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8/3/2019 Maint Philsp n Devlp Progr
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Agus Supriyanto
GATC , 17 – 18 November 2011
BATK Training
Maintenance Philosophy
and
Maintenance Program Development
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Definition
Philosophy
A set of ideas or beliefs relating to a particular field or activ ity.
Maintenance
The process (includes inspection, servicing, overhaul, repair, preservation, and
replacement) of ensuring that a system continually performs its intended functionat its designed in level of reliability and safety. It includes corrective maintenance
and preventive maintenance.
Maintenance Program
Program which define logical sequence of maintenance action to be performed as
even or pieces of whole which w hen performed collectively result in achievement of the desired Maintenance Standard. It is compiled of individual maintenance and
inspections functions util ized by an operator to fulfi l l its total maintenance needs.
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The Bathtub Curve as naturecharacteristic of equipments
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Maintenance shall be implemented toachieve Inherent Reliability
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Objectives of Maintenance Program
To ensure realization of the inherent safety and reliability
levels of the equipment.
To restore safety and reliability to their inherent levels when
deterioration has occurred.
To obtain the information necessary for design improvement
of those items whose inherent reliability proves inadequate.
To accomplish these goals at a minimum tota l cost, including
maintenance costs and the costs of resulting failures.
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FAR 121 that related to maintenance
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Manufacturer, Authority and Operator onMaintenance Program development
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Factor Influencing Aircraft Cost
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Aircraft cost of ownership breakdown
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Generally, Prevention Cost and Correction Cost are inverserly to each other.
Generally, Maintenance Cost is sum of Prevention Cost and Correction Cost.
Using Reliability Control Program, Maintenance Cost is adjusted to Minimum.
Maintenance Cost versus Reliability
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Maintenance Program DevelopmentHistory
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MSG Program has applied on the most oflatest aircraft types
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Aircraft Design Philosophy
Safe LifeSafe Life Fail SaveFail Save Damage TolerantDamage Tolerant
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MSG-2 Decision Tree Diagram
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1. HARD TIME
This is a primary maintenance process under which an item is removed
from service for discarded or recondition or heavy maintenance or bench
check before a previously specified time. (Safe Life)
2. ON CONDITION MAINTENANCEThis is a primary maintenance process having repetitive inspection or testto determine the condition of the item or system and to provide areasonable assurance that the item or system w ill survive to the nextschedule inspection or test. (Damage Tolerant)
3. CONDITION MONITORING MAINTENANCEData on the population of Maintenance Significant Items of system inservice is analyzed to determine Maintenance Requirement. ConditionMonitored allows failure to occurred and relies upon analysis of operatingexperience to indicate the need for appropriate action. (Fail Save)
MSG-2 Process Oriented Maintenance
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Hard Time
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C
o n d i t i o n
Time
Point where ithas failed
(functionalfailure)
Point Where failureis detectable
(potential failure)
Point wherefailure start to
occur
Scheduledinspection ortest interval
On Condition
Potential failure : Point wherefunctional failure is imm inent.
Functional failure : Point where thesystem does not longer fulfill itsminimum required performance
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FOR EXAMPLE , THE AIRCRAFT COMPONENT HAS 10 FLIGHT CYCLES LIFE TIME
MOST OF THE AIRCRAFT COMPONENTS LIFE TIME ARE MORE THAN 10.000 FLIGHT CYCLES.
Condition Monitoring
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Area inspection required by
CPCP C53-202-01 at interval
F:12Y R:6Y
Area inspection required by
SI S53-03-A at interval
24,000 FH
MSG-2 Structure Inspection Redundancy
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MSG-2 weakness
1. MSG-2 does not treat hidden functional failures adequately (this is even more
critical in today’s “electronic” aircraft where many redundant systems are
“hidden”).
2. MSG-2 logic needs to be more rigorous. A user can determine w hat he/ she want s
to be done to a component and work the logic so that that outcome is
generated. Emotion is not precluded from the decision making process.3. MSG-2 does not address current FAA regulations, e.g. FAR 25.571 (damage
tolerance and fatigue evaluation of structures), aging aircraft concerns,
Corrosion Prevention and Control Program (CPCP) requirements, Enhanced
Zonal Analysis Procedures (EZAP) that specifically address w iring concerns and
promotes a “clean as you go” culture or analysis for Lightning/High Intensity
Radiated Field (HIRF) tasks and intervals.
4. MSG-2 does not provides a strong and well tested analytical logic which helps
eliminate and minimize emotion from the decision making process of
determining if a maintenance task is needed or not.
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Top down approach resulting in less task .
Integration CPCP and Structural Inspection eliminate
redundancy.
Task oriented avoid confusing task to be done.
Clear differentiate safety task and economical task .
Promoted by FAA.
Significantly impact to economical return by 30 % in
reducing man-hour usage and reduce A/ C ground time for
routine maintenance.
MSG-3 is better
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MSG-3 results in over 20 % reduction inman-hours compare to MSG-2 (B737-C)
Zonal tasks
202 items
Structure tasks
166 tasks
System tasks
627 items
MSG-2 Maintenance Program (Total 1,657 Task Cards / 12,452 Man-hours*)
MSG-3 Maintenance Program (Total 994 Task Cards / 9,423 Man-hours*)
MSG-3 Analysis & Optimization
CPCP tasks101 items
Structure tasks150 items
System tasks1,114 items
ComponentMaintenance
292 items
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MSG-3 analysis form
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MSG-3 Analysis Flow 1
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MSG-3 Analysis Flow 2
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MSG-3 Analysis Flow 3
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MSG-3 Analysis Flow 4
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MSG-3 Analysis Flow 5
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MSG-3 Analysis Flow 5 (cont’)
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MSG-3 Logic Diagram (Level 1 analysis)
5 6 7 8 9
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MSG-3 Logic Diagram (Level 2 analysis)
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MSG-3 Task selection criteria
EFFECTIVENESS CRITERIA(based on consequences of item's failure)
TASKAPPLICABILITY CRITERIA
(based on item's failurecharacteristics) SAFETY OPERATIONAL NON-SAFETY
LUBRICATIONor SERVICING
(LU or SV)
The replenishment of the consumablesmust reduce the rate of functionaldeterioration.
The task must reduce therisks of failure.
The task must reduce therisks of failure to anacceptable level.
The task must be cost-effective.
OPERATIONALor VISUAL
CHECK
(OP or VC)
Identification of failures must bepossible.
The task must ensureadequate availability of thehidden function to reducethe risks of a multiplefailures.
Not applicable.
The task must ensureadequate availability of thehidden functions in order toavoid adverse economic
effects of multiple failuresand must be cost effective.
INSPECTION orFUNCTIONAL
CHECK(IN or FC)
Reduced resistance to failures mustbe detectable, and there exists areasonably consistent intervalbetween a deteriorated condition andfunctional failure.
The task must reduce therisks of failure to assuresafe operation
The task must reduce therisks of failure to anacceptable level.
The task must be cost-effective, i.e.; the cost ofthe task must be less thanthe cost of the failuresprevented.
RESTORATION(RS)
The item must show functionaldegradation characteristics at anidentifiable age and a large proportion ofunits must survive to that age. It must
be possible to restore the item to aspecific standard of failure resistance.
The task must reduce therisk of failures to assure
safe operation
The task must reduce therisks of failure to an
acceptable level.
The task must be cost-effective, i.e.; the cost ofthe tasks must be less than
the cost of the failuresprevented.
DISCARD(DS)
The item must show functionaldegradation characteristics at anidentifiable age and on a large proportionof units are expected survive to that age.
A safe-life limit mustreduce the risks of failureto assure safe operation
The task must reduce therisks of failure to anacceptable level.
An economic life limit mustbe cost-effective, i.e.; thecost of the task must beless than the cost of thefailures prevented.
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Maintenance interval determination(aircraft component)
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Maintenance interval determination(aircraft system)
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Maintenance Reference
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Format of Garuda’s CAMP (using MSG-3)
Unique identifier of
the item to bemaintained
Maintenance actionto be done at
regular time
Maintenanceinterval
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Maintenance Review Board Report
1. Affectivity2. Issue date3. Revised Item
4. etc
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Maintenance Planning Data (CMR)
1. Affectivity2. Issue date3. Revised Item
4. etc
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Maintenance Planning Data (CPCP)
1. Affectivity2. Issue date3. Revised Item
4. etc
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Airworthiness Directive
1. Affectivity2. Issue date3. Due date
4. Subject5. Content and task
6. Implementation reference7. etc
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Engineering Order
1. Affectivity2. Mandatory or not3. Issue date
4. Due date5. Subject
6. Content and task7. Work load / man-hour8. Required feed back9. Implementation reference10.etc
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Job Card
1. Affectivity2. Mandatory or not3. Issue date
4. Subject5. Content and task
6. Work load / man-hour7. Implementation reference8. etc
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Maintenance Discrepancy & Rectification
1. Affectivity2. Issue date3. Subject
4. Content and task5. Work load / man-hour
6. Required material7. Implementation reference8. etc
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Evaluate the source(basic of CAMP) orAnalyze The Dirty
Recordsby Engineers (TEA-TER)
Filter The DirtyRecords
by Engineer (TER-2)Insert The Dirty
Recordsby Data Loader (TER-2)
Make and PlanJobcards
by Planner (TLP-1)
Excecutionthe Jobcards
by Mechanics (TL/TB)
Issue orUpdate the CAMP Doc.
by Engineer (TER-2)
Store The DirtyRecords
by Planner (TLP-3)
Presented the Draft ofCAMP to DGCA for
Appropalby Engineer (MQ)
Distibutethe CAMP Doc.by staff (TER-4)
Garuda’s CAMP Close Loop
MRB Document
CMR Document ALI DocumentCPCP DocumentSSID DocumentRepair DocumentExisting ADService BulletinService LetterOperator’s Experience
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Environmental
Factor
Care about : lighting, noise, temperature, aroma,
weather, time, ergonomic of equipment, availability of
appliance, space lay out, and handling.
Physical Factor Care about the limitation of : five human senses, brain
capacity, sensation center, think center, muscle
strength, boring conditi on, and fatigue.Psychological
Social Factor
Care about the worse condition of : mind function,
among humans communication, human and machine
communication, conflict, and stress.
Knowledge,
Skill, and Attitude
Understanding of theory by course, study, and training.
Work experience by benchmarking, on the job training,and work practicing.
Enthusiastic for new information, new know ledge, and
new technology.
Human Factor that shall be consideredduring maintenance implementation
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Summary
1. Maintenance shall be implemented to achieve Inherent Reliability.
2. Manufacturer, Authority and Operator are close involved on
Maintenance Program development.
3. Maintenance Cost shall be considered during Maintenance
Program development.
4. Human Factor shall be considered during Maintenance Program
implementation.
5. Garuda Indonesia has experienced to develop Maintenance
Program refer to MSG-2 (DC-10, B747-200 and B737-Clasic) as
well as Maintenance Program refer to MSG-3 (MD-11, B747-400,
B737-NG, A330-200/300 and A320).