Scheduled Maintenance Program Seminar - 4. Maintenance Program Establishment-Part2

Maintenance Program
MPD Presentation Layout: Task Codes
TASK DESCRIPTION SKILL CODE CODE
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
51
Maintenance Program
MPD Presentation Layout: Task Codes
TASK CODE
52
Maintenance Program
MPD Presentation Layout: Preparation
TASK DESCRIPTION SKILL CODE PREPARATION CODE
53
Maintenance Program
MPD Presentation Layout: Access
TASK DESCRIPTION SKILL CODE PREPARATION CODE
ACCESS
54
Maintenance Program
MPD Presentation Layout: Threshold & Interval
SAMPLE THRESHOLD : ST SAMPLE INTERVAL : SI 100% THRESHOLD : T 100% INTERVAL : I
55
Maintenance Program
MPD Presentation: Focus on Threshold / Interval data
Commonly used threshold/interval units:
Usage Parameters intervals
DaYs, MOnths, YEars, Flight Hours, Flight Cycles, Equipment Operating Units
Letter intervals (1A, 2A, 4A, 1C, 2C, 4C, 8C)

A = X FH/FC/MO e.g. In A310 MPD: C = Y FH/FC/MO X,Y varies from one MPD to another. A = 500FH / 4MO & C = 6000FH / 24MO
Starting point for calculation of the due dates or times of maintenance tasks:
First flight of the aircraft (Flight Cycles, Flight Hours intervals) Date of Transfer of Title of the aircraft to the customer (Calendar intervals) Date of manufacture of the equipment when ageing of the equipment is not linked to the airframe
Interval rules:
Thresholds or intervals with multiple units: First to expire must be considered (when otherwise not stated)
56
Maintenance Program
MPD Presentation: Focus on Threshold / Interval data
Task Interval concept - units
Mixed concept
Letter Intervals + Usage Parameters Intervals
Still in use for LR
& Originally used to pre-package (for

the operator) a set of maintenance tasks with closer intervals Less engineering work
' Theoretical task interval not

reflected
New concept
Usage Parameters Intervals only
Used for WB, SA and LA
& Flexibility as no more preplanning/pre-packaging at airline level
A check C check
FH FC Cal. Time
& Maximum interval & Direct Maintenance Costs savings

due to Optimized Maintenance events based on real A/C utilization
Intervals are established in terms of the measure of exposure to the conditions that cause the failure at which the task is directed
' More planning work at airline level
57
Maintenance Program
MPD Presentation: Focus on Threshold / Interval data Airline ISE
In-service Experience (ISE) Tasks efficiency must be tracked by recording finding & non-finding Analysis must be frequently made to: - ensure inspection level & interval allow to identify finding - detect any additional unscheduled work which could require new tasks Any additional tasks or interval change must be documented to justify them in front of National Authorities and facilitate new analysis (see interval evolution "decision tree")
Note: Maintenance program evolution is primarily under operators responsibility. Nevertheless, operators can take benefit from evolution exercise led by Airbus fleet wide
an airline view
58
Maintenance Program
MPD Presentation: A320 FAM MPD Evolution
A Interval adjustment
Interval (Flight hours) 750 FH 4 MO 750 FC 600 FH 100 DY 750 FC 500 400 350
800 700 600 500 400 300

1988
Interval (Months)
1993
1998
2005
2007 2008
20 MO 6000 FH 4500 FC 24 MO 7500 FH 5000 FC
To be included in MPD rev 36 (June 11)
C Interval adjustment
24 20 15 12
1988
Interval (Years) 15
2005
2007 2008 12
4C & 8C Interval adjustment

8 9 10
12 10 6 5 4
1988 1994
4
6
5
1999
2005
2007 2008
59
Maintenance Program
MPD Presentation: A320 FAM
A320 Family - Rough Order of Magnitude
A320 Daily Weekly A-check
Interval 36 H 8 calendar Days 600 FH / 750 FC / 100 DY 6000 FH / 4500 FC / 20 MO 6 YE 12 YE
Man hours volume Up to 4 MH Up to 20 MH Up to 70 MH
Downtime / Elapsed time 0.5 to 4 Hours 0.5 to 8 Hours 5 to 20 Hours
Main Purpose General Visual Inspection
Servicing, GVI, Engine Boroscope
C-check
Up to 1500 MH
4 to 10 Days
Operational Check
4C-check 8C-check
Up to 10000 MH Up to 15000 MH
15 to 25 Days (3 weeks) 20 to 40 Days (4 to 6 weeks)
Structural Inspection (corrosion) Structural Inspection (corrosion + fatigue)
*Real figures from the field including non-routine times raised from routine + defect rectification + additional items (e.g mod embodiment) Airbus DMC Benchmarking 2007
60
Maintenance Program
MPD Presentation: A330/A340 MPD Evolution
Interval (Flight hours)
A Interval adjustment
* 600
** 800
* A340 MPD Rev 16

A330 MPD Rev 15
800 700 600 500 400

1993 2002
500
** A340 MPD Rev 17

A330 MPD Rev 16
2005
2007 2008 24
Interval (Months)
24 21 18 15 12
1993
15
C Interval adjustment
18
Not yet approved: 1C = 24 MO 2C = 48 MO
2002
2005
2007 2008 12
**
Interval (Years)
12 10 6 5 4
1993
10
4C & 8C Interval adjustment

6
2002
2005
2007 2008
61
Maintenance Program
MPD Presentation: A330/A340
A330/A340 - Rough Order of Magnitude
A320 Daily Weekly A-check C-check 4C-check 8C-check
Interval 36 H 8 calendar Days 600 FH 18 MO
Man hours volume Up to 15 MH Up to 20 MH Up to 150 MH Up to 3000 MH Up to 10000 MH Up to 20000 MH
Downtime / Elapsed time 1.8 to 3 Hours 2 to 8 Hours 5 to 20 Hours 4 to 14 Days (A330) 8 to 18 Days (A340) 20 to 30 Days 40 to 50 Days
Main Purpose General Visual Inspection
Servicing, GVI, Engine Boroscope Operational Check
6 YE 12 YE
Structural Inspection (corrosion) Structural Inspection (corrosion + fatigue)
*Real figures from the field including non-routine items raised from routine + non-routine (defect rectification) + additional items (e.g mod embodiment) Airbus DMC Benchmarking 2007
62
Maintenance Program
MPD Presentation: Focus on SAMPLING
SAMPLING: The Sampling Program is designed to detect systematic deterioration on the oldest 20% of aircraft in each operators fleet. The Sampling Program is applicable to both Fatigue Damage (FD) and Environmental Deterioration (ED) SSIs, where deterioration, should it occur, is considered as being progressive with age or operating usage. SSIs which are susceptible to Accidental Damage (AD) are not considered for the Sampling Program. The inspections performed on sampling fleet aircraft prevent performing the inspections on 100% of one operators fleet. In case no sampling fleet is defined, consider applicable sampling inspection requirements as 100% MRBR inspections (to be performed on all aircraft of the operators fleet). 100% inspection tasks not showing a sampling requirement are applicable to sampling fleet aircraft too
SAMPLE THRESHOLD : S TH SAMPLE INTERVAL : S INT 100% THRESHOLD : TH 100% INTERVAL : INT
MPD
63
Maintenance Program
SELECTION OF AIRCRAFT FOR SAMPLING PROGRAM: Sampling size: - For a given aircraft type, generally 1/5 of the fleet is to be selected - Additional rules may apply (e.g. at least one a/c per operators fleet, minimum sampling size is one aircraft, maximum sampling size is 5 aircraft, ) Sampling aircraft: - When sampling size is defined, select the oldest aircraft in years since the initial manufacturers delivery date Operational Conditions: - In similar operational conditions: A group of operators may establish common rules acceptable to each operators Airworthiness Authorities in order to combine their fleets to form one fleet for the Sampling Program. - If the operational conditions within an operators fleet differ significantly, it is advisable to consider dedicated sample aircraft for this sub-fleet.
64
Maintenance Program
Sampling fleet selection
The Operator has to consider the A/C the sampling program applies to: Wide-body: The sampling fleet must be selected per aircraft type (A300, A300-600, A310) Single-aisle: The sampling fleet must be selected per aircraft type (A318 ,A319, A320, A321) Long-range: The sampling fleet must be selected per aircraft type (A330, A340) and per weight variant group (42A, 43A or 43B)
65
Maintenance Program
ARRANGEMENT OF INSPECTIONS: For the selected sampling A/C, inspections commence at the Sample (S_TH) or 100% Threshold (TH) (whichever occurs first) and continue at each subsequent repeat interval (S_INT or INT, whichever occurs first).
Different source document requirements (MRBR, ALI,..) consolidated in one MPD task may lead to a task which has a 100% Threshold/Interval which is lower than the S_TH/S_INT The more conservative requirement must be followed.
For all aircraft not selected for Sampling only the 100% TH/INT must be taken into account.
66
Maintenance Program
No
Apply 100% Threshold
Is A/C part of Sampling Fleet ?
Yes
100% value
Which Threshold value (100% or Sample) is the most restrictive ?
Sample value
Apply Sample Threshold
Apply Sample Interval as long as 100% Threshold is not reached
Apply 100% Interval
100% value
Which Interval value (100% or Sample) is the most restrictive ?
Sample value
Apply Sample Interval
67
Maintenance Program
Example:
ST :
24000 FC OR 54000 FH
SI :
18000 FC OR 45000 FH
T: I:
12 YE 12 YE
Case 1: Aircraft not part of sampling fleet (3600FH/YE; 1.3FH/FC) Case 2: Aircraft part of sampling fleet (3600FH/YE; 1.3FH/FC) Case 3: Aircraft part of sampling fleet (3600FH/YE; 1.95FH/FC)
68
Maintenance Program
Case 1: Aircraft not part of sampling fleet (3600FH/YE; 1.3FH/FC)
ST : 24000 FC OR 54000 FH SI : 18000 FC OR 45000 FH T: I: 12 YE 12 YE
No
Yes
100% value
Sample value
Apply 100% Interval
100% value
Sample value
* MPD Task 533103-01-1 coming from A320 MPD rev 29
69
Maintenance Program
No
Yes
100% value
Sample value
Apply 100% Interval
100% value
Sample value
70
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
A/C MSN01* MSN02 MSN03 12 YE * MSN01 is considered as Sample AC Aircraft Delivery Aircraft Inspection (43200 FH) 24 YE (86400 FH)
71
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
72
Maintenance Program
No
Yes
100% value
Sample value
Apply 100% Interval
100% value
Sample value
73
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
100% T
74
Maintenance Program
No
Yes
100% value
Sample value
Apply 100% Interval
100% value
Sample value
75
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
100% T
100% I
76
Maintenance Program
Case 2: Aircraft part of sampling fleet (3600FH/YE; 1.3FH/FC)
ST : 24000 FC OR 54000 FH SI : 18000 FC OR 45000 FH T: I: 12 YE 12 YE *
No
Yes
100% value
Sample value
Apply 100% Interval
100% value
Sample value
77
Maintenance Program
No
Yes
100% value
Sample value
Apply 100% Interval
100% value
Sample value
78
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
79
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
80
Maintenance Program
ST : 31200 FH (24000 FC) ST : 24000 FC OR 54000 FH SI : 18000 FC OR 45000 FH T: I: 12 YE 12 YE OR
No
54000 FH
SI : 18000 FC OR 45000 FH
T:
43200 FH (12 YE)

12 YE
Yes
I:
100% value
Sample value
Apply 100% Interval
100% value
Sample value
81
Maintenance Program
ST : 31200 FH (24000 FC) ST : 24000 FC OR 54000 FH SI : 18000 FC OR 45000 FH T: I: 12 YE 12 YE OR *
No
54000 FH
SI : 18000 FC OR 45000 FH
T:
43200 FH (12 YE)

12 YE
Yes
I:
100% value
Sample value
Apply 100% Interval
100% value
Sample value
82
Maintenance Program
ST : 31200 FH (24000 FC) OR 54000 FH
SI : 18000 FC OR 45000 FH
ST :
24000 FC OR 54000 FH
SI :
18000 FC OR 45000 FH
T:
I:
43200 FH (12 YE)

12 YE
T: I:
12 YE 12 YE
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
A/C MSN01* MSN02 MSN03
ST
12 YE * MSN01 is considered as Sample AC Aircraft Delivery Aircraft Inspection (43200 FH)
24 YE (86400 FH)
83
Maintenance Program
ST : 24000 FC OR 54000 FH
* ST : 24000 FC OR 54000 FH SI : 18000 FC OR 45000 FH T: I: 12 YE 12 YE
No
SI :
23400 FH (18000 FC) OR 45000 FH
Yes
T: I:
12 YE 12 YE
100% value
Sample value
Apply 100% Interval
100% value
Sample value
84
Maintenance Program
ST :
24000 FC OR 54000 FH
ST :
24000 FC OR 54000 FH
SI :
23400 FH (18000 FC) OR 45000 FH SI :
18000 FC OR 45000 FH
T: I:
12 YE 12 YE
T: I:
12 YE 12 YE
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
ST
100% T
SI
85
Maintenance Program
ST : 24000 FC OR 54000 FH
ST :
24000 FC OR 54000 FH
No
SI :
23400 FH (18000 FC) OR 45000 FH SI :
18000 FC OR 45000 FH
Yes
T:
12 YE
T: I:
12 YE 12 YE
I:
43200 FH (12 YE)
100% value
Sample value
Apply 100% Interval
100% value
Sample value
86
Maintenance Program
ST : 24000 FC OR 54000 FH
ST :
24000 FC OR 54000 FH
No
SI :
23400 FH (18000 FC) OR 45000 FH SI :
18000 FC OR 45000 FH
Yes
T:
12 YE
T: I:
12 YE 12 YE
I:
43200 FH (12 YE)
100% value
Sample value
Apply 100% Interval
100% value
Sample value
87
Maintenance Program
ST :
24000 FC OR 54000 FH
ST :
24000 FC OR 54000 FH
SI :
23400 FH (18000 FC) OR 45000 FH SI :
18000 FC OR 45000 FH
T:
12 YE
T: I:
12 YE 12 YE
I:
43200 FH (12 YE)
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH 110,000 FH
ST
100% T
SI
SI
SI
SI
88
Maintenance Program
ST : 24000 FC OR 54000 FH SI : 18000 FC OR 45000 FH T: 12 YE 12 YE *
No
Yes
I:
100% value
Sample value
Apply 100% Interval
100% value
Sample value
89
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
90
Maintenance Program
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
91
Maintenance Program
No
Yes
100% value
Sample value
Apply 100% Interval
100% value
Sample value
92
Maintenance Program
ST : 24000 FC OR 54000 FH SI : 18000 FC OR 45000 FH
No
Yes
T: I:
12 YE 12 YE
100% value
Sample value
Apply 100% Interval
100% value
Sample value
93
Maintenance Program
No
54000 FH
SI : 18000 FC OR 45000 FH
Yes
T:
I:
43200 FH (12 YE)

12 YE
100% value
Sample value
Apply 100% Interval
100% value
Sample value
94
Maintenance Program
No
54000 FH
SI : 18000 FC OR 45000 FH
Yes
T:
I:
43200 FH (12 YE)

12 YE
100% value
Sample value
Apply 100% Interval
100% value
Sample value
95
Maintenance Program
ST : 46800 FH (24000 FC) OR 54000 FH
SI : 18000 FC OR 45000 FH
ST :
24000 FC OR 54000 FH
SI :
18000 FC OR 45000 FH
T:
I:
43200 FH (12 YE)

12 YE
T: I:
12 YE 12 YE
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
100% T
96
Maintenance Program
ST : 24000 FC OR 54000 FH
ST :
24000 FC OR 54000 FH
No
SI :
35100 FH (18000 FC) OR 45000 FH SI :
18000 FC OR 45000 FH
Yes
T:
12 YE
T: I:
12 YE 12 YE
I:
43200 FH (12 YE)
100% value
Sample value
Apply 100% Interval
100% value
Sample value
97
Maintenance Program
ST : 24000 FC OR 54000 FH
ST :
24000 FC OR 54000 FH
No
SI :
35100 FH (18000 FC) OR 45000 FH SI :
18000 FC OR 45000 FH
Yes
T:
12 YE
T: I:
12 YE 12 YE
I:
43200 FH (12 YE)
100% value
Sample value
Apply 100% Interval
100% value
Sample value
98
Maintenance Program
ST :
24000 FC OR 54000 FH
ST :
24000 FC OR 54000 FH
SI :
35100 FH (18000 FC) OR 45000 FH SI :
18000 FC OR 45000 FH
T:
12 YE
T: I:
12 YE 12 YE
I:
43200 FH (12 YE)
0 FH
10,000 FH 20,000 FH 30,000 FH
40,000 FH 50,000 FH 60,000 FH 70,000 FH 80,000 FH 90,000 FH 100,000 FH
A/C MSN01* MSN02 MSN03 12 YE * MSN01 is considered as Sample AC Aircraft Delivery Aircraft Inspection (43200 FH)
SI
SI
100% T
24 YE (86400 FH)
99
Maintenance Program
MPD Presentation Layout: Source
SOURCE
100

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Maintenance Program

MPD Presentation Layout: Task Codes

TASK DESCRIPTION SKILL CODE CODE

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

TASK DESCRIPTION SKILL CODE PREPARATION CODE

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

TASK DESCRIPTION SKILL CODE PREPARATION CODE

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

SAMPLE THRESHOLD : ST SAMPLE INTERVAL : SI 100% THRESHOLD : T 100% INTERVAL : I

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Usage Parameters intervals

Letter intervals (1A, 2A, 4A, 1C, 2C, 4C, 8C)

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

& Originally used to pre-package (for

' Theoretical task interval not

Used for WB, SA and LA

& Flexibility as no more preplanning/pre-packaging at airline level

& Maximum interval & Direct Maintenance Costs savings

' More planning work at airline level

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

800 700 600 500 400 300

To be included in MPD rev 36 (June 11)

4C & 8C Interval adjustment

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Man hours volume Up to 4 MH Up to 20 MH Up to 70 MH

Downtime / Elapsed time 0.5 to 4 Hours 0.5 to 8 Hours 5 to 20 Hours

Main Purpose General Visual Inspection

Servicing, GVI, Engine Boroscope

15 to 25 Days (3 weeks) 20 to 40 Days (4 to 6 weeks)

Structural Inspection (corrosion) Structural Inspection (corrosion + fatigue)

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

* A340 MPD Rev 16

800 700 600 500 400

** A340 MPD Rev 17

Not yet approved: 1C = 24 MO 2C = 48 MO

4C & 8C Interval adjustment

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Man hours volume Up to 15 MH Up to 20 MH Up to 150 MH Up to 3000 MH Up to 10000 MH Up to 20000 MH

Main Purpose General Visual Inspection

Servicing, GVI, Engine Boroscope Operational Check

Structural Inspection (corrosion) Structural Inspection (corrosion + fatigue)

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Apply 100% Threshold

Is A/C part of Sampling Fleet ?

Apply 100% Threshold

Which Threshold value (100% or Sample) is the most restrictive ?

Apply Sample Threshold

Apply Sample Interval as long as 100% Threshold is not reached

Apply 100% Interval

Which Interval value (100% or Sample) is the most restrictive ?

Apply Sample Interval

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Apply 100% Threshold

Is A/C part of Sampling Fleet ?

Apply 100% Threshold

Which Threshold value (100% or Sample) is the most restrictive ?

Apply Sample Threshold

Apply Sample Interval as long as 100% Threshold is not reached