010 Elements PP

Elements of Production Planning

l

Presented by: Bill Abbott

Speaker Biography: William G. Abbott - Senior Engineer, Maintenance Planning & Programs, Maintenance Engineering Technical Services (METS). Bachelor of Science Degree in Aeronautical Studies with a Core Concentration in Maintenance Management. Five years experience with Boeing in current METS as Senior Engineer position. DC-10/ MD-11 Generic and Custom Maintenance Programs. Forty-eight (48) Months A&P mechanic with Pan Am World Airways and Continental Airlines. Forty-eight (48) Months Aircraft Heavy Maintenance Production Planner.

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Essential Elements of Production Planning Production Scheduling

Task Card Packaging

Planning the Check

Executing the Check

Post Production Analysis 2

NOTES:

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Production Scheduling Typically Involves Five Main Departments Engineering

Planning

Heavy Maintenance

Material Control Quality Control 3

NOTES:

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Engineering Department Responsibilities

Maintenance Program Engineer

Non-Routine Findings

Modifications

4

Engineering Non-Routine Functions : •Structural Findings •Issues Engineering Orders (EO) •Repairs •Fleet Campaign Directives •Modifications •Service Bulletins •Airworthiness Directives •Assists with Modifications •Passenger to Freighter Conversion •Moving, Removing or Adding Galleys & Lavatories •Seat Configuration Changes / Bulkhead •Maintenance Program Engineer •Track Reliability Trends •Recommend Maintenance Program Adjustments based on Findings

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Planning Department Responsibilities Planning Supervisor

Airplane Planner

Production Coordinator

5

Planning Department: Planning Supervisor •Oversees Pre-Planning Process Airplane Planner Tracks: •Airplane (Time & Cycles) •Airworthiness Directives •Routine Checks •Fleet Campaigns Production Coordinator •Packages Work Cards for Check •Creates Flow Chart for Check •Interfaces with Heavy Maintenance •Interfaces with Material Control Department •Many Tasks have Overlapping Coverage •Each Cognizant Individual is Able to Share the Responsibilities of others •Cross Training Utilization Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Heavy Maintenance Department Responsibilities Production Supervisor

Tool Crib & Ground Support Equipment (GSE)

Production Coordinator

6

Production Supervisor •Attends Pre-Planning Meetings •Controls Hangar Maintenance •Advises Departments of Up-Coming Requirements •Tool Crib Supervisor Tool Crib & GSE •Provide Tools and Equipment for Check Production Coordinator •Supports Check including Repairs and Tests on Parts Removed from Airplane

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Material Control Department Responsibilities Material Control Supervisor

Stores Supervisor

7

Material Control Supervisor •Attends Pre-production Planning Meetings •Interfaces With Production Coordinator •Advises Stores Supervisor Upcoming Check Requirements •Orders Parts AOG As Required •Procedure Unique Vendor Items (Interior Modifications, Etc.) Stores Supervisor •Provides Kits for Routine Checks •Audits Kit Contents for Completeness & Readiness for Installation •Provides Parts for Non-routine Items

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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The Quality Control Department Has Several Responsibilities Quality Control Supervisor

Inspectors

Non-Destructive Testing Lab

8

Quality Control Supervisor Attends Pre-Production Planning Meetings Ensures Adequate Inspector Coverage for Up-Coming Check Notifies NDT Lab of Special Inspections Inspectors Perform Inspection & Buy-Offs as Required Review Completed Check Package for Accountability and Compliance NDT Lab Perform Special Inspections as Required

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Task Card Packaging Has Several Aspects Identify Check Routine Inspection Requirements Identify Additional Workload Requirements Package Task Cards for use at Airplane Provide Accountability Sheets for All Work Cards in Package

9

NOTES:

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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The Planner Identifies the Routine Check Package For the Aircraft l

Identify Check Requirements: n

Routine Checks to "Zero-out" Maintenance Check Time u u u u

“A” Check “C” Check Zonal Structures (SSI) u

u u

Both Initial and Repetitive

Certification Maintenance Requirements (CMR) Airworthiness Limitations Instructions (ALI) for MSG-3 u

Or Supplemental Inspection Document (SID) for MSG-2

10

Routine Checks: •Typically an “A & C” Check for MSG-3 •“A & D” Check for MSG-2 NOTE: “B” check is an non-Boeing interval term Maintenance Review Board (MRB) items: •Maintenance Significant Items (MSI) for Systems and Powerplant •Zonal Inspections Items •Structural Inspection Items (SSI) Other Routine Maintenance Items: •CMR •ALI •SID

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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The Planner Identifies the Additional Items for the Check Package l

Identify Additional Check Requirements: n

These Items Are Normally Referred to As Non-routine and or Over and Above Items, Which Are Added to the Check Package u u u u u u u

Deferred Maintenance Items Airworthiness Directives (AD’s) Engineering Orders (EO’s) Modifications Service Bulletins Refurbishment Fleet Campaigns

11

Non-routine Checks: •Maintenance Planner Must Plan for These Non-routines as Best He/she Can. •Planner Must Work These Tasks Into the Planned “Routine Check” Package.

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Elements to Package Task Cards l

The Planner Must Schedule Time for These Tasks:

Deferred Maintenance Items •Determine Parts Availability •Lead Time for Parts Not in Stock •Importance Is Critical •Deferred Items to Be Cleared

l

Over & Above Requirements •Airworthiness Directives •Engineering Orders •Modifications •Service Bulletins •Refurbishment

The Planner Then Issues Non-routine Task Cards Into the Package s

The Planner Is Most Likely Processing Additional Non-routine Task Cards That Are Typically Discovered Continuously During the Heavy Check.

12

Deferred Maintenance Items •Minimum Equipment List (MEL) Items Can Be Deferred by Category •Non-MEL Maintenance Items Can Also Be Deferred •Non Scheduled Maintenance Item •Non-placard Items •Paint, Carpet, Upholstery, Reading Lights •Maintenance Usually Issues a Control Number So Other Stations Know What’s Coming and What Parts Are Needed •Other and More Critical Items for Deferment need to be Reviewed by Engineering Non-routine Task Card Packaging: •The Mechanic or Technician Typically Writes a Non-routine Task Card and Makes Every Effort to Link It to the Routine Task Card That Signifies Where the Mechanic Was or What Task Was Being Performed When He/she Found the Discrepancy.

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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This Is a Typical “Routine, A & C Check” Workload Packaging “A” Check Work Packaging FLIGHT

550

1100

1650

2200

2750

3300

3850

4400

4950

5500

6050

6600

1

2

3

4

5

6

7

8

9

10

11

12

4800

9600

14400

19200

38400

43200

48000

52800

57600

HOURS CHECK NO. 1A 2A 3A 4A 5A 6A

“C” Check Work Packaging FLIGHT

24000

28800

33600

HOURS CHECK NO.

1

2

3

4

5

6

7

8

9

10

11

12

MONTHS

15

30

45

60

75

90

105

120

135

150

165

180

1C 2C 3C 4C 5C 6C 8C

13

Work Packaging Schematic For Letter Checks •This Work Packaging Matrix Assumes an Aircraft With a 550 FH "A" Check and a 4800 FH "C" Check Interval. •Any Letter Check Assigned, Requires That All Previous Checks Divisible by the Check Interval Number Be Accomplished (E.G. A Check #6 Requires That All 1A, 2A, 3A & 6A Tasks Be Accomplished, Yet 4A & 5A Are Not Divisible by 6, Thus Are Not Required). •The Cells Are Shaded at the Intersection of the Row Consisting of a Letter Check Versus the Corresponding Check Number in the Column. •Structural Inspections Are Typically Done at the Heavy “C” Check Due to the Involved Access Requirements. •The Maintenance Planner Applies the Appropriate SSI Checks to This Matrix (E.G., The 30 Month SSI Checks Are Completed at the 2C Check.)

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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There Are Several Steps to Package the Tasks

Package Routine, Non-Routine, and Over & Above Work Cards for Work Dock Production Coordinator Package Tasks to Fit Operation •By Zone •By Skill •By System •By Flowchart •Combination of Above

14

Packaging Task Cards Has Many Aspects: •The Task Cards Are Often Packaged by Zone So That Tasks in That Zone Are Performed With a Minimum of Back and Forth Activities •Then Assign by Skill / System •Flowchart Schedule Drives the Whole Check

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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There Are Several Steps to Package the Tasks l

Provide Accountability Sheet to Insure All Work Cards in Package n

Routine Checks u

n n

Include Lower Level Routine Checks

Non-routine Checks Over and Above Items u u

EO’s Special Inspections

15

Non-routine Checks Non-routine Tally Consists of a Sequentially Numbered Control Sheet to Account for Open and Closed Non Routine Tasks. The Non-routine Tally Sheets Are Sub Divided by Zone The Sheets Contain a Brief Description of the Discrepancy, Issued Block and QC Buy Back Boxes. This Is Similar to the Routine Tally Seen ne xt. Non-routine Task Card Usually Displays the Routine Task Card Number so That Planning Knows What Routine Task Drove the Non-routine Very Important for Structural Programs

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Sample “4C” MSI Routine Tally Sheet

16

Accountability Sheets Allow for the Efficient Tracking of Tasks •Displays Task Card Number •Displays Task Description •Displays Task Code •Displays Interval •Displays Unit if applicable (Flight Hours, Cycles, etc.) •Displays Task Card Revision Date •Displays Issued (applicable to check package) box •Displays Issued & Completed task box •Necessary for sign-offs These elements should be considered as the minimum required

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Sample “Zonal” Routine Tally Sheet

17

Sample Routine “Zonal” Check Tally: •Displays Task Card Number •Displays Task Description •Displays Task Code •Displays Interval •Displays Unit if applicable (Flight Hours, Cycles, etc.) •Displays Task Card Revision Date •Displays Issued (applicable to check package) box •Displays Issued & Completed task box •Necessary for sign-offs These elements should be considered as the minimum required

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Sample “SSI” Routine Tally Sheet

18

Sample Routine Structural “SSI” Check Tally: •Displays Task Card Number •Displays Task Description •Displays Task Code •Displays Interval •Displays Unit if applicable (Flight Hours, Cycles, etc.) •Displays Task Card Revision Date •Displays Issued (applicable to check package) box •Displays Issued & Completed task box •Necessary for sign-offs These elements should be considered as the minimum required

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Plan The Check Package And Airplane Down Time l

Determine Manpower Requirements Production Coordinator / Production Supervisor Production Coordinator n

Break Down Work Force Make-up u

Skills Required u u u u u

u u

Cleaners Hydraulics/mechanical Avionics Engine Structure

Inspectors Required Outside Services Required 19

There Are Several Aspects to Planning the Work or Task Package: •Determine Manpower Requirements •Estimate Total Man-hours •Determine Required Hold Time for Check •Schedule Pre-planning Meetings •Prepare Hangar and Work Dock

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Plan The Check Package And Airplane Down Time l

Estimate Total Man-hours Required:

Determine Man-hour Requirements for Basic Routine Check & Known NonRoutine • Deferred Maintenance Items

Determine Man-hour Requirements for Additional Nonroutine and Over & Above Work u Plan for Overtime for Special Circumstances/projects u Borrow Manpower From Other Departments If Necessary 20

Planner Reviews All of the Deferred Maintenance Items From the Aircraft Log Book • Maintenance Control Center Supplies These Items Usually Through Some Type of Computer System Temporary Manpower Allocation • Large Tasks Such As Open Up, Cleaning Bilge Areas

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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There Is a Tool for Estimating Non-routine Hours for the Check Package l

Non-routine Hour Estimations Are Calculated Via a Boeing Standard Formula: n

n

n

A Planner Uses a Productivity Factor to Estimate the Hours of Non-routines That Each Hour of Routine Maintenance Will Generate. Productivity Factor = (1 Hour of Routine Maintenance + 1.2 Hours of Non-routine Maintenance)* Efficiency Factor. Efficiency Factor = Maintenance Technician Skill Level on a Scale of 1 to 5. Boeing Uses 2.5 As an Typical Number. s

n

n

Level 1 Is the Most Competent

Actual Estimated Time = (Productivity Factor) + (efficiency Factor)*(oamp Listed Time). Example - Productivity Factor = s s

[(1 Hr Routine)+(1.2 Hrs Non-routine)]*(2.5) = 5.5 (Oamp Time, 1 Hr)*(productivity Factor, 5.5) = 5.5 Actual Estimated Time 21

Non-Routine Checks: Douglas products Division Philosophy: 1.0 hr Routine Maintenance (R) = 1.2 hr NonRoutine Maintenance (NR). Formula (R + NR) x EF = PF. (The 1.2 hr NR can be adjusted to fit any airlines maintenance requirements established on past history). Example: (1.0 + 1.2) x 2.5 = 5.50 The Productivity Factor can be used to convert the man-hours in the OAMP which are inspection look-times only and does not include set up and fix times to reflect both routine and non-routine maintenance times as shown above. Sample: OAMP time = 1.025 MH routine x 5.50 (PF) = 5.6375 MH routine and nonroutine. •Adjust Efficiency Factor up for inexperienced maintenance crew, and adjust down for experienced crew. •Adjust Non Routine Hours (1.2) up for aircraft in poor shape, (many anticipated nonroutines). •Adjust Non Routine Hours (1.2) down for aircraft in good shape. Make small adjustments if needed. •Note: OAMP - On Aircraft Maintenance Planning for DC & MD series aircraft and MPD - Maintenance Planning Document for B series aircraft. Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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PROJECTED MAN-HOUR ESTIMATE PLANNED INPUT __________

BASIC CHECK

SKILL

RELEASE __________

E.O.s & SPEC. INSP.

TIME COMPONENTS

TIME ITEMS

TYPE OF HOLD:

TOTAL ROUTINE HOURS

PLAN NON ROUTINE

C-CHECK

A/C:

NON-ROUTINE SUB TOTAL HR'S N/RTN PER N/RTN HOURS

LINE MAINT. SHEET METAL INTERIORS AVIONICS PAINT SUBTOTAL

260 40 250 90 60 700

204 143 2 13 0 362

173 0 0 0 0 173

292 0 144 87 0 523

929 183 396 190 60 1758

640 530 180 150 50 1550

1.8 2.2 1.5 1.4 1.1

INSPECTION N.D.T. TOTAL

130 24 854

32 15 409

10 0 183

118 12 653

290 51 2099

1550

0.125

3100

ADDTNL N/TRN HOURS

1152 1166 270 210 55 2853

250 400 100 50

194 0 3047

48

800

848

DC -10

TOTAL ROUTINE & REQUIRED N/ROUTINE DAYS FOR HOURS HOLD 2331 1749 766 450 115 5411

9.3 DAYS 10.9 DAYS 7.7 DAYS 5.6 DAYS 5.8 DAYS 10 DAYS

532 51 5994

22

Planner Builds the Projected Man-hours Table Production Supervisor Advises Planner on How Many Men / Women Are Required

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Plan The Check Package And Airplane Down Time l

The Production Supervisor & Production Coordinator Determine Hold-time Required for the Maintenance Check: n

Check Long Range Hangar Schedule for Opening u

n

Assure Hold-time Is Adequate Based on Available Manpower

Have Alternate Plan Identified If Airplane Is Late Coming Into Check u u

Aircraft Arrival Delayed Due to Maintenance Problem Aircraft Swap

23

Alternate Plan •Move Man-power to an Alternate Aircraft •Consider Having Alternate Aircraft Check Package Ready •Alternate Aircraft Parts Procurement Is Expensive Basic Example Sample MSG-3, 2C Check May Take 10,000 Manhours (Routine + Non-routine) 15 Day Hold for Same 2C 6.0 Hrs. Actual Work Time Per Man / Woman Per Shift 10,000hrs/15 Day Hold = 666 Manhours 666 Manhours / 6 Hrs. = 111 Technicians Per Day 111 Technicians / 3 Shifts = 37 Technicians Per Shift NOTE: Example Serves to Illustrate Mathematics of Crew LoadingNot Demonstrate Suggested Crew Loading

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Plan The Check Package and Airplane Down Time l

Hold Pre-production Planning Meetings n

n

Advise All Departments of Their Responsibilities and Projected Work Load Requirements Quality Control u u

n

Production (Maintenance) u u

n

u

Pre-draw Parts List Identified and Shortages Noted Estimated Arrival Date of Parts Not in Stock

Support Shops u

n

Skill Requirements Ground Support Equipment Special Requirements

Parts Control u

n

Number of Inspectors Non Destructive Testing (NDT) Requirements

Turn Around Time for Shop Items

Planning u

Introduce Flow Chart Plan 24

Meeting Attendees (Minimum) •Quality Control •Production Supervisor •Production Coordinator •Material Control •Support Shops Other Discussion Topics Check Package Mile-stones Flow-chart

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Plan The Check Package And Airplane Down Time l

Prepare Work Dock - Production Coordinator n

Prepare Work Dock u u

Display Flow Chart Place Work Cards on Assignment Boards u

u

u

Organize and Prioritize According to the Flow Chart Plan

Put Technicians Name Tags by Assigned Task to Track Work in Progress Have Routine & Non-routine Task Cards and Accountability Sheets in Place

25

Flowchart All Departments Agree on Flowchart Form the Pre-production Meeting Functions As an Adjustable Guide Throughout the Check

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Sample DC-10 “HMV” Flow Chart TASK

DAY 1 DAY 2

DAY 3

DAY 4 DAY 5 DAY 6

DAY 7

DAY 8 DAY 9 DAY 10

DAY 11

DAY 12

1. STRIP/PAINT AIRCRAFT WASH AIRCRAFT DOCK AIRCRAFT PREPAIR FOR PAINT STRIP STRIP PAINT 2. AVIONICS/ELECTRICAL DISCONNECT LAVS/GALLEYS CONNECT LAVS GALLEYS OPS FUNCT CKS 3. OUTSIDE CHECKS APU SHROUD CHECK FLIGHT CONTROR CHECK 4. GALLEYS DISSCONNECT GALLEYS REMOVE GALLEYS-CLN INSP. INSTALL GALLEYS 5. CABIN DISCONNECT AND REMOVE SEATS REMOVE FLOOR PANELS INSTALL FLOOR PANELS REMOVE O/H PNL/SIDEWALL PANELS INST O/H PNLS SIDEWALL

26

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Sample DC-10 “HMV” Flow Chart TASK

DAY 1

DAY 2 DAY 3

DAY 4 DAY 5

DAY 6 DAY 7

DAY 8 DAY 9

DAY 10

DAY 11

6. LAVATORIES DRAIN & FLUSH LAVS DISCONNECT AND REMOVE LAVS CLEAN AND INSPECT AREAS INSTALL LAVS 7. FORWARD CARGO REMOVE PANELS CLEAN AND INSPECT INSTALL PANELS 8. AFT CARGO REMOVE PANELS CLEAN AND INSPECT INSTALL PANELS 9. LEFT WING REMOVE PANELS 6-7 SLAT TRACK MOD SLAT CABLE CHANGE RIG SLATS CLOSE PANELS 10. RIGHT WING REMOVE PANELS 6-7 SLAT TRACK MOD SLAT CABLE CHANGE RIG SLATS CLOSE PANELS

27

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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There Are Several Steps to Execute the Check Outside Pre-Check Tasks

Functional/Operational Checks & Engine Runs (Pre -Docking) Flight Control Checks

Defuel Aircraft

Wash Aircraft

28

Outside Pre -check Tasks •Some Tasks Cannot Be Performed in Than Hanger Under Any Circumstances •Critical to Operate Systems That Are Difficult in the Hanger •Pre-check Tasks Are Used to Identify As Many Non-routines As Possible Before Entry Into Hanger Crew-loading •Optimum Crew- loading Calls for Personal to Be On-site When the Aircraft •Typically There Can Be Some Delay Between Arrival and Hands on Work Pre-induction Inspections •Protect Heavy Maintenance From Mistaken Claims of Damage •Quality Control Typically Performs •Video Tape Is Optimum Method )Inside and Outside)

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Prepare Facility for Check Execution Hangar and Work Dock Preparation Prepare Hangar Bay

Required Equipment and Special Tools in Place Materials and Parts

Provide Adequate Storage for Parts Removed from Airplane Sufficient Quantity of Maintenance Tags

29

Prepare Hangar Bay Required Equipment and Special Tools in Place •Miscellaneous Tools for Panel Removal •Stands for Pylons or Engines •Jacks •Special Structural Repair Tools Material and Parts •Free Stock Bins Replenished •Inventory Pre-draw Parts (Locate in Hold Area for Airplane) Sufficient Quantity of Maintenance Tags •Parts Removal •Warning Provide Adequate Storage for Parts Removed from Airplane •Some Parts will Need to be Routed to Shop •Some Parts will Need to be Adequately Protected

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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There Are Several Steps to Execute the Check Open-Up

Inspect

Lube

Perform Hanger Tasks Repair

Close-Up

Other Tasks

30

Panels Open-up Is Usually Performed by a Dedicated Crew That Open-up the Necessary Areas for the Check. •Not Recommended to Open-up Areas Not Required for the Check. Lubrication •Standard During Most Checks Over a 1A. Inspection Can Include: •Operation Checks •Functional Checks •Detailed Inspections •General Visual Inspections Repairs: •Repairs Are Non-routines and Planning Tools Can Do a Fair Job of Estimating the Time Required. Other Tasks Discards & Restoration Tasks The Afore Mentioned “Additional Tasks” Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Planner Responsibilities During the Check Main Responsibility Is Issuing and Statasing Task Cards Must Issue Cards When Aircraft Is Most Ready for That System Task

Alters Flow Chart With Completed and Late Tasks

Closing Log Pages for MEL Deferred Items

31

Main responsibility is issuing and statusing Task cards When technician completes section of task card requiring inspection, planner issues task card to inspection for closure - then technician goes back to work on another issued task Must issue cards when aircraft is most ready for that system tas k Not issuing task cards during pre-check (outside hanger) that are difficult or near impossible to do in the hanger: Difficult

Near Impossible

Stripping and or painting

Engine Runs

Thrust Reverser, pneumatic

Fuel Transfer / Dump Checks

Some avionics checks

Avionics System Checks e.g., compass swing

Alters flow chart with completed and late tasks Advises production Supervisor to assign additional man-power Closing log pages for MEL deferred items Planner follows closure of all deferred MEL items closely and advises Production Supervisor as soon as it appears as if items may not close

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Production Supervisor Duties During the Check Production Supervisor Responsibilities

Daily Production Meetings

Flow Chart Schedule

32

Daily Production Meetings Are Held With the Responsible Departme nts •Conducted by Production Supervisor •Involves All Departments •Coordinate Efforts Between Departments •Update Progress on Flow Chart •Re-adjust Flow Chart When Necessary •Evaluates Non-routine Write- ups for Parts Requirements and Manhours •Reassigns Technicians As Necessary •Determine Ramp Work Requirements, Engine Runs •Identify Problem Areas •Update Status on Airplane •Status Parts Availability (Shop and AOG Items) •Ensures That All Previously Deferred MEL Items Are Closed Before Departure

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Production Coordinator Duties During the Check Production Coordinator Responsibilities

Daily Production Meetings

Flow Chart Schedule

33

Production Coordinator Responsibilities •Distributes Tasks by Priority •Accounts for all Paperwork •Maintains Accountability List for all Paperwork •Makes Sure all Paperwork is Completed Properly •Up-Dates Flow Chart •Advises Production Supervisor of Areas Behind the Flow Chart Schedule

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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There Are Several Steps to Execute the Check Perform Post-Check Tasks

Functional Checks

Post-Check Run-Ups

Test Flight (if required)

34

Post Check Tasks: Functional Checks After Repairs Have Been Accomplished Engine Run-ups Post Check Runs Can Be Performed to Confirm Proper Operation After Repairs/replacement or to Provide Power/pressurization for More Involved Checks.

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Post Production Analysis Is Performed After the Check Hold Post-Production Meetings with All Departments Involved in the Process

n n n n n

Heavy Maintenance Material Control Engineering Planning Quality Assurance

Non-Routine Tracking 35

Analyze The Check Results to Identify Areas for Improvement Re-cap Man-hours Expended During Check •Actual Verses Planned •Adjust Projections for Future Checks As Required Identify Problems Encountered During Check •Recommend Solutions to Overcome Similar Problems During Next Maintenance Check Track Airplane the First Few Days in Service •Determine If Any Delays Taken Are Chargeable to Work Performed During The Check •Take Steps to Prevent Any Recurrence During Future Checks Non-routine Tracking Is the Responsibility of Several Departments •Engineering •Planning •Quality Assurance

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Heavy Maintenance Reviews Several Check Tasks Overtime Man-Hours Expended

Training Requirements

Crew Loading

36

Man-hours Must Be Closely Reviewed for a Cause & Effect Relationship •Routine Task Cards Shouldn’t Have Significant or Large Changes in Completion Time •Investigate If the Task Card Truly Had a Significantly Greater Amount of Time Charged to the Task. •Often, the Card Was Not Closed After the Task Was Completed, Which Leads to Poor Tracking of Hours •Simply Raising the Planned Time to Meet the Last Actual Time Is Not Planning’s Job and Doesn’t Uncover the Manhours That Were Expended. This Is Most Applicable to Routine Tasks

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Material Control Reviews Several Check Tasks l

Were Parts / Kits / Spares on Hand When Required n

l

Poor Pre-draw or Insufficient Lead Time

Were Components Returned From Backshops When Required n

Investigate Reason for Delay s s s s

l

Forgot to Route on Priority Spares Did Not Materialize or Were Defective Lost Tag on In-station Mis-routed Through Backshops

Review Other Material Concerns: n

Left Over Parts - Excessive Pre-draw s

n

Replace in Inventory When Possible

Free Bins of Consumables and Expendables s

Technicians Often Keep Abundant Supplies in Tool-boxes 37

Material Control Reviews Pats Problems •Must develop ways to handle unforeseen parts problems •Borrow parts form your own fleet •Use priority system for stores routing (internal system) •Don’t abuse priority system by routing everything AOG •Floor wax •Broom handles •Lav Blue water tablets •Mop heads •Tissue paper •May consider restrictions on who has authority to route AOG.

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Engineering Reviews Several Check Tasks l

Engineering Reviews Eo’s for Effectiveness Wrong Instructions or Poor Instructions s Wrong Drawing s Wrong Parts s Wrong Man-hour Estimate s Wrong Function or Fit With Modification s Wrong Function of Task Card s

n

Engineering Solution s s

Issue Revised Eo Based on Feedback Track New Results

38

Engineering Orders Need to Be Reviewed on All Eos •Repairs •Fleet Campaign Directives •Modifications •Service Bulletins •Airworthiness Directives •Maintenance Program Engineer •Track Reliability Trends •Recommend Maintenance Program Adjustments Based on Findings •Put Figures Together for Program Escalation or Deescalation (Intervals) •Regulatory Agency Will Not Normally Accept Any Proposal for Escalation Without Reliability Figures •Non Technical Objection From Boeing Is Not Available Without a Review of Reliability Figures

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Planning Reviews Check Package l

Check Package Review Contains: n

Planning Advises Engineering of Technical Changes or Clarifications to the the Task Cards s s s

Incorrect Procedures Confusion About Procedures Ineffective Procedures u

s

Pneumatic ITCAN Test for Air Pressure Leak ( Tin Foil Over Pneumatic Joints & Lines Is More Effective

Inefficient Procedures u

u

Older Task Card Started Engines to Perform Take-off Warning Check Revised Task Card Does Not - Procedure Simplified to Check Micro-switches in Quadrant, Which Is the MRB Intent

39

Planning Reviews Task Cards for the Following and Advises Engineering Incorrect Procedures Task Card Didn’t Work Most Likely Solved During Check Confusion About Procedures Procedure Worked, but Steps Were Ambiguous Ineffective Procedures A Task Card Was Completed, However the MRB Intent of the Inspection Was Not Accomplished Inefficient Procedures A Task Card Was Completed, Which Met the MRB Intent of the Inspection but a Greater Cost

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Planning Reviews Check Package l l

Check Package Review Contains: Man-hours: n

Routine & Non-routine s s

Review Planned Vs. Actual If Actual Is Significantly Higher Than Planned u

u u

Was Aircraft in Poor Shape Relative to Similar Aircraft Types and Checks ( Was the Non-routine Portion of the Productivity Factor to Low (1.2 Vs. 1.4) Was Crew Loading Similar Was Crew Competency Similar

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Man-hours Must Be Closely Reviewed for a Cause & Effect Relationship •Routine Task Cards Shouldn’t Have Significant Changes in Completion Time •Investigate If the Card Truly Had a Significantly Greater Amount of Time Charged to the Task. •Often, the Card Was Not Closed After the Task Was Completed, Which Leads to Poor Tracking of Hours. •Simply Raising the Planned Time to Meet the Last Actual Time Is Not Planning’s Job and Doesn’t Uncover the Manhours That Were Expended. This Is Most Applicable to Routine Tasks

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Quality Assurance Tracks Non-Routines to Identify Trends l

Tracking Non-routine Maintenance Tasks Allows an Operator to Identify Trends n

Quality Assurance Should Study All Non-routine Tasks in Order to Identify the Following: s s

Aircraft Problem Station Problem u

s

Component Problem u

n

Training Problem Tracking by Serial Number Can Isolate Rogue Components

Compare Your ATA Specific Reports to the Boeing Component Reliability Reports s s

Identify If Problem Is Fleet Wide. Possible Team Conference Issue for Permanent Resolution. 41

Aircraft Problem: Aircraft May Have Chaffed Wires That Routinely Lead to False Troubleshooting of a Component. Problem Reappears Soon After Check, Leading to More False Trouble -shooting at Every Station. Station Problem: •Level of Experience and / or Training •Turn Around Time Pressure •Deficient Documentation, E.G., Lack of or Old Revision •Aircraft Maintenance Manual •Fault Isolation Manual •Trouble -shooting Manual Component Problem •Component Problem by Part Number and ATA •Typical to Track MTBF and MTBUR •Component Problem by Serial Number •Must Track by Serial Number •Essential to Track No Fault Found Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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Summary Production Scheduling Task Card Packaging Planning the Check Executing the Check Post Production Analysis 42

Production Scheduling All Five Main Departments Assist With Production Scheduling Task Card Packaging Identified Routine and Over & Above Tasks Packaged Them Accounted for All Task Cards Planning the Check Pre-production Meetings Hanger Schedule / Crew Loading Executing the Check Importance of Pre-checks Importance of Hanger Preparation Responsibilities of Critical Personnel / Departments Post Production Analysis Minimum Number of Departments Perform Analysis Non-routine Tracking Is Critical

Elements of Production Planning Production Planning Requirements to Maintain Continued Airworthiness Seminar. Section 10

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