Aircraft Maintenance Aircraft maintenance is an area of significant importance because maintaining an aircraft in a good condition increases aviation safety.

Modern aviation maintenance is divided into four checks: A; B; C; and D checks. These checks are carried out at predetermined times based on the number of flight cycles (landings and take-offs) or flight time. These checks are performed under a maintenance program founded on MSG-3. History of MSG-3 In 1968 the Boeing Company developed the Maintenance Steering Group (MSG), maintenance schedule to ensure the safety of their B747-100 aircraft. This approach moved away from the tradition of "overhaul and replace at time intervals" to one that considered the type of tasks and intervals needed to keep the aircraft safe. MSG was found to be very successful because it saved time, money and unnecessary interference with components therefore, the company found a need to apply the same approach to all their aircraft. Thus, MSG was made applicable to more aircraft by making it more general. This new general version was named as MSG-2. However, over time MSG-2 was found to have some significant drawbacks (Kinnison, 2004 1). To overcome these failures MSG-3 came into existence in 1980. Today, most of the world's aircraft maintenance organizations are using MSG-3 approach. Drawbacks of MSG-2

Does not take the economic view into the considerations. Simply maintains aircraft safety at any cost Does not treat hidden failures to pilots: electric and electronic failures, fatigue inside the structure etc Is a bottom-up approach requiring more staff The definitions in MSG-2 contradicts themselves

Does not take the modern corrosion prevention approach into account

Advantages of MSG-3

Top-down process Reduced maintenance costs Fewer maintenance tasks Some tasks are carried out for economic reasons and others for safety reasons Eliminates emotions

Aircraft Maintenance Checks A Check A Check is a light check carried out usually overnight at an airport gate. This check is carried out every month or every 500 flight hours, however, depending on the aircraft type the timing can change. B Check B Check is also a light check carried overnight at an airport gate. This check is normally performed every 3 months. C Check C Check is a heavy maintenance check usually carried out every year or every 1.5 years. Since this check requires dissemble of critical parts, this check is performed in a hangar. D Check D Check is sometimes called overhaul check or heavy maintenance check. This check is performed in every 4-5 years: inspection of entire aircraft is carried out.

Maintenance and overhaul technologies

Combustors: The repair of "hot oven"The combustor is the heart of the engine. Here thermal energy which will be converted downstream into kinetic energy is generated. The stresses that a combustor can actually withstand vary according to manufacturer and type, but in

every case they will be extreme. ... more RFID small transponder, huge effectRFID (Radio Frequency Identification), a method of contactless identification, is making its way into a rapidly growing number of areas. For the Lufthansa Technik workforce, the use of RFID actually begins at the start of every working day. ... more

Airbus A380 - Lufthansa Technik present from the very beginningSince 19 May 2010 the first Airbus A380 flies in Lufthansa colors. Entry into service of the megaliner presented special challenges, not just because of its size. From a technological point of view, the A380 marks

the peak of modern aircraft design. ... more Airbus A380 Maintenance in new dimensionsThe catalog of tasks which had to be completed by the handover of the first Airbus A380 to Lufthansa in May 2010 was long. First of all, there was the preparation of Lufthansa Techniks

facilities. ... more Composite materials: Repairing the "Black Gold, part 1In the aviation business they are often called the black gold: Composite materials. As their name suggests, they combine several positive characteristics of different substances in a single

material. ... more Composite materials: Repairing the "Black Gold, part 2Composite materials challenge the personnel in Lufthansa Techniks painting hangars. Unintentional chippings and cracking paint are more often found on CFRP structures than on comparable aluminium surfaces, mostly due to differences in thermal

expansion. ... more Aircraft maintenance at Lufthansa TechnikOne of the most important factors influencing the success of an airline is the maintenance of its aircraft. Because only when the fleet is in a technically excellent condition can the flying operations be run

punctually and profitably. ... more Airline Support Teams: The aircraft "doctors"When the Hamburg logistics center of the world's largest provider of aircraft technical services receives the call for help, "Aircraft on Ground", an Airline Support Team (AST) stationed in Frankfurt can be dispatched to any airport on earth within

a very short time. ... more Engine Condition Monitoring: Listening to an engines heartbeatWhen an

airline receives the alarm "aircraft on ground," it's already too late. If an aircraft has suffered engine damage, it has to undergo costly repairs before it can take off again. To prevent things going that far, Lufthansa Technik provides

continuous engine monitoring. ... more Aircraft cleaning: Handcraft still in demandEven nowadays the cleaning of aircraft is mainly handcraft. Cleaning management on the other side requires comprehensive know-how. For clean aircraft do not only leave a good impression - they considerably save fuel. ... more

Fuel tank inspection: A job that calls for eagle eyesAfter the first six years of operation, the Airbus A340 is due for a general overhaul. As part of this IL check, the fuel tanks are inspected carefully from the inside for leaks

or damage. ... more Landing Gear Overhaul: Vital buffer between airframe and runwayA full landing gear overhaul is a task for specialists that requires the use of special tools, equipment and technology. ... more

Maintenance work on decommissioned aircraftAn aircraft which normally flies thousands of kilometres every day cannot simply stay on the ground without special measures being taken for its care and protection. Appropriate technical support is needed here. ... more

rotable
Definitions (2)
1. Comp nent or inventory item that can be repeatedly and economically restored to a fully serviceable condition. 2. Servicing method in which an already-repaired equipment is exchanged for a failed equipment, which in turn is repaired and kept for another exchange.

A320 Family (A320 FAM) Means Airbus A318, A319, A320 and A321 aircraft. A Check The most frequent regular check carried out on an aircraft (apart from daily/before flight check). Typically performed every 8 to 12 weeks and often generically referred to as a Light Maintenance check. These checks can be sequentially numbered with, for example, a 2A check including a few more tasks than a 1A check. Aircraft Availability the time for which an aircraft was available for flight service, usually referred to in percentage terms. Aircraft on Ground (AOG) when an aircraft has been grounded and is unable to fly for technical reasons it is referred to as an AOG. An urgent request is sent out for parts or components or engineering assistance to enable the aircraft to be repaired and put back into service in the shortest possible time. Aircraft Phase-In When an aircraft (new or used) is first delivered to an operator, the airline itself (or its maintenance partner) must record all details of Part Number, Serial Number, Maintenance Planning Document (MPD) schedule for all components within its maintenance planning and control system. This will also include details of the Flight Hours (FH)/Flight Cycles (FC) undertaken to date by each component, plus the lives already consumed on all installed life limited parts (LLPs). An Aircraft Phase-In is a particularly extensive task in the case of a used aircraft requiring a large amount of time and resources. Aircraft Phase-Out The reverse of Phase-In, performed when an aircraft is sold (or leased) to another operator. The previous operator (or its maintenance partner) must extract all the Phase-In data which must have been continuously updated to reflect all the lives consumed and maintenance events which have taken place throughout the time in service with the previous operator/s. In addition, this term is also used to describe the physical work performed on the aircraft and its engines and components in order to meet the Lease Agreement Return Conditions (if leased) or the Sales Agreement Acceptance/Delivery Conditions (if sold). Airworthiness Directive (AD) Issued by one or more Airworthiness Authorities, this is a legally-binding requirement for work to be done on a specific aircraft, or engine, or component (type, model, or serial number/s). The work may involve modification, inspection, or other preventative measures, and may involve a one-off task or a task that needs to be repeated. ADs always have a threshold expressed in Flight Hours (FH) and/or Flight Cycles (FC) and/or Calendar Time (by which time the task must have been performed). Approved Standard Indicates a manufacturing/design/ maintenance/quality standard approved by the relevant Authority. Auxiliary Power Unit (APU) A small gas turbine engine, usually mounted at the tail of an aircraft, which provides additional power for services (e.g. electrics, hydraulics, air conditioning and engine starting). Normally used only whilst the aircraft is on ground with the main engines shut down. Not permitted to be used at some airports (mainly for environmental reasons). Avionics Modern passenger aircraft are highly automated and are often referred to as being

computerised, and as having glass cockpits (as opposed to the old-fashioned needles on dials type of instrument). The numerous electronic units including the various computers themselves, plus items such as interfaces, display generators, sensors, signal distributors, etc. are all generically referred to as avionics. C Check Next most frequent check after an A check. Typically performed every 12 to 18 months. These checks can also be sequentially numbered with, for example a 2C check including rather more tasks than a 1C check, and so on. Component Maintenance Component maintenance means bringing unserviceable components of the operators aircraft into a serviceable (airworthy) condition. This maintenance can be performed internally or externally and comprises of one or a combination of the following tasks: repair, overhaul, test, modification, inspection and re-certification. The incorporation of ADs etc. is also part of the component maintenance services. Component maintenance services comply with the airworthiness requirements of the operators authority and are in accordance with vendor or manufacturer requirements or the relevant Component Maintenance Manual (CMM). Component Management Component Management comprises of Repair Cycle Management, Inventory Management, Component Technical Management and Warranty Management. In addition, this service is performed to improve reliability (component history reports analysis, analysis of suggested modifications, etc.) and to secure the availability of interchangeable and qualitatively equal components. Consignment Stock Consignment Stock means an onsite stock at the operators main base or another specified location. The components remain under the ownership of SR Technics. In order to ensure aircraft are not delayed for technical reasons, the consignment stock comprises of the most critical components that are likely to be require. Component means a rotable or repairable part (re-usable). Aircraft components whose maintenance intervals are individually scheduled separately to the maintenance intervals of the aircraft itself. Cycle Cycle means one aircraft take-off and subsequent landing. Cycle is often used as a charging basis for Wheels,Tyres and Brakes, but it is also a measurement of the length of time an item is in service before maintenance and/or exchange becomes necessary. D Check a major overhaul of the airframe itself, plus many of an aircrafts internal components. Typically performed every 58 years. Also often generically referred to as heavy (or major, or Base) Maintenance. Deferred Defect Rectification Faults or defects found on an aircraft which do not need immediate action and can be deferred for repair at a later date. This deferred defect status is only given for a strictly limited period of time and rectification must take place before that time has elapsed. EASA (European Aviation Safety Agency) While national authorities continue to carry out the majority of operational tasks such as certification of individual aircraft or licensing of pilots, EASA, the European Aviation Safety Agency ensures common safety and environmental standards at the European level. Responsibilities include drafting safety legislation and providing technical advice to the European institutions and the member states; inspections; safety and environmental type-certification of aircraft, engines and parts; approval and oversight of aircraft design organisations worldwide and of production and maintenance organisations outside the EU; data collection ,analysis and research to improve aviation safety. EasyTech easyTech is a joint venture facility at London- Luton between SR Technics and easyJet to provide maintenance support to easyJet, the airline. This joint venture is called SR Technics easyTech Limited with SR Technics holding 75% ownership.

Engine Condition Monitoring (ECM) Today engine work shop visits are normally scheduled on the basis of On Condition. To establish the condition of an engine while installed (on-wing), various parameters are regularly monitored and plotted graphically for comparison against norms stored using special PC software. By comparing actual parameters with previous values, and comparing those against the stored norms, it is possible to predict engine removal with some accuracy since it is the gradual deterioration of various parameters affecting overall engine performance and efficiency which are being monitored. When used together with complementary techniques such as analysis of lubricating oil samples or particles lodged in filter elements, plus the use of borescopes to view various internal parts whilst the engine is still installed, the planning of engine servicing can be predicted quite accurately. Engine Engineering The analysis and preparation of customised work scopes for the customers engine. This also covers key activities like inspections after disassembly, the preparation of a tailor-made reliability programme and repairs development. Engine Financing Engine financing is the use of material exchange services (stock provision) as well as engine leasing service to support the customers need for spares availability. Engine Fleet Management Engine Fleet Management includes the engine trend monitoring (analysis of the performance of an engine on-wing), the trend analysis and recommendations of on-wing maintenance actions. The key objective of the Engine Fleet Management is in determining the most appropriate removal plan for every single engine. Engine Maintenance The off-wing maintenance that is performed in a workshop. This includes the overhaul and repair of complete engines, modules, accessories and QEC; the engines component repairs; the engine and accessory testing; the incorporation of Service Bulletins, Airworthiness Directives, campaigns and modifications and also the management of the entire Repair Cycle. Engine Management Engine Management comprises the management of the shop visit, the engineering activities (mentioned before), the Engine Fleet Management, the on-wing/field team assistance (24hrs/365day), the Warranty Management (including special reports, occurrences analysis with customers and the OEM), the data management, the engine change and transportation and the access to Maintenance Control Centre (MCC) 24 hours a day, 365 days a year. Federal Aviation Administration (FAA) The Airworthiness Authority of the USA. Federal Aviation Regulation (FAR) Regulation/s issued by the FAA. Fleet Technical Management Tasks such as scheduling maintenance work, evaluating Airworthiness Directives (ADs) and Service Bulletins, monitoring maintenance costs and reliability, arranging the escalation of maintenance intervals, etc. are referred to as Technical Fleet Management. This can also be referred to as a maintenance partner carrying Engineering Responsibility for a fleet. Flight Hour (FH) Basic unit for measuring length of time in service/before maintenance becomes due. The Flight Hour (FH) represents one hour of flight. Ground Time Expression used to define the total time an aircraft will spend (start to finish) undergoing a defined maintenance check. Heavy (or Major) Maintenance See D Check and HMV. Heavy Maintenance Visit (HMV) The maintenance visit (or ground time) for performing a D Check (or similar major work). Integrated Airline Solutions (IAS) SR Technics total offering. Click here for further details. Integrated Component Solutions (ICS) SR Technics total component offering. Click here for further details.

Integrated Engine Solutions (IES) SR Technics total engine offering. Click here for further details. Integrated Maintenance Services The maintenance services delivered to the airline by a maintenance partner such as SR Technics. The services may be carried out by the maintenance partner or outsourced to other reliable suppliers but the maintenance partner will oversee and integrate all aspects of the services provided for the airline. Integrated Service Provider A maintenance partner who is responsible for providing all technical services for an airline. The services may be carried out by the maintenance partner or outsourced to other reliable suppliers but the maintenance partner will oversee and integrate all aspects of the services provided for the airline. International Bureau Of Aviation Founded in 1988, IBA Group is a consulting company who are completely independent from any financial institution, leasing company, manufacturer or supplier. Inventory Technical Management The technical management of the component stock to support an airlines fleet. Landing Gear (LDG) The complete assembly of legs, struts, wheels, brakes, steering gear, etc. that allows the aircraft to move and steer on the ground. A ship set LDG is one set of all the units required by one aircraft Light Maintenance See A Check. Line Engineer A licenced certified engineer who performs the Line Maintenance functions. Maintenance Control Centre (MCC) /Maintenance Operations Control (MOC) An office at a maintenance provider (or airline) open 24 hours/365 days, staffed with qualified technical specialists and equipped to communicate both verbally and by written message with technicians and pilots of aircraft away from base, both while airborne and on ground. Modification Modification means the alteration of an aircraft/aircraft component in conformance with an approved standard. Such modification can be initiated by the Authorities (Airworthiness Directives mandatory) or by the Vendors or other market participants (Vendor Bulletins,Service Bulletins, etc. non-mandatory). MRO Maintenance, Repair and Overhaul. MRO Provider Maintenance companies who hold Airworthiness Authority approvals for the maintenance and repair of specific aircraft, engine, and component types/models. N1 Vibrations N1 relates to engine low pressure rotor speed, i.e. how fast the first set of turbine blades in a jet engine are turning. New Paradigm Carriers New niche market of airlines, which are not classified as low cost carriers but who have the same challenging principles of continuously cutting costs to reduce total overhead. Original Equipment Manufacturer (OEM) An original equipment manufacturer (frequently abbreviated OEM) is a company that builds products or components that are used in products sold by another company. Rotable/s (Components) Aircraft components whose maintenance intervals are individually scheduled separately to the maintenance intervals of the aircraft itself. Serviceable Means certified release to service in accordance with the applicable requirement. Technical Snags Damage, problems or faults of a technical nature.

Turn Around Time (TAT) The time taken (usually an average, expressed in days) between the arrival of a component, engine or aircraft (usually for overhaul) and the time at which the overhaul will be completed and unit released ready for service. Type Courses Also known as type training. These are technical courses for a specific aircraft type, e.g. Boeing B737-300 or A320 training. Work Scope Official document (usually part of the contract between a maintenance provider and an aircraft operator or owner) precisely defining the tasks to be performed during a specific aircraft ground time (or engine shop visit).