Embry-Riddle Aeronautical University
Requirements for a
Maintenance Program
Chapter 6
Development of Maintenance
Programs
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Introduction
Aviation Maintenance Program Outlined
(AC 120-16E with Chg 1)
Summary of the Maintenance Program
Objectives (1 – 5)
Additional Maintenance Program
Requirements
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Engineering, Materiel, Planning, Maintenance
Control, Training, Computing, and Publications
Summary
Introduction
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Regulatory and additional maintenance
requirements need to be adhered to in
order to achieve the objectives of a
sound maintenance program (the 5
maintenance objective covered in Ch. 3)
Maintenance Program Objectives
1. To ensure the realization of the
inherent safety and reliability
levels of equipment.
2. To restore safety and reliability
to their inherent levels when
deterioration has occurred.
Maintenance Program Objectives
3. To obtain the information
necessary for adjustment and
optimization of the maintenance
program when these inherent
levels are not met.
4. To obtain the information
necessary for design
improvement of those items
whose inherent reliability
proves inadequate.
Maintenance Program Objectives
5. To accomplish these objectives at a
minimum total cost, including the
costs of maintenance and the cost of
residual failures.
Aviation Maintenance Program Outlined
(AC 120-16E with Chg 1)
 FAA requires OPSpecs and for maintenance
the requirements are identified in the FAA
Advisory Circular, AC 120-16E with chg 1
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“Air Carrier Maintenance Programs”
 Airworthiness Responsibility
 Maintenance manual
 Maintenance organization
 Maintenance schedule
 Maintenance record keeping system
 Accomplishment and approval of maintenance
and alterations
 Contract maintenance
 Personnel training
 Hazardous materials and dangerous goods
Aviation Maintenance Program Outlined
(AC 120-16E with Chg 1)
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FAR 121.373 requires each operator to have a
“continuing analysis and surveillance” (CASS)
effort to ensure the maintenance and inspection
programs are effective
FAR 121.380 – record keeping – maintenance
recording requirements
FAR 121.380a – txfr of maintenance records
FAR 43.2 – records of overhaul and rebuilding
FAR 43.9 and 43.11 – content, form, and
disposition of records
All have been incorporated in the AMP
Airworthiness responsibility
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The airline must adhere to the FAA
approved maintenance program the Ops
Specs identifies.
Can be modified with appropriate
justification and approval of the FAA
The airline is “ULTIMATELY”
responsible for maintaining its own
aircraft in an airworthy condition
regardless of who actually performs the
maintenance.
Maintenance Manual
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A system of manuals and an
expansion of the manufacturer’s
manuals
The maintenance manual is the
primary, all-inclusive, expression of
how maintenance will be conducted
and how the program will be
monitored and improved.
Maintenance Organization
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The FAA states:
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“An airline must have a maintenance
organization that is able to perform,
supervise, manage, and amend your
program, manage and guide your
maintenance personnel, and provide the
direction necessary to achieve your
maintenance program objectives.”
– AC 120-16E with chg 1
Maintenance Organization
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Essential elements:
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An organization that is capable of doing the
required work.
A director of maintenance responsible for the
overall activity – must be FAA licensed
mechanic.
For part 121 operators, a chief inspector.
An organization or process to develop and
upgrade a maintenance manual that describes
all aspects of the maintenance program.
Oversight and supervision activities to ensure
that maintenance is accomplished in
accordance with the airline’s manual.
Maintenance Organization
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Essential elements:
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An inspection function for required inspection
items (RIIs) that is separate from other routine
inspection and maintenance functions.
Competent personnel and adequate facilities
available for the maintenance to be performed.
Procedures to ensure that each aircraft
released for service after maintenance is
airworthy and properly maintained.
Efforts to ensure that the maintenance
program remains effective as conditions
change.
Management personnel who are qualified and
have sufficient experience and expertise to
effectively organize, manage, and control the
maintenance program.
Maintenance Schedule
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FAA requires a schedule which identifies
what, who, when or how often
maintenance is to be performed.
Tasks are found in the Maint Review
Board, Maint Planning Data
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Intervals – flt hrs, cycles, calendar time, daily,
every flt, or flt hrs – 200, 300 etc.
It is an airline’s responsibility to adjust the initial
MRB schedule to comply with individual airline
needs.
Maintenance Record-keeping
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FAA requires an airline to keep accurate
records of maintenance and alteration
activities.
Two types required:
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Maintenance logbook – in aircraft and
“home” activity
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Summary information and airworthiness status
information
Includes flt time, fuel, crew data, and flt crew
maintenance related problems and corrective action
Mechanical reliability report (MRR) and
Mechanical Interruption Summary (MIS)
Accomplishment & Approval of Maintenance &
Alterations
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Program must include instructions for
conducting maintenance on the aircraft as well as
specific maintenance for engines, propellers,
parts, and appliances
Scheduled, unscheduled, on aircraft and off.
Must address aging and corrosion problems
Required Inspection Items (RIIs) – FAA defined as
“those items that could result in unsafe operation
of the aircraft if maintenance is not performed
correctly or if improper parts are used.”
FAA doesn’t specify but requires airline to
identify its own, in writing, the mechanics
qualified and authorized to perform those
inspections.
Contract Maintenance
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Airline “ULTIMATELY” responsible for
ALL maintenance
Airline is responsible for providing
outside units with proper training on your
procedures and for assuring that these
outside units have the personnel, skills,
and facilities to accommodate the work
required.
Continuing Analysis & Surveillance System (CASS)
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Fed Aviation Reg. (FAR) requires that a
monitoring program exists and ensures
maintenance and inspection programs
outlined in the Ops Specs are effective.
CASS is a program to detect and correct
deficiencies in maintenance program
effectiveness and performance.
Looks at problem areas, determines
corrective action, tracks the activity to
determine effectiveness of the correction.
Data collection and analysis, daily monitoring
of all activities of maintenance, suppliers, and
its contractors.
Personnel Training
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FAR states, “have a training program to
ensure that each person (including
inspection personnel) who determines
the adequacy of work done is fully
informed about procedures and
techniques and new equipment in use
and is competent to perform the duties.”
Many require an airframe and power
plant license (A&P) – just means
qualified for the job
Must have orientation, trained on
policies, procedures, and equipment
configuration
Hazardous materials & dangerous goods
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Caustic substances dangerous to eyes,
skin, lungs and as well to metal, fabric,
and other materials.
Storage, handling and environmental
concerns and the regulatory requirements
Safety issues, fatigue, and other human
conditions
Airlines required to provide employees
with the necessary equipment and training
on protection, storage, handling etc..
OSHA mandates most elements
Summary of FAA Requirements
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To ensure the 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
adjustment and optimization of the maintenance
program when these inherent levels are not met.
To obtain the information necessary for design
improvement of those items whose inherent
reliability proves inadequate.
To accomplish these objectives at a minimum
total cost, including the cost of maintenance and
the cost of residual failures.
Homework Assignment
- Define the purpose of the
following additional
Maintenance Program
Requirements
Additional Maintenance Program Requirements
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Engineering
Materiel
Planning
Maintenance Control Center
Training
Computing
Publications
Summary
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Introduction
Aviation Maintenance Program Outlined
(AC 120-16E with chg 1)
Summary of the Maintenance Program
Objectives (1 – 5)
Additional Maintenance Program
Requirements

Engineering, Materiel, Planning, Maintenance
Control, Training, Computing, and Publication
Questions?
Engineering
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Primary purpose is to establish the initial
maintenance program from the
manufacturer’s maintenance manual and
other documents and to upgrade the
program over time.
Provide technical assistance, review
manufacturers service bulletins, changes,
and provide engineering expertise to the
company or hired consultants in the
design of facilities or modification.
Materiel (Supply)
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Provide maintenance with parts and
supplies to carry out maintenance
activities.
Includes purchasing and warehousing of
the parts, supplies and tools.
Handle warranty claims and pass on the
repairable components to the appropriate
workshop or vendor for repair.
Planning
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Responsible for planning all of the
scheduled maintenance including
manpower, facilities, and supplies needed
Also to collect data on the time,
manpower, facilities actually used to
subsequently plan for future maintenance
actions/requirements.
Maintenance Control Center
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The nerve center of line maintenance
Responsible for keeping track of all
vehicles and service and status
Coordinates the numerous activities
between operations, engineering and
maintenance and within the various
maintenance work centers.
Coordinates the personnel for
troubleshooting, repair or parts
assistance required.
Training
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Responsible for follow on training and
upgraded skills as required.
May even coordinate initial training.
Maintains records of all training,
qualifications, and certifications of all
personnel assigned.
Trains engineers, supervisors, managers,
inspectors not only maintenance specific
but managerial/supervisory roles.
Computing
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Provides the equipment, software, training
and support for all computing activities.
Includes:
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Data collection on malfunctions
Parts tracking and control
Collection and manipulating reliability data (MTBF)
 Failure rates, removal rates
Tracking of serial numbered items
Publications
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Responsible for keeping all technical
publications up to date
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Paper, microfilm, or electronic media
Distributes to appropriate work centers
Provides revisions and additions
Inspects periodically for completeness
Maintains Master Library