Chapter 6

Requirements for a
Maintenance Program
 AC 120-16E
• Aviation Maintenance Program Outlined
• FAA Advisory Circular
• Requires Ops Specs
• Authorizes maintenance program
• Required maintenance manuals
• Operational equipment as commercial airliner
• Describes airline responsibility for performing
approved maintenance/alterations
• Accomplished by airliner or contractor
• Applies to any individual employed/engaged
• Air carrier maintenance
• Preventative maintenance
• Alteration of its aircraft
 Maintenance AC 120-16E
• Scope/Content
• Background of programs
• FAA regulatory requirements
• Airworthiness responsibility
• Air carrier maintenance manual/organization
• Maintenance record keeping system
• Accomplishment/approval of maintenance and
alterations
• Maintenance schedule
• Required inspection items (RII)
• Contract maintenance
• Personnel training
• Continuous analysis surveillance system (CASS)
Airworthiness Responsibility
• Air carrier/operator
• Responsible
• Maintenance/alterations of aircraft
• Ops specs for each model aircraft
• Adhere to FAA approved maintenance program
• Must follow their policies/procedures/regulatory
• Changes
• Approved by FAA
• Maintenance completed by
• Carrier
• Another carrier
• Third party maintenance organization
Airworthiness Responsibility
• Operating airline
• Responsible for
• Ensuring work completed to their
• Maintenance schedule
• Standards
• Requirements
• Airline’s regulatory authority requirements
Air Carrier Maintenance Manual
• Expansion of manufacturer’s manuals
• All-inclusive expression of maintenance plan
• Manuals guide maintenance program
• Administrative policies and procedures
• Administration management and accomplishment
• Audit/inspection
• Flight/ground events
• Severe turbulence
• Hard landings
• Overweight landings
• Manual identifies
• Types of inspections
• Maintenance processes
 Maintenance Organization
• FAA requires organization
• Perform
• Supervise
• Manage
• Amend
• Manage/guide personnel
• Provide direction necessary to achieve
program objectives
 Maintenance Organization
• Essential elements
• Director of Maintenance (DOM)
• Responsible for overall maintenance
• Have current FAA A&P rating
• Chief inspector
• Maintenance duties/responsibilities
• Current functions at site
• Names
• Aircraft
• Ensure after maintenance service
• Airworthy
• Properly maintained
• Highest degree of safety
 Maintenance Organization
• Essential elements
• Maintenance personnel
• Current/qualified
• Sufficient experience
• Delegate
• Manage
• Control
• Highest degree of safety
• RII inspections
• Separate from routine/daily inspections
• Management activities
• All functions are being accomplished
• Program remains effective
 Manufacturer Record Keeping
• Manufacturer
• Aircraft built to type certificate
• Airworthy condition at delivery
 Manufacturer Record Keeping
• Airline
• Keep aircraft in airworthy condition
• Accurate records of maintenance/alterations
• Summary/airworthiness status information
• Logbook
• Maintained in aircraft
• Flight information
• Flight times, fuel/oil uplift, crew data
• Crew can identify maintenance related problems
• Corrective action/aircraft release
• Mechanical reliability report (MRR)
• Mechanical interruption summary (MIS)
• Reports of major alterations/repairs
 Maintenance Program
• Instructions
• Conducting maintenance on aircraft
• Specific maintenance
• Engines
• Propellers
• Parts
• Appliances
• Scheduled maintenance
• Tasks according to time limitations
• Unscheduled maintenance
• Follow
• Procedures
• Instructions
• Maintenance standards
 Maintenance Program
• Instructions
• RII
• “Those items which could result in unsafe
operation of the aircraft
• “If maintenance is not performed correctly or if
improper parts are used”
• Propellers
• Parts
• Appliances
• FAA does not specify
• Airline required to identify their own unique items
• Identify names of qualified/authorized personnel
 Manufacturer Schedule
• Maintenance Task Schedules
• What maintenance to be accomplished
• Time limitations
• How to accomplish
• When/how often to accomplish
• Airlines
• Organize individual tasks into scheduled work
packages
• Comply with their needs
• Input from MRB report
• Tasks divided into groups
• Flight hours/cycles
• Calendar items
• Programs vary from airline to airline
 RII
• Related to flight safety/airworthiness
• Must be identified in manuals
• Identify RII procedures
• RII authorization
• Requirement on
• Job cards
• Work forms
• Engineering orders
 Contract Maintenance
• Complies with Part 121/135
• Airline responsible for
• Providing proper training to contractors
• Airline policies/procedures
• Clear authority
• Responsibility
• Direction
• Contractor maintenance personnel
• Skills
• Facilities
• Knowledge of airline’s manuals
• On-site audit
• Inspection of facilities/equipment
• Competent personnel
 Contract Maintenance
• Maintenance options
• Other airline
• Repair station
• Third-party maintenance organization
 Personnel Training
• Initial training
• Indoctrination
• Company orientation
• Policies/procedures
• Courses
• Aircraft systems
• Ground equipment
• Hazardous materials training
• Airlines
• Validate AMT’s skills through testing
• Provide recurrent training
• Specialized training
• Changes to equipment, procedures,regulations
 CASS
• Quality Assurance Program
• Detect/correct program deficiencies
• Surveillance
• Analysis
• Data collection
• Corrective action
• Problem areas
• Tracks effectiveness
• Disconnect power
• Tie up loose cables for removed equipment
 CASS
• System requires
• Audits
• Trends analysis
• Self-reporting
• Analysis of effectiveness
• Identifying deficiencies
• Safety management
• Risk management
• Investigation analysis
• Corrective action/follow-ups
 Additional Documentation
• Engineering
• Establish initial maintenance program
• Continually upgrade
• Technical assistance
• Troubleshooting
• Workable maintenance processes/procedures
• Review manufacturer’s service bulletins
• Other maintenance tips, changes, suggestions
• Engineering expertise
 Additional Documentation
• Materials
• Part and supplies
• Purchase/warehousing
• Tools
• Issuance of parts
• Handling of warranty claims
• Planning
• Scheduled maintenance activities
• Manpower
• Facilities
• Supplies
• Collects data on time, manpower, facilities used
 Additional Documentation
• Maintenance Control Center
• Keep track of all vehicles in operation
• Location
• Maintenance/servicing needs
• Other requirements
• Minimize delays/down time
• Dispatches personnel for support
 Additional Documentation
• Training
• Records of all training
• Engineers
• Supervisors
• Managers
• Inspectors
• Type of training
• Initial
• Recurrent
• New skills
• Processes/procedures
 Additional Documentation
• Computing
• Provides
• equipment
• Software
• Support
• Programs
• Parts tracking/control
• Collecting/manipulating reliability data
• Data collection on malfunctions
 Additional Documentation
• Publications
• All technical publications
• Up-to-date
• Paper
• Microfilm
• Electronic media
• Distribution