Maintenance Program Development

Engr. Vincent Frank Nasiad

 Development of Maintenance Programs
● Maintenance Steering Group (MSG) Approach
● Process-Oriented Maintenance
● Task-Oriented Maintenance
● Maintenance Program Documents
● Maintenance Intervals Defined
● Changing Basic Maintenance Intervals

Engr. Vincent Frank Nasiad

 Maintenance Steering Group Approach (MSG)
A structured methodology used in aviation maintenance to develop
and manage maintenance programs. It is designed to ensure that
maintenance activities are based on sound analysis and are
tailored to the specific needs of aircraft and components.
The approach focuses on optimizing maintenance tasks to enhance
safety, reliability, and cost-effectiveness.
The MSG approach involves a detailed analysis of aircraft systems
and components to determine the most effective maintenance
strategies. It uses a structured process to assess maintenance
needs and frequencies.

Engr. Vincent Frank Nasiad

 Maintenance Steering Group Approach (MSG)
MSG-1: Initial Analysis
This is the initial MSG approach that focuses on analyzing the
maintenance requirements for a system or component based on its
design and operational history.
Objective: Establish a foundational maintenance based on design
and operational assumptions.
Task: Identifies essential maintenance tasks based on the
component’s criticality and failure modes.

Engr. Vincent Frank Nasiad

 Maintenance Steering Group Approach (MSG)
MSG-2: Refinement with Operational Data
This level expands on MSG-1 by incorporating additional data and
feedback from operational experience to refine the maintenance
program.
Objective: Refine and adjust the maintenance program using actual
operational experience and data.
Task: Modifies inspection frequencies and overhaul schedules based
on actual usage and wear patterns.

Engr. Vincent Frank Nasiad

 Maintenance Steering Group Approach (MSG)
MSG-3: Advanced Optimization
The third level introduces advanced methodologies, including
reliability-centered maintenance (RCM) principles, to further
optimize the maintenance program based on detailed failure
analysis and risk assessment.
Objective: Optimize the maintenance program using advanced
methodologies, including predictive and condition-based
maintenance techniques.
Task: Introduces condition-based maintenance, where tasks are
performed based on the actual condition of components rather than
fixed schedules.

Engr. Vincent Frank Nasiad

 Maintenance Steering Group Approach (MSG)
MSG-1: Establishes the initial maintenance program based on design
and theoretical assumptions.
MSG-2: Refines the program using real-world operational data to
make adjustments and improve accuracy.
MSG-3: Optimizes the program with advanced techniques and
technologies, focusing on predictive and condition-based
maintenance to maximize efficiency and safety.

Engr. Vincent Frank Nasiad

 2 Basic Approaches to Maintenance
1. Process-Oriented
Process-Oriented maintenance focuses on optimizing the entire
maintenance process, including workflows, methodologies, and
overall system performance. It looks at how various maintenance
activities interact and how they can be improved holistically.
2. Task-Oriented
Task-Oriented maintenance focuses on specific maintenance tasks
related to individual components or systems. It involves
scheduling and performing predefined tasks based on criteria such
as operational hours, cycles, or failure modes.

Engr. Vincent Frank Nasiad

 2 Basic Approaches to Maintenance
Process-Oriented Task-Oriented

Looks at the entire Focuses on specific

maintenance process tasks and schedules
and how to improve it for individual
Scope
using advanced components or
techniques and systems.
real-time data.

Uses holistic and Follows predefined

integrated methods to task lists and
optimize maintenance schedules based on
Approach
strategies and operational criteria
overall performance. and individual
component needs.

Engr. Vincent Frank Nasiad

 2 Basic Approaches to Maintenance
Process-Oriented Task-Oriented

Relies on real-time Typically uses fixed

condition data, schedules and
predictive analytics, predefined criteria,
Data Utilization
and continuous with less emphasis on
improvement. real-time condition
data.

Allows for Follows a rigid

adjustments and schedule or criteria
Flexibility optimizations based for performing
on ongoing data and specific tasks.
performance insights.

Engr. Vincent Frank Nasiad

 Process-Oriented Maintenance
Hard Time (HT)
The removal of an item at a predetermined interval (hrs, cycles,
calendar time)
On-condition (OC)
Based on physical inspections, only replaced if wear is detected.
Condition Monitoring (CM)
Monitors failure rates, removal rates etc. to facilitate
maintenance planning

Engr. Vincent Frank Nasiad

 Hard Time (HT)
Requires item be removed and either completely overhauled,
partially overhauled (restored), or discarded before exceeding the
specified interval
● (calendar time, engine change, cycles, flight hours, specified
flights and etc..)
● Items that can have an adverse effect on safety but no
maintenance check for that condition
● Rubber seals, bushing etc..
● Structural inspection, landing gear overhaul, and life limited
engine parts, mechanical actuators, hydraulic pumps and
motors, electric motors and generators
● Can be OC as long as not safety related…

Engr. Vincent Frank Nasiad

 On-Condition (OC)
Requires item be periodically inspected or tested to determine if
item can continue in service – overhaul, restore or replace
● On-condition limited to continued airworthiness by
measurements or tests without doing a tear-down inspection
● Examples – tire thread and brake linings, scheduled borescope
inspections of engines, engine oil analysis
● Other include – Brake wear indicator pins
● Control cables (measure for diameter, tension, and broken
strands)
● Linkages, control rods, pulleys etc (measure for wear, end or
side play, or backlash

Engr. Vincent Frank Nasiad

 Condition Monitoring (CM)
Involves the monitoring of the failure rates, removals, etc. of
individual components or systems that do not have a definite
lifetime or noticeable wear out period
CM components are operated until failure occurs – unscheduled
maintenance
FAA states regarding CM:
● Item has no direct, adverse effect on safety
● Must not have any “hidden function” (not evident to crew) that
could affect safety
● Must be in condition monitoring or reliability program
● Avionics and electronic components

Engr. Vincent Frank Nasiad

 Condition Monitoring (CM)
Basic elements include – data on unscheduled removals, maintenance
log entries, on-board data systems, shop findings etc. – can be
used to adjust HT and OC intervals
Only monitors failure not the condition of items

Engr. Vincent Frank Nasiad

 Task-Oriented Maintenance
“Top-down” approach or “consequence of failure” – safety driven
Used to identify suitable scheduled maintenance tasks to prevent
failures and maintain the inherent reliability of the system
Failure is assigned safety and economic whether it is an evident
or hidden failure
Three categories:
● Airframe systems tasks
● Structural item tasks
● Zonal tasks

Engr. Vincent Frank Nasiad

 Maintenance Tasks for Airframe Systems
● Lubrication
● Servicing
● Inspection
● Functional Check
● Operational Check
● Visual Check
● Restoration
● Discard

Engr. Vincent Frank Nasiad

 Maintenance Tasks for Structural Systems
● Environmental Deterioration
○ Climate or environment – may be time dependent
● Accidental Damage
○ Result of human error or impact with an object
● Fatigue Damage
○ Crack or cracks due to loading or stress

Engr. Vincent Frank Nasiad

 Inspections for Deterioration of Structural Items
● General Visual Inspection
○ Visual exam that will detect obvious conditions or
discrepancies
● Detailed Inspection
○ Use of inspection aids, (i.e. mirrors, hand lenses) may
require surface cleaning and detailed access
● Special Detailed Inspection
○ Use of Nondestructive inspection (NDI): dye penetrant,
high-powered magnification, magnetic particle, eddy current

Engr. Vincent Frank Nasiad

 Zonal Maintenance Tasks
● Ensures all systems, components, and installations within a
specified zone receive adequate screening, security of
installation and general condition

Look, Listen, and Feel Test is not a formal inspection but a

routine operational check.
General Visual Inspection (GVI) is a basic, formal inspection.
Detailed Visual Inspection (DVI) is a more in-depth, tool-assisted
inspection.

Engr. Vincent Frank Nasiad

 Maintenance Program Documents
A collection of detailed documents and procedures that outline how
an aircraft’s maintenance will be performed to ensure its safety,
airworthiness, and operational efficiency. These documents are
essential for planning, executing, and tracking maintenance tasks
and ensuring compliance with regulatory authorities like the FAA
(Federal Aviation Administration) or EASA (European Union Aviation
Safety Agency).

Engr. Vincent Frank Nasiad

 Maintenance Program Documents
● Maintenance Review Board Report (MRBR)
● Maintenance Planning Document (MPD)
● Aircraft Maintenance Manual (AMM)
● Minimum Equipment List (MEL)
● Component Maintenance Manual (CMM)
● Service Bulletins (SBs)
● Airworthiness Directives (AD)
● Continuing Airworthiness Maintenance Program (CAMP)

Engr. Vincent Frank Nasiad

 Maintenance Review Board Report (MRBR)
The MRB report is a detailed document created by a committee of
experts that outlines the maintenance requirements for an aircraft
or its components. It provides recommendations on maintenance
tasks, intervals, and procedures based on the reliability and
safety data.
Contains the initial scheduled maintenance program for US
certificated operators
Includes the systems and power plant maintenance program, the
structural inspection program, and the zonal inspection program
Also includes aircraft zone diagrams, a glossary, and list of
abbreviations and acronyms

Engr. Vincent Frank Nasiad

 Maintenance Planning Document (MPD)
A maintenance planning document is a detailed plan that outlines
the schedule, resources, and procedures for performing maintenance
on an aircraft. It includes specific tasks, timelines, and
responsibilities.
Contains all the maintenance task information from the MRBR report
plus additional tasks by the airframe manufacturer
Sorts tasks in various ways: letter check, hrs, cycles and
calendar time
Includes diagrams showing locations and numbering of access doors
and panels, aircraft dimensions, planning for maintenance checks –
to include man-hour requirements

Engr. Vincent Frank Nasiad

 Maintenance Planning Document (MPD)
● Monthly Maintenance Plan
○ The monthly maintenance plan is a document that specifies
the maintenance tasks to be performed within a particular
month. It details the scheduled inspections, repairs, and
other maintenance activities for that period.
○ The Monthly Maintenance Plan is used to identify the
projected maintenance workload such as inspections,
receipts/transfers, technical directive compliance, etc.
○ The Monthly Maintenance Plan provides requirement data for
aircraft maintenance, SE material, manpower and training.
○ The Monthly Maintenance Plan is under the cognizance of the
MO.

Engr. Vincent Frank Nasiad

 Maintenance Planning Document (MPD)
MRBR as the source of requirements
MPD as the implementation plan

The MRBR provides the what: What needs to be done (e.g., periodic
inspections, overhauls, checks), how frequently, and under what
conditions.
The MPD provides the how and when: It operationalizes the MRBR’s
recommendations by specifying the precise timing, frequency, and
sequence of maintenance tasks, and helps airlines or maintenance
organizations execute these tasks efficiently.

Engr. Vincent Frank Nasiad

 Maintenance Intervals
● Most intervals are standard but airlines can create own
intervals as long as the integrity of the original task is
maintained or receive FAA approval
● Transit Check – pre-flight and turn
○ Visual, open/loose panels, fluid leaks
● 48 hour Checks – “daily”
○ Wheels, brakes, fluid levels, hydraulic fluid
● Hourly limit Checks – (100, 200, 250 etc.)
○ Engines, flight control systems

Engr. Vincent Frank Nasiad

 Maintenance Intervals
● Operating cycle limit Checks
○ Tires, brakes, landing gear, airframe structures
● Letter Checks – (A, B, C, and D)
○ Development of 777
● Changing Intervals
○ Hot, humid climates – more CC
○ Dry, desert climates – check for sand and dust
○ As aircraft age intervals for some items may shorten while
others may lengthen

Engr. Vincent Frank Nasiad