010 elements pp
TRANSCRIPT
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Elements of Production Planning
Production Planning Requirements to Maintain Continued Airworthiness Seminar.
Section 10
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Production Scheduling
Essential Elements of Production Planning
Executing the Check
Task Card Packaging
Post Production Analysis
Planning the Check
NOTES:
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Elements of Production Planning
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Engineering Planning
Heavy Maintenance Material Control
Quality Control
Production Scheduling Typically Involves
Five Main Departments
NOTES:
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Production Planning Requirements to Maintain Continued Airworthiness Seminar.
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Engineering Department Responsibilities
Non-Routine
Findings
Modifications
Maintenance
Program
Engineer
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
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Elements of Production Planning
Production Planning Requirements to Maintain Continued Airworthiness Seminar.
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Material Control Department
Responsibilities
Material ControlSupervisor
Stores Supervisor
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
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Elements of Production Planning
Production Planning Requirements to Maintain Continued Airworthiness Seminar.
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The Quality Control Department Has
Several Responsibilities
Quality ControlSupervisor
Inspectors
Non-Destructive Testing
Lab
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
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Production Planning Requirements to Maintain Continued Airworthiness Seminar.
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Task Card Packaging Has Several Aspects
Identify Check Routine Inspection
Requirements
Package Task Cards for use at
Airplane
Identify Additional Workload
Requirements
Provide Accountability Sheets for All Work
Cards in Package
NOTES:
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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 “A” Check
u “C” Check
u Zonal
u Structures (SSI)
u Both Initial and Repetitive
u Certification Maintenance Requirements (CMR)
u Airworthiness Limitations Instructions (ALI) for MSG-3
u Or Supplemental Inspection Document (SID) for MSG-2
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
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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-routineand or Over and Above Items, Which Are Added to the
Check Package
u Deferred Maintenance Items
u Airworthiness Directives (AD’s)
u Engineering Orders (EO’s)
u Modifications
u Service Bulletins
u Refurbishment
u Fleet Campaigns
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.
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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
Over & Above Requirements
•Airworthiness Directives
•Engineering Orders
•Modifications
•Service Bulletins
•Refurbishment
l 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.
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.
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This Is a Typical “Routine, A & C Check”
Workload Packaging“ A ” C h e c k W o r k P a c k a g i n g
F L I G H T
H O U R S
550 1 10 0 1 65 0 2200 2750 33 00 38 50 4 4 0 0 4950 5500 6 050 6 6 0 0
H E C K N O . 1 2 3 4 5 6 7 8 9 10 1 1 12
1 A
2 A
3 A
4 A
5 A
6 A
“ C ” C h eck W o rk P a ck a g i n g
F L I G H T
H O U R S
4800 9 60 0 14 400 1 9 2 0 0 24000 2880 0 33600 3 8 4 0 0 43200 480 00 528 00 5 7 6 0 0
H E C K N O . 1 2 3 4 5 6 7 8 9 10 1 1 12
M O N T H S 15 30 4 5 60 75 90 1 0 5 1 2 0 135 150 1 6 5 1 8 0
1C
2C
3C
4C
5C
6C
8C
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 bythe 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.)
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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
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
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l Provide Accountability Sheet to Insure All Work
Cards in Packagen Routine Checks
u Include Lower Level Routine Checks
n Non-routine Checks
n Over and Above Items
u EO’s
u Special Inspections
There Are Several Steps to Package the
Tasks
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 next.
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
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Sample “4C” MSI Routine Tally Sheet
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
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Sample “Zonal” Routine Tally Sheet
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
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Sample “SSI” Routine Tally Sheet
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
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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 Cleaners
u Hydraulics/mechanical
u Avionics
u Engine
u Structure
u Inspectors Required
u Outside Services Required
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
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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 Non-
Routine• Deferred Maintenance Items
Determine Man-hour Requirements for Additional Non-
routine and Over & Above Work
u Plan for Overtime for Special
Circumstances/projects
u Borrow Manpower From Other Departments If
Necessary
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
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There Is a Tool for Estimating Non-routine
Hours for the Check Package
l Non-routine Hour Estimations Are Calculated Viaa Boeing Standard Formula:n A Planner Uses a Productivity Factor to Estimate the Hours of
Non-routines That Each Hour of Routine Maintenance WillGenerate.
n Productivity Factor = (1 Hour of Routine Maintenance + 1.2 Hoursof Non-routine Maintenance)* Efficiency Factor.
n Efficiency Factor = Maintenance Technician Skill Level on a Scaleof 1 to 5. Boeing Uses 2.5 As an Typical Number.
s Level 1 Is the Most Competent
n Actual Estimated Time = (Productivity Factor) + (efficiencyFactor)*(oamp Listed Time).
n
Example - Productivity Factor =s [(1 Hr Routine)+(1.2 Hrs Non-routine)]*(2.5) = 5.5
s (Oamp Time, 1 Hr)*(productivity Factor, 5.5) = 5.5 Actual EstimatedTime
Non-Routine Checks:
Douglas products Division Philosophy: 1.0 hr Routine Maintenance (R) = 1.2 hr Non-
Routine Maintenance (NR). Formula (R + NR) x EF = PF.
(The 1.2 hr NR can be adjusted to fit any airlines maintenance requirementsestablished 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 areinspection 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 non-routine.
•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 non-
routines).
•Adjust Non Routine Hours (1.2) down for aircraft in good shape. Make smalladjustments if needed.
•Note: OAMP - On Aircraft Maintenance Planning for DC & MD series aircraft and
MPD - Maintenance Planning Document for B series aircraft.
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PROJECTED MAN-HOUR ESTIMATE
PLANNED INPUT __________ RELEASE __________ TYPE OF HOLD: C-CHECK A/C: DC-10
NON-ROUTINE TOTAL
E.O.s & TOTAL PLAN SUB TOTAL ADDTNL ROUTINE & REQUIRED
BASIC SPEC. TIME TIME ROUTINE NON HR'S N/RTN N/TRN N/ROUTINE DAYS FOR
SKILL CHECK INSP. COMPONENTS ITEMS HOURS ROUTINE PER N/RTN HOURS HOURS HOURS HOLD
LINE MAINT. 260 204 173 292 929 640 1.8 1152 250 2331 9.3 DAYS
SHEET METAL 40 143 0 0 183 530 2.2 1166 400 1749 10.9 DAYS
INTERIORS 250 2 0 144 396 180 1.5 270 100 766 7.7 DAYS
AVIONICS 90 13 0 87 190 150 1.4 210 50 450 5.6 DAYS
PAINT 60 0 0 0 60 50 1.1 55 115 5.8 DAYS
SUBTOTAL 700 362 173 523 1758 1550 2853 800 5411 10 DAYS
INSPECTION 130 32 10 118 290 1550 0.125 194 48 532
N.D.T. 24 15 0 12 51 0 51
TOTAL 854 409 183 653 2099 3100 3047 848 5994
Planner Builds the Projected Man-hours Table
Production Supervisor Advises Planner on How Many Men / Women
Are Required
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Plan The Check Package And Airplane
Down Time
l The Production Supervisor & Production Coordinator
Determine Hold-time Required for the MaintenanceCheck:
n Check Long Range Hangar Schedule for Opening
u Assure Hold-time Is Adequate Based on Available Manpower
n Have Alternate Plan Identified If Airplane Is Late Coming
Into Check
u Aircraft Arrival Delayed Due to Maintenance Problem
u Aircraft Swap
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 Loading-
Not Demonstrate Suggested Crew Loading
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Plan The Check Package and Airplane
Down Timel Hold Pre-production Planning Meetings
n Advise All Departments of Their Responsibilities and Projected Work Load
Requirements
n Quality Control
u Number of Inspectors
u Non Destructive Testing (NDT) Requirements
n Production (Maintenance)
u Skill Requirements
u Ground Support Equipment Special Requirements
n Parts Control
u Pre-draw Parts List Identified and Shortages Noted
u Estimated Arrival Date of Parts Not in Stock
n Support Shopsu Turn Around Time for Shop Items
n Planning
u Introduce Flow Chart Plan
Meeting Attendees (Minimum)
•Quality Control
•Production Supervisor
•Production Coordinator
•Material Control
•Support Shops
Other Discussion Topics
Check Package Mile-stones
Flow-chart
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Plan The Check Package And Airplane
Down Time
l Prepare Work Dock - Production Coordinator
n Prepare Work Dock u Display Flow Chart
u Place Work Cards on Assignment Boards
u Organize and Prioritize According to the Flow Chart Plan
u Put Technicians Name Tags by Assigned Task to Track Work
in Progress
u Have Routine & Non-routine Task Cards and AccountabilitySheets in Place
Flowchart
All Departments Agree on Flowchart Form the Pre-production Meeting
Functions As an Adjustable Guide Throughout the Check
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Sample DC-10 “HMV” Flow ChartTASK 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
AP U S HR OUD CHE CK
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
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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 AREASINSTALL LAVS
7. FORWARD CARGO
REM OVE PANEL S
CLEAN AND INSPECT
INSTALL PANELS
8. AFT CARGO
REM OVE PANEL S
CLEAN AND INSPECT
INSTALL PANELS
9. LEFT WING
REM OVE PANEL S
6-7 SLAT TRACK MOD
SLAT CABLE CHANGE
RIG SLATS
CLOSE PANELS
10. RIGHT WINGREM OVE PANEL S
6-7 SLAT TRACK MOD
SLAT CABLE CHANGE
RIG SLATS
CLOSE PANELS
Sample DC-10 “HMV” Flow Chart
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There Are Several Steps to Execute the Check
Flight Control
Checks
Functional/Operational
Checks & Engine Runs
(Pre-Docking)
Wash Aircraft
Defuel Aircraft
Outside Pre-Check Tasks
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)
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Prepare Facility for Check Execution
Required Equipment and Special
Tools in Place
Materials and Parts
Sufficient Quantity of
Maintenance Tags
Provide Adequate Storage for
Parts Removed from Airplane
Hangar and Work Dock Preparation
Prepare Hangar Bay
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
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There Are Several Steps to Execute the Check
Perform Hanger Tasks
Open-Up
Inspect
Lube
Repair
Close-Up
Other Tasks
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”
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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
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 task
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
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Production Supervisor Duties During the
Check
Flow ChartSchedule
Daily Production
Meetings
Production Supervisor
Responsibilities
Daily Production Meetings Are Held With the Responsible Departments
•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 Man-
hours
•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
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Flow ChartSchedule
Daily Production
Meetings
Production Coordinator
Responsibilities
Production Coordinator Duties During the
Check
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
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There Are Several Steps to Execute the Check
Functional
Checks
Post-Check
Run-Ups
Test Flight
(if required)
Perform Post-Check Tasks
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.
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Elements of Production Planning
Production Planning Requirements to Maintain Continued Airworthiness Seminar.
Section 10
35
Post Production Analysis Is Performed After
the Check
n Heavy Maintenance
n Material Control
n Engineering
n Planning
n Quality Assurance
Hold Post-Production Meetings
with All Departments Involved
in the Process
Non-Routine Tracking
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
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Elements of Production Planning
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Section 10
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Heavy Maintenance Reviews Several Check
Tasks
Overtime Man-Hours
Expended
Training Requirements
Crew Loading
Man-hours Must Be Closely Reviewed for a Cause & Effect
Relationship
•Routine Task Cards Shouldn’t Have Significant or LargeChanges 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 Man-
hours That Were Expended.
This Is Most Applicable to Routine Tasks
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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 Poor Pre-draw or Insufficient Lead Time
l Were Components Returned From Backshops When
Required
n Investigate Reason for Delay
s Forgot to Route on Priority
s Spares Did Not Materialize or Were Defective
s Lost Tag on In-station
s Mis-routed Through Backshops
l Review Other Material Concerns:
n
Left Over Parts - Excessive Pre-draws Replace in Inventory When Possible
n Free Bins of Consumables and Expendables
s Technicians Often Keep Abundant Supplies in Tool-boxes
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.
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Elements of Production Planning
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Section 10
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Engineering Reviews Several Check Tasks
l Engineering Reviews Eo’s for Effectiveness
s Wrong Instructions or Poor Instructions
s Wrong Drawings Wrong Parts
s Wrong Man-hour
Estimate
s Wrong Function
or Fit With Modification
s Wrong Function of Task Card
n Engineering Solution
s
Issue Revised Eo Based on Feedback s Track New Results
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 De-
escalation (Intervals)
•Regulatory Agency Will Not Normally Accept AnyProposal for Escalation Without Reliability Figures
•Non Technical Objection From Boeing Is Not
Available Without a Review of Reliability
Figures
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Elements of Production Planning
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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 Incorrect Procedures
s Confusion About Procedures
s Ineffective Procedures
u Pneumatic ITCAN Test for Air Pressure Leak
( Tin Foil Over Pneumatic Joints & Lines Is More Effective
s Inefficient Procedures
u Older Task Card Started Engines to Perform Take-off Warning
Check
u Revised Task Card Does Not - Procedure Simplified to Check
Micro-switches in Quadrant, Which Is the MRB Intent
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
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Elements of Production Planning
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Planning Reviews Check Package
l Check Package Review Contains:
l Man-hours:
n Routine & Non-routine
s Review Planned Vs. Actual
s If Actual Is Significantly Higher Than Planned
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)
u Was Crew Loading Similar
u Was Crew Competency Similar
Man-hours Must Be Closely Reviewed for a Cause & Effect
Relationship
•Routine Task Cards Shouldn’t Have Significant Changes inCompletion 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 Man-
hours That Were Expended.
This Is Most Applicable to Routine Tasks
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Elements of Production Planning
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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 Aircraft Problem
s Station Problem
u Training Problem
s Component Problem
u Tracking by Serial Number
Can Isolate Rogue Components
n Compare Your ATA Specific Reports to the BoeingComponent Reliability Reports
s Identify If Problem Is Fleet Wide.
s Possible Team Conference Issue for Permanent Resolution.
Aircraft Problem:
Aircraft May Have Chaffed Wires That Routinely Lead to False Trouble-
shooting 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
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Summary
Production
Scheduling
Executing the
Check
Task Card
Packaging
Post Production
Analysis
Planning the
Check
Production Scheduling
All Five Main Departments Assist With Production Scheduling
Task Card Packaging
Identified Routine and Over & Above TasksPackaged 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