AIRCRAFT MAINTENANCE MANAGEMENT

Course By NUR RACHMAT, DIPL. ING

(PROGRAM STUDI TEKNIK AERONAUTIKA POLITEKNIK NEGERI BANDUNG)

AIRCRAFT MAINTENANCE MANAGEMENT

Session 2. MAINTENANCE REGULATION

BACKGROUND (1)
Aviation is one of the most heavily regulated industries today. This stems from the very nature of this type of transportation system, which tends to be very unforgiving of any shortcoming. As a result, the traveling public has looked to government to ensure that a safe and reliable service is provided. While the industry was developing in the early years of the last century, regulations were progressively put into place relating to design standards, maintenance requirements, and operations. Much of this regulation was driven by lesson learned from experience. Unfortunately, much of this experience manifested itself as catastrophic accident. It has been the mandate of the government and its regulatory authority to investigate all accidents and ensure any necessary corrective action is put into place. This includes not only current design and operating airplanes but also regulatory requirements for new design.

BACKGROUND (2)
This process has developed at a national level in all countries that manufacture airplanes or operate significantly sized commercial airplane fleets. These national requirements tend to be very similar in nature since the sources for the requirements are mainly the same and there has been considerable cooperation between the regulatory authorities. In addition, the U.S. Federal Aviation Regulation (FARs) has been used as a basis for regulation for many countries. Some countries have actually adopted the FARs. Other countries with fewer resources have negotiated with larger countries to provide regulatory oversight.

BACKGROUND (3)
International airplane travel has forced countries to recognize each others requirements and to provide the stimulus for harmonization. This is very evident in Europe, where the majority of regulatory authorities have formed a Joint Airworthiness Authority (JAA). At present 20 countries are full members of the JAA and a further 12 are candidate members. The objective is to develop and adopt Joint Aviation Requirements (JARs) in the fields of aircraft design and manufacture, aircraft operations and maintenance, and the licensing of aviation personnel. The JAA establishes procedures for joint certification of products and services and, where it is considered appropriate, performs joint certification.

BACKGROUND (4)
Since 1947, the International Civil Aviation Organization (ICAO) has existed as a specialized agency of the United Nations. The ICAO is not a regulatory body, but contracting states collaborate to secure the highest practicable degree of uniformity in regulations, standards, procedures, and licensing. These international standards are adopted as annexes to the ICAO Convention. From a maintenance perspective, the following are relevant:
Annex Annex Annex Annex 1, Personnel Licensing 6, Operation of Aircraft 8, Airworthiness of Aircraft 13, Aircraft Accident Inquiry

BACKGROUND (5)
Harmonization of requirements and the ICAO Convention enable regulatory authorities to accept the airworthiness of airplanes flying in from other states, including both standards and workmanship. This has facilitated not only the international operations but also airplane marketing, sales, and leases throughout the world.

FEDERAL AVIATION REGULATIONS (FAR)

Since the processes that have been established worldwide are similar to or based on the U.S. model, the remainder of this part will describe how the FARs impact on maintenance. The U.S. Congress established that the promotion of aviation safety and the development if civil aeronautics were in the public interest. As a result, the Federal Aviation Administration (FAA) was created as the regulatory authority to set up procedures and standards for the design, manufacture, and operation of airplanes. The standards for design and operation are issued as regulations. These can apply to both manufacturers and operators. Approvals by the regulatory authority showing compliance with these standards are shown by means of certificates. The FAA issues its standards through the Federal Aviation Regulations. The Code of Federal Regulations Title 14, Chapter I, Parts 1 through 199.

FEDERAL AVIATION REGULATIONS (FAR)

The major Parts from chapter I of the Code that have an impact on Maintenance are as follows: FAR Part 21, Certification Procedures for Product and Parts FAR Part 25, Airworthiness Standards: Transport Category Airplanes FAR Part 33, Aircraft Engines FAR Part 34, Fuel Venting and Exhaust Emission FAR Part 36, Noise Standards FAR Part 39, Airworthiness Directives FAR Part 43, Maintenance, Preventive Maintenance, Rebuilding and alteration FAR Part 121, Certification and Operations FAR Part 129, Foreign Air Carriers and Foreign Operators of US - Registered Aircraft FAR Part 135, Air Taxi Operators and Commercial Operators

FEDERAL AVIATION REGULATIONS (FAR)

Parts 25, 33, 34, and 36 contain the design standards that are aided as the basis of certification. Parts 39, 43, 121, 129, and 135 are applicable to operating airplanes. FAR Part 21 specifies the Certification Procedures for Products and Parts. This FAR contains the general certification under which the FAA approves a design and a manufacturer may subsequently produce a product. The subparts covering each certificate are as follows: Parts 21B, Type Certificate Parts 21E, Supplemental Type Certificate Parts 21G, Production Certificate Parts 21H, Airworthiness Certificate Parts 21K, Part Manufacture approval Parts 21O, Technical Standard Order

FEDERAL AVIATION REGULATIONS (FAR)

Standards for safety in Design are contained in Part 25, which prescribes the airworthiness standards for the issue of type certificates, and changes to the certified design are covered by Part 39, Airworthiness Directives, which prescribes inspections and conditions and limitations associated with certified aeronautical products that affect safety. Part 25.1529 (Appendix H) contains the requirement for Instructing for Continued Airworthiness. This means that a manufacturer must support a new design by Maintenance Manuals including an approved Maintenance Program.

FEDERAL AVIATION REGULATIONS (FAR)

The standards in the FARs that relate to how an operator must perform maintenance are found in part 43 and Part 121. Part 43, Maintenance, Preventive Maintenance, Rebuilding and Alteration, requires that methods. Techniques and practices acceptable to the administrator are used for inspection and repair of civil aircraft. Part 121, Certification and Operations-Domestic, Flag and Supplemental Air Carriers and Commercial Operators of Large Aircraft, governs the operations of most U.S. carriers engaged in air transportation. Other Parts address commuter, air taxi, agricultural, and foreign operators. Part 121, Subparts L, Maintenance, Preventive Maintenance and Alterations, includes Parts 121.361 through 121.380a.

FEDERAL AVIATION REGULATIONS (FAR)

The significant Parts of Subpart L are detailed as follows: Part 121.365, Maintenance, preventive maintenance and alteration organization, requires a certificate holder to have an adequate maintenance and inspection organization. Part 121.367, Maintenance, preventive maintenance and alterations programs, requires a certificate holder to have a program to ensure maintenance is performed in accordance with the manual by competent personnel using adequate facilities and equipment and that each aircraft released to service is airworthy. Part 121.380, Maintenance recording requirements, requires a certificate holder to keep records of airworthiness releases and current status of all maintenance items and life limits, including airworthiness directives. Part 121.379, Authority to perform and approve maintenance, preventative maintenance and alterations, requires certificate holders to use approved data for major repairs and alterations. Part 121.703, Mechanical Reliability Report, requires a certificate holder to report to the FAA the occurrence or detection of failures, malfunctions, or defects. Part 121.705, Mechanical Interruption Report, requires a certificate holder to provide to the FAA a summary report of certain occurrences, such as flight interruptions and premature engine removals. Part 121.373, Continuing Analysis and Surveillance Program, requires a certificate holder to establish and maintain a system for the continuing analysis and surveillance of the performance and effectiveness of its maintenance program.

Advisory Circulars (ACs)

The FAA issues Advisory Circulars (ACs) to inform the aviation public in a systematic way of non regulatory material providing guidance, policy, and information. These ACs provide a generally accepted means, but not only means, of compliance with the FARs. Operators can deviate from an AC with the consent of FAA. A master Index lists all effective ACs. There are several Advisory Circulars that have an impact on Maintenance Programs, as follows: AC 120-16C, Continuous Airworthiness Maintenance Programs, provides information and guidance on continuous airworthiness maintenance programs which gives the airline the privilege and responsibility for aircraft maintenance. There are five elements of an airworthiness maintenance program: Responsibility for airworthiness Maintenance and inspection organization Performance and approval of maintenance and alterations Arrangements for maintenance and alterations Continuous analysis and surveillance

Advisory Circulars (ACs)

AC 25-19, Certification Maintenance Requirements, provide guidance on the selection and documentation and control of certification maintenance requirements. AC 43-9C, Maintenance Records, describes methods, procedures and practices determined to be acceptable for showing compliance with the general aviation maintenance record making and record-keeping requirements of Parts 43 and 91. This material is issues for guidance and outlines several methods of compliance with the regulations. AC43-12A, Preventive Maintenance, provides information concerning preventive maintenance, which may perform it, the standards of performance applicable to it, authority for approving aircraft for return to service, and the applicable recording requirements.

Advisory Circulars (ACs)

AC 43.13-1B, Acceptable methods, Techniques and PracticesAircraft Inspection and repair, contains methods, techniques, and practices acceptable to the Administrator for inspection and repair of no pressurized areas of civil aircraft only when there are no manufacturer repair or maintenance instructions. This is a good general source of information used by maintenance to satisfy FAR part 43. This FAR part 43 identifies the documentation required (sign-off) to return an aircraft back to service and also defines what is a major and minor repair or alteration. AC 120-17A, Maintenance Control by Reliability Methods, provides information and guidance materials which may be used to design or develop maintenance reliability programs utilizing reliability control methods. This will satisfy the FAR Part 121.373 requirement for each certificate holder to establish and maintain a system for the continuing analysis and surveillance of the performance and effectiveness of its maintenance program. AC 120-42A, Extended Range Operation with Two-Engine Airplanes (ETOPS), states an acceptable means, but not the only means, for obtaining approval under FAR Section 121.161 for two-engine airplanes to operate over a route that contains a point farther than one hour flying time at the normal one-engine inoperative cruise speed from an adequate airport.

Advisory Circulars (ACs)

AC 121-1A, Standards Operations Specifications Aircraft Maintenance Handbook, provides procedures acceptable to the FAA that may be used by operators when establishing inspection intervals and overhaul times. AC 121-22A, Maintenance Review Board, provides guidelines that may be used by industry during the development and revision of the initial minimum scheduled maintenance/inspection requirements for derivative or newly type certificated transport category aircraft and power plants for submittal to the FAA for approval. These initial minimum scheduled maintenance/inspection requirements are referred to in this AC as the maintenance Review Board Report (MRBR). The requirements, after approval by the FAA become the framework around which each air carrier develops its own individual maintenance program and which the manufacturer uses in the manuals to satisfy the requirement for instructions for continuing airworthiness. AC 129-4, Maintenance Program for Foreign Operators of USRegistered Aircraft under FAR Part 129, provides information and guidance about acceptable maintenance programs for U.S.registered aircraft subject to FAR Part 129.

Advisory Circulars (ACs)

Operation specifications are based on FAR Part 121.25. FAA regulations require that specific operational authorization and limitations applicable to an air operator certificate be issued in conjunction with the issues of the air operations specifications. These are to supplement the general requirements of the basic certificate and to list authorizations and limitations not specifically covered by other FAA regulations. Part 121.25 lists the contents of the operating certificate and operations specification. The operations specification documents the complete maintenance program for the operator. This combined issuance of the air operator certificate and the operations specification constitute the FAA approval of the unique airline operation.

Variable affecting carrier operations are:

Aircraft types Operating environment Operator capability Level of experience Facilities Organizational structure

FEDERAL AVIATION REGULATIONS (FAR)

Manufacturers and operators are required to report certain types of service problems in accordance with FAR Parts 21.3, Reporting of failures, malfunctions, and defects, 121.703, and 135.415, Service Difficulty Reports. The FAA, if it determines that a reported services problem constitutes an unsafe condition, can mandate corrective action. This mandatory corrective action is accomplished by issuing an airworthiness directive. Airworthiness directives are rules and must be complied with 21 to develop any service instructions (inspections, repairs, or modifications) that are necessary and that will be approved by the FAA. In the United State, an airworthiness directive is the only means by which owners and operators (airlines) can be forced to accomplish a manufacturer service bulletin. Airworthiness directives are the end result of the Continued Airworthiness Program performed by the FAA.

FAA CERTIFICATION
The FAA Aircraft Certification Office (ACO) evaluates design for compliance with regulations and special conditions and issues design approvals by type certificate (TC), supplemental type certificate (STC), technical standards orders (TSO), and engineering approvals for parts manufacturing and repairs (see Figure 18.7. the ACO monitors service difficulties reporting and ensures continued airworthiness by issuing airworthiness directives. This office has the prime responsibility for proposing the need for regulation change.

FIGURE 18.7 Federal aviation airworthiness and carrier

FAA CERTIFICATION
The FAA Manufacturing Inspection District Office (MIDO) approves and surveys production approvals by issuing production certificates and part manufacturing approvals and confirming first article products and witnessing tests. MIDO issues airworthiness and export certificates. The FAA Aircraft Evaluation Group (AEG) provides coordination between certification and flight standards. In particular, the AEG manages the Maintenance Review Board (MRB) for the FAA and provides the communications link between the Flight Standards District Office (FSDO), the Principal Maintenance Inspectors (PMI), the Principal Operations Inspectors (POI), and the Aircraft Certification Office (ACO).

FAA CERTIFICATION
An aeronautical product must conform to its type design, supplemental type design, and any applicable airworthiness directives and be in a condition for safe operation. The word airworthiness is used throughout the regulations without being define. A clear understanding of its meaning is essential. Two conditions must be met for an airplane to be considered airworthy: An aeronautical product is airworthiness when it conforms to the regulations under which it has been certified. This means that the product has to comply with the documentation that demonstrates that the design meets the regulations. This documentation has been submitted to the FAA as the basis for certification approval. The airplane configuration and the components installed must be consistent with the drawings, specifications, and other data that are part of the type certificate. An aeronautical product must conform to its type design, supplemental type design, and any applicable airworthiness directives, and be in a condition for safe operation. This means that an airplane continues to be airworthy when it continues to meet the design (or approved design changes) and is being inspected in accordance with, and meeting the requirements of, the approved manuals. The condition for safe operation refers to the condition of the airplane relative to wear and deterioration.

The manufacturer requires three certificates: (1)

Regulatory approvals of airplane certification are shown by means of certificates. These certificates cover the manufacture and delivery if each airplane. The airplane requires three certificates: The Type Certificate (FAR 21 Subpart B) is issued by the FAA Aircraft Certification Office (ACO) to approve each specific airplane type design as conforming to the Airworthiness Standards.
Type certification requires that the configuration and features of the type design comply with the requirement of the FARs that is applicable. This compliance must be substantiated by test or analysis and presented as documentation to support the type approval application. It establishes the airworthiness of the design by showing conformity to the basis of certification. The basis of certification (FAR PART 25, 33, 34, and 36) includes: Configuration and features of the product Structural strength of the product (dimensions, materials, and processes) Life limits, airworthiness limitations, and certification maintenance requirements Operating limitation in the Airplane Flight Manual (noise, fuel, venting, and exhaust emissions)

The manufacturer requires three certificates: (2)

The fatigue evaluation if structure required by Part 25.571 for certification can result in mandatory maintenance requirements. These can take the form of life limits for the safe life structure and supplemental fatigue-related inspections (airworthiness limitations, AWL) for the principal structural elements for which the baseline inspection program does not satisfy the damage tolerance requirements. System design and analysis required by Part 25.1309 for certification can result in mandatory maintenance requirements. Now days design certification is much dependent on reliability substantiation by analysis and, where necessary, by appropriate ground, flight, or simulation tests. Failures are classified according to their severity, that is, the failure effect on the airplane and its occupants, both direct and consequential. To demonstrate analytically that catastrophic and hazardous events will be extremely improbable or remote, a requirement for maintenance then becomes mandatory as part of certification and is known as a certification maintenance requirements (CMR). The production certificate (FAR 21 Subpart G) is issued by FAA Manufacturing Inspection District Office to the manufacturer as approval pf the manufacturing and quality system for building airplanes. It certifies that the manufacturer has established and can maintain a quality control system so that each product will meet the design provision of the pertinent type certificate. To obtain a production certificate, it is necessary that a manufacturer satisfy a FAA inspection that there are adequate facilities, quality control procedures and a drawing system that will enable manufacture of repeat airplanes that conform to the type certificate requirement. The production certificate shows that the manufacturer has approved facilities and approved quality control procedures to meet the design provision of the type certificate. The production certificate authorizes the manufacturer to produce the particular type airplane.

The manufacturer requires three certificates: (3)

The airworthiness certificate (FAR 21 subpart H) issued by FAA manufacturing inspection district office as approval to deliver and operate an airplane that has been built and tested in compliance with production and type certification. It certifies that, as of the date of issuance, the aircraft to which the certificate has been issued has been inspected and found to conform to its type certificate and to be in a condition for safe operation. Note that this certificate is also used by the operator. With a type approval certificate and a production certificate, a manufacturer is authorized to produce airplanes and apply for an airworthiness certificate for each copy to show that it conforms to the type design and is in a condition for safe operation. The airworthiness certificate confirms that the aircraft is airworthy, that is, conforms to its type certificate, and is in a condition for safe operation. As long as the airworthiness certificate remains valid, it permits the operation of the airplane within the limitations and conditions provided.

The operator requires two certificates:

1. The airworthiness certificate (FAR 21 Subpart H) is issued by the FAA Manufacturing Inspection District Office.
This Certificate was originally issued to the manufacturer and remains valid as long as the airplane is being maintained and inspected in accordance with the requirements of the approved manuals and regulations.

2. The operating certificate (FAR 121) is issued by the FAA Flight Standards District Office (FSDO).
This is the approval that a carrier meets the requirements for the operation for which he has applied and may operate while those conditions apply. It authorizes an air carrier to engage in scheduled air transportation.

Summary
The airline must define the type of operation, the airplane type operated, the operating environment, and the operator capability. The Operations Specification matches Part 121 to the unique operation of the airline and documents the complete maintenance program for the operator. It is necessary for maintenance organizations to be cognizant of applicable national and international regulations. Failure to comply can result in disruption to operations and degradation in safety. This description of regulation and certification procedures demonstrates the complexity and extent of the necessary regulation. These or similar requirements are in use throughout world and are in place to promote aviation safety.

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