Aircraft Maintenance
Management Module
Maintenance & Engineering
Gen Organization Structure
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Maintenance & Repair (MRO)
Organisation Structure
 Maintenance & Repair (MRO) Organisation efficient
Structure will vary according to the size and type of the
airline(organisation) and management philosophy of the
Airline.
 The MRO structure must allow the airline to meet its
strategic goals/objectives
 The following is an example of what could be referred to
an efficient Engineering and Maintenance Organisation
structure(emirates case).
 In the next few slides and to the rest of this chapter, will
endeavour to review separately and in great detail each
business unit of this structure.
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 However before we go into details of these units,
we need to understand the hierarchy of the
maintenance and Engineering structure starting
from the EVP level and continue downward with
designators to DSVP, VP, Managers and
supervisors as appropriate. Emirates Airlines used
as test case example.
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Engineering Systems
 Emirates Engineering operates an organisation-wide,
standardised technical environment, which is managed and
maintained by the Engineering Systems section. It provides
information systems and enables function integration,
resource optimisation and improvements in technical
reliability to the Engineering department. Constant efforts
of improving these information systems will continue to
provide support to all engineering departments, which will
produce further benefits.
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Engineering Systems functions
 Business user solutions to support Business Process
Implementation, Integration and Information solutions to
carry out assigned roles in most efficient and effective
way.
 Enable safe, secure and efficient management of Business
Solutions, the section coordination with Emirates Group IT
to deliver hardware, software & Infrastructure Support for
smooth Business Operation.
 Engineering Systems support team is in continuous liaison
with Business Focal to ensure timely system support for
on-going systems and evaluating Induction of new
systems.
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QUALITY ASSURANCE
The Quality Assurance section monitors all technical and
technical support functions within the company to ensure that
they comply with engineering procedures and remain within
the scope of the Terms of Approval and requirements of the
GCAA as published.
Technical Resources Centre
a) The Technical Resources Centre holds and makes
available to personnel, a range of technical publications
appropriate to the class of work covered by the company
approval. It makes suitable arrangements to ensure these
documents are maintained at the latest state of amendment.
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UAE Quality Model- Emirates
 When it comes to Quality, Emirates Engineering prides
itself on having the highest possible standards. Which is
why the UAE GCAA, EASA 145, FAA 145 and ISO 9002
Quality Assurance is such a vital addition to Emirates
engineering activities, allowing monitoring and approving
of work as well as liaising between Emirates and foreign
airworthiness authorities for whose aircraft Emirates
Engineering undertakes maintenance. Emirates Engg is
approved by three airworthiness authorities - the UAE
General Civil Aviation Authority, the European Aviation
Safety Agency and USA Federal Aviation Authority, to
undertake aircraft maintenance.
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UAE QA Cont’d
 Additionally, Emirates Engineering holds ISO 9002
accreditation.
 At Emirates, a wide range of intensive technical training
programmes is provided covering the whole range of
engineering disciplines, including courses in type training,
servicing, procedures and systems - all backed up by
closely supervised on-the-job-training.
 The Emirates Engineering Training School holds both
GCAA and EASA 147 approval. Emirates in apprentice
training, carefully selected school leavers may
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UAE QA Cont’d
join the Company on a three and a half year apprenticeship,
approved by the General Civil Aviation Authority, which
includes workshop, on-the-job and classroom training and
leads to accreditation as a skilled aircraft mechanic. Fully
equipped to ICAO standards, Emirates extensive training
facilities include basic engineering, machine welding,
composites repair, airframe, engines and avionics workshops.
Graduates from the apprenticeship may then acquire an
Aircraft Maintenance Engineer's Licence and subsequent type
approvals.
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UAE QA Cont’d
 Approved aircraft type training is conducted on Airbus
A330, A340-300, A340-500, A380 and Boeing 777200/200ER/200LR/300/300ER and -200LRF variants plus
the B737NG aircraft.
 Courses on these aircraft are available in Airframe, Engine
and Electrical/Avionics trades that meet both EASA Part
66 level l, 2 and 3 and ATA 104 Level l, 2, 3 and 4
standards.
 Aircraft training utilities include advanced computer-based
training systems and Ground Based Maintenance Training
Devices for the A330, A340, B777 and A380 aircraft.
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BASE MAINTENANCE & WORKSHOPS
a) The function of the Base Maintenance section is to carry
out all routine scheduled maintenance tasks and any
unscheduled major repair, replacement and modifications on
company operated aircraft.
b) This will consist mainly of planned maintenance inputs
extracted from the applicable Approved Maintenance
Schedule including replacement of time expired equipment,
component repair, modifications and any specific inspections
which may be required as approved by the GCAA.
c) In support of this activity, various workshops are available
and will undertake component, structural and avionic
overhauls within the limits of the Terms of
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Approval
and Capability Aircraft
Lists
applicable
to them.
UAE Base Maint- Emirates
 Base Maintenance conducts all levels of scheduled and
unscheduled maintenance including major repairs,
replacements and modifications. Our fully qualified
personnel, with vast expertise in meeting critical dedicated
downtimes, provide the necessary support in maintaining
consistent reliability to the operation.
 All Heavy Maintenance work is located within a state-ofthe-art hangar complex, able to accommodate all widebodied aircraft through a fully computerised docking
system.
 Heavy Maintenance supports all levels of 'C' Checks,
major modification, aircraft redeliveries, inspection
on Airbus/Boeing
and major
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structural modifications on the Airbus fleet.
Line & Base Maintenance
 Whether at its home base in Dubai, or at one of the many
'outstations' served by the airline, Emirates Engineering
can provide line maintenance support to third party
airlines. Comprehensive engineering services are provided
and supported by sophisticated ground equipment,
specialist vehicles and high IV qualified engineers.
Dubai
 The Engineering Line Maintenance Department in Dubai
provides 24 hours support for all Emirates aircraft and
those of our customer airlines.
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Line Maintenance cont’d
 Engg teams of licensed engineers, recruited from“ around
the world, hold licences issued by several authorities,
including the GCAA, EASA and FAA, in airframe, engine
and avionics categories. This is supplemented by full
aircraft type training for all fleet types handled.
 In addition to the Emirates fleet of Boeing B777, Airbus
A330, A340 and A380 aircraft, we also provide services
supporting more than 30 customer airlines' aircraft,
including the B737NG, B747-400, A330 and A340.
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Maintenance Control Centre (MCC)
 MCC coordinates core departments and external handling
agencies to ensure prompt aircraft turnaround times, with
minimum technical delays using our state-of-the-art
systems.
 MCC plays a pivotal role in aircraft "on-ground
situations", requiring skilled and dynamic responses. MCC
is staffed 24 hours a day with dedicated senior engineers,
who liaise close with operational departments and flight
crew to help ensure Emirates operations run smoothly and
to minimise the impact of unscheduled
maintenance/technical delays.
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Base Operations & Outstations
 Base Operations Maintenance supports scheduled and
unscheduled maintenance activity, including service,
weekly and 'A' checks, to full casualty support to the
Emirates fleet. At all outstations, Line Maintenance selects
the most appropriate form of maintenance support from
several available options to suit our own needs and that of
our customers. For details on outstation capability, please
refer to the insert on the last page.
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Overhaul Workshops
 Emirates Engineering Overhaul Workshops are state of-
the-art facilities that offer an extensive range of services
and support for an ever-growing variety of aircraft,
including components for the A380, A330, A340-300/S00
and B777 series. The workshops are also capable of
offering other support services such as Non-Destructive
Testing (NDT), tool calibration and aircraft weighing.
With a wide variety of support services, competitive rates
and excellent turnaround times.
 Safety Workshop is designed to meet all safety equipment
requirements, including survival kits, life vests, stretchers
and oxygen masks and offers coverage on slides/rafts.
Hydrostatic Testing facility
for cylinders and gas bottles. 18
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Cabin Maint Workshop
 The latest addition to the Cabin Interiors Workshop this
year is a state-of-the-art cabin sidewall panel laminating
machine capable of covering all current wide and narrow
body aircraft sidewall panels, quickly and efficiently, in a
dedicated workshop area.
 Also recently installed is a fully automated aircraft carpetcutting machine. It operates from a drawing database and
cuts carpet to the required shape and quantities by simply
uploading drawings into the AutoCAD system and the
machine does the rest.
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Cabin Maintenance cont’d
The Cabin Workshops perform testing, repair, overhaul and
modifications of interior soft furnishings, seats and safety equipment
installed across the Emirates fleet to ensure the highest standards of
interior functionality and presentation is achieved. The Cabin
workshops comprise:
Evacuation and Safety Workshop - performs repair, overhaul and
modification of escape slides, slide/rafts, ramp and over-wing slides,
life jackets, baby-cots, fire extinguishers, oxygen masks, cockpit seats
of A310, A330, A340, A380, B777ER and ULR fleets.
Cabin General Workshop- performs repair, overhaul and modifications
of passenger seats, galleys, lavatories, carpets and general furnishing
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items
on the A330, A340,A380,
and ULR fleets
Avionics Workshop
 Avionics Workshop offers extensive cover for many of the
avionics component fitted throughout fleet. A large
dedicated Automatic Test Equipment Complex (ATEC)
machines available with level two repair capability along
with new ATEC Series 6 machine, which supports A380
aircraft rotable units. battery condition checks, oxygen
charging, software development, customised development
of Airshow system or even electrical and radio
components, this dynamic workshop is more than capable
of meeting all avionics maintenance requirements.
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Airframe workshop
 Our impressive Airframe Workshops are capable of
offering Non-Destructive Testing to level three
requirements with coverage for a wide variety of tests and
aircraft, including:
• Magnetic Particle testing
• Penetrant, Eddy Current and Ultrasonic testing
• Wheel and brake support for various fleet of Airbus/Boeing
Equipment
 Coverage on Honeywell, Goodrich and Messier Bugatti
wheels and brakes, electrical, pressure, torque, mass tools
and equipment. Extensive coverage and support on engine
Nacelle components
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• Structural, metallic and composite repairs
Emirates Engine Test Cell
 Emirates Engine Test Cell is the largest facility of its kind
in the Middle East and one of the most modern globally.
This state-of-the-art facility is built on a 24,000 square
metre site and includes an engine preparation area covering
3,250 square metres, dedicated to 6-engine work stations,
each served by a 30-tonne crane. The system is
interconnected by monorail with a bridge and turntable,
which links the preparation area to the test cell chamber,
making internal engine movement easier' to achieve.
 The Engine Test Cell has been built to prepare and test
engines with thrust levels of up to l50,000 ps of thrust, far
in excess of what manufacturers produce today or are
for or in the foreseeable
future.
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Test Cell cont’d
 The Test facility is certified by GCAA, EASA and FAA to
test a large spectrum of Jet Engines such as General
Electric GE90-11SB (B777), Engine Alliance GP7200
(A380), Rolls-Royce Trent 500 (A340-S00), Rolls-Royce
Trent 700 (A330) and Rolls-Royce Trent 800 (B777);
Auxiliary Power.
 Units (APU) Honeywell GTCP331-3S0 (A330/A340),
GTCP331-S00 (B777) and GTCP331-600 (A340-S00).
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Test Cell cont’d
 The APU Test Cell has been designed and built to test
different types of APU's including the APU installed on
the latest A380 Aircraft.
 With a capacity to test 300 engines and APU's per year efficient test centre was designed to meet all stringent
regulations for noise emissions and waste management, in
addition to all safe and environmental requirements.
 Emirates Engine Test Cell has set the standards of
excellence in the aero engine testing industry by working
in collaboration with the most Engine manufacturers, such
as Rolls-Royce, General Electric, Engine Alliance and
Honeywell to support Emirates ever-growing fleet and
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party requirements
within
Engineering Planning
The Planning Section identifies and plans the routine
maintenance program, remaining within the constraints of the
applicable Approved Maintenance Schedule and any other
applicable mandatory requirements.
Technical Records
a) The maintenance of a complete and comprehensive
technical record of each Company operated aircraft and
associated equipment in accordance with the requirements of
the GCAA and the relevant sections of engineering
procedures.
Reliability Support
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 Aircraft configuration management and control
Production of long and short-term maintenance plans
 Development and management of aircraft and component
maintenance schedules
 Reliability programme development and administration for
aircraft and components Technical records administration
and control
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Engineering Planning
 Engineering Planning provides comprehensive planning
and technical records services to the highest possible
standards, ensuring efficient scheduling, administration,
monitoring and control of maintenance activities using
fully integrated computer platforms to provide optimum
support.
 Engineering Planning service provides:
 Preparation of work scopes and the production of
Maintenance Task Operating Plans [MTOP], Maintenance
task cards, Job Instruction Cards [JIC] and Works
packages Aircraft and component modification planning
and control
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Production Planning
 Production Planning provides vital planning and support
services for Base Operations, Base Heavy Maintenance
and Workshops to carry out smooth and effective
maintenance/repair on the Emirates fleet; with an aim of
ensuring minimum aircraft ground time and in-house
component repair turnaround time
 highlights MQs and parts which have not yet issued to the
package, displays all tasks which have a status other than
in progress where user action might be required. Visibility
to captured man-hours and available vs. consumed
resources.
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Production planning cont’d
 Work Package management, flow of package tasks to
assign schedule date to tasks using typical resource
allocation and task estimated hours, manual Package Task
Scheduling is also available. Graphical visibility to task
schedule, duration, status and actual man-hours. Package
Monitor gives graphical visibility to the package progress.
 Pre-load Monitoring and Adjustment of where quantities
and due dates of MQs can be adjusted. Extensive views
and reports available for package progress management
and monitoring, pre-load material availability and
management, non-routine management and man-hours
monitoring.
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Modification Planning and
Control
 Modification Planning and Control is a primary component
of the Engineering team. IT is one of the core sections in
the Maintenance Planning department and has several roles
and responsibilities, but the main role is controlling and
planning of all modifications decided by Emirates to be
incorporated in its fleet and the component thereof in line
with the established and planned maintenance activities.
The primary purpose of incorporating Modification in the
aircraft maintenance cycle is to improve performance,
safety and reliability of aircraft, engine and components. It
is accomplished either by introduction of new/enhanced
component/system or by alteration of items already fitted
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 Modification Planning: Mods planning use mainframe
Mod Control module to record all SB's (Mods) that are
required to be carried out on an aircraft and or component.
 Materials required for the accomplishment of the Mods are
requested through Purchase requests. The forecasting,
planning and control of the modifications is achieved
through using the Maintenance Requirements module.
 The Mod Control System is also used for reporting the
mods accomplished and pending to the regulatory
authorities.
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Reliability Reviews
 a) Emirates Technical Services Engineers evaluate data
obtained through pilot reports (pireps), premature
component changes, strip reports, and various other
 relevant documents, and make recommendations as
necessary. A Reliability Engineer produces a monthly
statistics report.
 A.D., S.B., SIL and any other relevant documentation is
reviewed for its applicability to Emirates aircraft and
equipment.
 Emirates modification committee will review all ADs,
SBs, and SILs for their possible incorporation into
Emirates aircraft or equipment.
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Modifications not covered by the above, which are derived by
Emirates will be submitted to the UAE GCAA for
classification and approval.
LINE MAINTENANCE
The Line Maintenance section will carry out day to day
maintenance on the company aircraft and those of other
operators under contractual agreements.
The section liaise with operations and responds efficiently to
requirements as they arise while ensuring sufficient
serviceable aircraft are made available to satisfy the
companies operational requirement.
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Materials Management
The materials section supports the engineering production
effort by procuring such material as is necessary for that
purpose. While being mindful of cost, the section identifies
and utilizes sources of supply acceptable to the company and
the GCAA.
The section maintains a sufficient stock level to meet the
companies operational requirement and keeps a
comprehensive record of all stock movement
The section accepts, stores and reissues both aircraft and
commercial material.
The section segregates the aircraft and commercial stores and
further provides a quarantine and a bonded aircraft stores area
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April 2015 the airworthiness requirements.
IAW
Materials Management cont’d
 The Materials Management Department is responsible for
the spares supply chain strategy, policies and processes
and optimises inventory investment and operating costs for
the Emirates fleet.
 This includes forecasting, planning, procurement, storing,
usage monitoring, repairs, stock reviews, replenishment,
obsolescence and disposal of materials.
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Materials Management cont’d
 The Material Management section is responsible for the
development of policies, processes, procedures, systems and
organisation to optimise the inventory investment and operating
costs. This includes forecasting, procurement planning, storing,
usage, repairs, stock reviews, replenishment, obsolescence and
disposal of materials.
 Emirates Engineering has modern logistics facilities. Inward
aircraft material and equipment are thoroughly inspected to
ensure the highest quality and airworthiness standards and
thereafter, stored in fully air-conditioned and environmentally
controlled stock rooms. High-rise racking and semi-automatic
shuttle technologies are used to ensure efficient storage and
retrieval
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Materials Provisioning
 The Materials Provisioning teams are organised along
commodity lines; Cabin, IFE, BFE, Airframe and Engines.
They are supported by the Inventory Systems and
Operations support group.
 The section's prime responsibility is to establish optimum
re-order and safety levels, raise timely purchase requests
and coordinate availability of items. It is also responsible
for the entire inventory, including its data accuracy and
follows the highest standards of quality and safety policies
as defined by aviation agencies such as CAA, EASA, FAA
and ATA. One of its core functions is to provide on-site
 support for the critical/AOG requirements of all aircraft
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Component Management
 The Component Management section is divided into three
subsections: Component Repair, Material Planning and
Pooling, Loans and Borrowing, and deals with high value
rotable aircraft component assets.
 This includes initial-provisioning, re-provisioning and
optimising the inventory, as well as managing the repair
and pooling of assets. By adopting supply chain
management best practice, it maintains the highest quality
standards and service levels at the lowest possible cost,
end-to-end for the Rotable Assets.
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Component Management cont’d
 Component Management (CM) section deals with Rotable
parts and aircraft assets. This includes initial provisioning,
re-provisioning, optimising inventory, repair, overhaul,
refurbishment, pooling and purchasing of assets such that
the highest quality standards and service levels are
maintained at lowest possible cost by adopting supply
chain management best practice, performance metrics and
processes.
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Component Management cont’d
An accurate stock control and comprehensive records of stock
flow and an update of inventory is maintained by the
materials section.
In the event of spares being obtained from other airlines,
either as outright purchase, exchange or loan, the airline
spares transfer procedure will be used.
Only airlines nominated by the General Manager Quality
Assurance will be used, unless prior consent from the General
Manager Quality Assurance or his authorized
deputy is obtained.
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Component Management cont’d
The company approval granted by GCAA requires that a
provision is made for training personnel. This training will
comprise of aircraft type training, aircraft servicing, company
procedures and systems update training.
Aircraft type training in all disciplines will initially be carried
out by the aircraft manufacturer, terminating in an
examination which meets the approval of GCAA.
Emirates subsequently undertake to have additional staff who
require the same standard of course to be trained by Emirates
or a company approved by GCAA for that purpose.
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Component Management cont’d
Aircraft servicing courses designed to provide training for
contracted outstation personnel will be carried out at Emirates
by the contracted company training staff.
Company procedures training requirements will be identified
by the Emirate General Manager Quality Assurance and
carried out within the company.
Each course to be completed will require agreement by the
General Manager Quality Assurance and the UAE GCAA.
The time scale of OJT will depend upon the type of course,
available training facilities and content of course, and the
results of a Quality Assurance audit of the training facility.
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Warehousing and logistics
 Emirates Engineering has modern, state-of-the-art Stores
and Logistics facilities. Aircraft materials and equipment
are thorough IV inspected at receipt to ensure the highest
quality and airworthiness standards, then stored in fully
air-conditioned and environmentally controlled stock
rooms. High-rise racking and semi-automatic shuttle
technologies are used to ensure efficient storage and
retrieval.
 A spares supply service and AOG support is provided 24
hours a day in Dubai, as well as at Emirates outstations.
Being a member of the IATP, spares and equipment are
pooled at most stations.
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Engineering Projects
 Engineering Projects are experts in the evaluation,
recommendation, specification and negotiation of aircraft
acquisitions. The team monitors projects from inception,
through the inspection phase during aircraft assembly,
right until delivery and acceptance. Qualified and
experienced engineers will:
• Evaluate and recommend BFE and SFE
• Define BFE and establish budget
• Work to establish own specification
• Monitor BFE
• Ensure defined specifications are complied with
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Engineering Projects cont’d
• Follow up and inspect aircraft during assembly Phase
• Inspect and accept aircraft during delivery
• Negotiate delivery commitments
• Ensure the aircraft is service-ready for commercial use
• Develop cabin layout and LOPA based on‘ specific needs
and ground rules
• Design and develop configuration changes to cabin and
aircraft interior
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Inflight Entertainment &
Cabin Interiors
 Provides technical support services for the industry most
sophisticated, state-of-the-art I FE systems,
 including audio/video on-demand (AVOD) systems,
SMS/emails, SATCOM, telephone, air show moving map,
games, connectivity /and the related software controls.
 Provides technical services for passenger compartment and
flight deck seats, galley/s, toilets, stowage structures,
interior markings, emergency/equipment, seat controls,
galley/equipment and systems.
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 This section also designs and implements in-house cabin
reconfigurations in accordance with Emirates demanding
brand standards. It also prepares and manages retrofit
configuration layouts and carries out in-house
modifications to bring aircrafts up to Emirates operating
standards
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TOTAL CABIN MAINTENANCE (TCM)
The Total Cabin Maintenance department is responsible for
carrying out day to day maintenance of both Cabin and IFE
systems installed on company aircraft.
The section will liaise with both Line Maintenance and MCC
to ensure that serviceability of Cabin and IFE systems is
maintained, so as to satisfy the company’s operational
requirements.
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Aircraft Maintenance Management
 Introducing Aircraft Maintenance Management, adopting
1.
2.
3.
4.
an efficient maintenance programs and Understanding all
relevant tools and techniques will bring the following
benefits to the Airline organisation:
Maintain Aircraft to a high standard and subsequently
save money.
Minimize aircraft downtime while slashing maintenance
and repair costs.
Apply systems concepts for improved integration and
communication.
Upgrade technical and provisioning functions.
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5. Improve efficiency in meeting regulatory requirements
6. Identify and monitor maintenance program
problems/trends.
7. Stay on top on quality assurance, quality control,
reliability standards and safety matters.
8. Adjust and tune the organisation approach towards human
factors in maintenance.
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