintenance When serving a distant airport at which they do not have When serving a distant airport at which they do not have

maintenance supportmaintenance supportWhy?Why? Different types of aircraft requires different expertise from different Different types of aircraft requires different expertise from different

areasareas Low labor costLow labor cost Important note:Important note:

Some contracts extend to other functions, such as cleaning and Some contracts extend to other functions, such as cleaning and fueling the aircraftfueling the aircraft

Expectation from Engine MRO Provider

QualityQuality

TATTAT

CostCostManage workscope vs. required TAT

Manage scrap replacement vs. repair

Manage stock level vs. required TAT

The key challenge for an Engine MRO Provider is to manage the balance between TAT and Cost maintaining

The key challenge for an Engine MRO Provider is to manage the balance between TAT and Cost maintaining

Performance, Flexibility, QualityPerformance, Flexibility, Quality Performance, Flexibility, QualityPerformance, Flexibility, Quality

Expectation from Engine MRO Provider

0 1 2 3 4 5

OEM

Long Term Partner

Full Service

Innovative Pricing

Convenient Scheduling

Customer Service

Low Total Price

Fast TAT

Reputation for Quality

Completion Date Reliability

Reliability, Quality and Speed are nowadays more important than Price for the Airline Operator

Reliability, Quality and Speed are nowadays more important than Price for the Airline Operator

Factor Relative importance

Source: A.T. Kearney

MRO Challenges

In order to reduce costs and increase survivability, Airline Operators focus on their core businesscore business and reduce staff to a minimum

Shortage of Shortage of skilled staff skilled staff is one of the greatest obstacles today for future performance gains among Airline Operators

Newer engines are becoming increasingly more increasingly more complexcomplex requiring higher levels of engineering expertise

Added responsibilities on JAR-145 approved organisations stress National Authorities and Internal Audit to maintain proper control

Added responsibilities on JAR-145 approved organisations stress National Authorities and Internal Audit to maintain proper control

In general, Airline capability to control their JAR-OPS 1.890 responsibilities in respect to engines has decreased significantly in the past years and will probably continue in the near future

Highly Highly competitivecompetitive engine MRO situation prevents Providers from obtaining desired profit margins

Stresses MRO Quality Assurance departments

MRO Challenges

Authority

JAR-OPS

QA - MROMechanic

I guess I will end up in the hands of an MRO Provider… I just hope it is really good !

Hey pal, I have some friends in the technical dept. who take real good care of me.

Airlines are for flying ! I’ve got to reduce some resources in other departments.

Sometimes there are just so many rules, so much to learn and so little time !...... and my boss always tells me to hurry up.

Humm... These mechanics know what they’re doing, but are always under stress. I’d better tighten the control and check them more often.

Time is money. Hurry up !

Oh..fly boys…! just want to fly, but they must take care of their planes too. I’d better keep close control.

My QA friend really knows his place and his people. He’s doing a fine job. I have to help him more.

Authority

JAR-145

Question 1The aircraft maintenance, repair and overhaul (MRO) sector has seen tremendous growth in recent years that involve cost centre within an airline, the maintenance, modification and aftermarket servicing of commercial aircraft, engines and components.

a)Briefly explain in your own words the concept of maintenance, repair and overhaul (MRO). (3 marks)

b) Describe in your own words the responsibility of the airline MRO operator? (9 marks)

c) From your opinion, which is the most challenging task for an MRO operator and state your reason why. (3 marks)

Question 2Airliner would develops its own MRO program, based on manufacturer’s planning documents, but includes adjustments for the airline’s own operations.

a)Discuss in details the four categories of Maintenance, Repair and Overhaul (MRO) (9 marks)

b) Discuss in your own words significance of MRO engine maintenance . (3 marks)

c) From your opinion, what are the key success indicator for an MRO service provider? (3 marks)

Question 3

MRO today has become more sophisticated in identifying, diagnosing and transmitting defects that require the important feature of MRO Management.

a)Briefly explain the difference in refurbishments and modifications in MRO. State some examples to support your answer. (4 marks)

b) Discuss in your own words the standard expectations from an MRO Provider (8 marks)

c) From your opinion, which MRO provider would you prefer to service your aircraft? State your reasons (3 marks)

Question 4

One of the most critical activities for airline MRO is to strike a balance between supply and demand, as insufficient stock of spare parts can lead to stock outs and creating lost revenue opportunities.

a)Briefly discuss all the challenges that the MRO provider faces. (8 marks)

b)Guide MAS that has more than 1 year old aircraft with 3000 flight hours completed in the MRO routine scheduled maintenance. Which types of checks-in grades is suitable for this aircraft. (5 marks)

c) From your opinion, would you opt to use contracted maintenance for your airline company. State your reasons. (2 marks)

MRO- Maintenance, Repair & Overhaul

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