MRO- Maintenance, Repair & Overhaul

All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions.

MRO- Maintenance, Repair & Overhaul

Aircraft MRO is the overhaul, repair, inspection or modification of an aircraft or aircraft component Maintenance includes the installation or removal of a component from an aircraft or aircraft subassembly, but does not include:

Elementary work, such as spark plugs, checking cylinder compression, etc ervicing, such as refueling, washing windows !ny work done on an aircraft or aircraft component as part of the manufacturing process, prior to issue of a certificate of airworthiness or other certification document

Regulation of Maintenance
JAA - Joint Aviation Authorities JAR - Joint Aviation Requirements JAR-OPS 1 & 3 issued in May 1
JAR-OPS 1 - Aero"lanes JAR-OPS 3 - #elico"ters

A""lica$ility% i&a&'& JAR-OPS 1 & 3 Su$"art A(

)ivil aero"lanes in commercial air trans"ortation O"erators 'hose "rinci"al "lace of $usiness is in a JAA Mem$er State

JAR-OPS 1 & 3 Su$"art M(

Su$"art M defines the aircraft maintenance requirements as vie'ed from the "ers"ective of the Airline O"erator Su$"arts * and ) also define maintenance related requirements

Res"onsi$ilities of Airline O"erators

An Airline O"erator shall ensure the air'orthiness of the aero"lane and the servicea$ility of $oth the o"erational and emergency equi"ment% $eing res"onsi$le to "erform and + or control the follo'ing&
Preflight ins"ection ,efect rectification to an a""roved standard -ffectiveness analysis Maintenance i&a&'& maintenance "rogramme 0ife limits and e1"iry dates Air'orthiness ,irectives .A,s/

Modifications and its "olicy

2hese requirements must $e "erformed in accordance 'ith "rocedures acce"ta$le to the Authority

Res"onsi$ilities of Airline O"erators

2he Airline O"erator is therefore res"onsi$le for(
The The airworthy airworthy condition condition of of the the aeroplane, aeroplane, even even ifif the the Airline Airline Operator Operator does does not not perform performany anymaintenance maintenance Managing Managing aa maintenance maintenance programme programme (what (what maintenance maintenance is is required, required, when when to to perform performit, it,by bywhom whomand andto towhat whatstandard) standard)and andgetting gettingAuthority Authorityapproval approval Amending Amendingthe themaintenance maintenanceprogramme programmeand andgetting gettingAuthority Authorityapproval approval Maintaining Maintainingadequate adequateknowledge knowledgeof ofthe thedesign designstatus statusof ofthe theaeroplane aeroplane stablishing stablishing aa policy, policy, and and work work to to that that policy, policy, to to assess assess non!mandatory non!mandatory information informationsuch suchas ascertain certain"ervice "ervice#ulletins, #ulletins,"ervice "ervice$etters, $etters,etc% etc% Analysing Analysing the the effectiveness effectiveness of of the the maintenance maintenance programme, programme, with with regard regard to to spares, spares,established establisheddefects, defects,malfunctions malfunctionsand anddamage damage &roviding &rovidingaaclear clearwork workorder orderto tothe the'A(!)*+ 'A(!)*+maintenance maintenanceorgani,ation organi,ation -hecking -heckingthe thesubcontracted subcontractedwork workat atthe themaintenance maintenancefacilities facilities

Res"onsi$ilities of Airline O"erators

An Airline O"erator shall esta$lish and maintain a 3uality System in accordance 'ith JAR-OPS 1&43! .Su$"art */& An Airline O"erator shall therefore esta$lish a 3uality System and designate a 3uality Manager% acce"ta$le to the Authority& 2he 3uality System must at least monitor(
)om"liance 'ith a""roved "rocedures% ref& JAR-OPS 1&43!.a/ 6eed$ac7 system to the Accounta$le Manager% ref& JAR-OPS 1&43!.a/ 3uality Assurance Programme% ref& JAR-OPS 1&43!.$/ JAR-OPS 1&8 4 activities i&a&'& acce"ted "rocedures% ref& JAR-OPS 1& 44.a/.1/ )ontracted maintenance i&a&'& the contract% ref& JAR-OPS 1& 44.a/.9/ )ontinued com"liance 'ith Su$"art M% ref& JAR-OPS 1& 44.a/.3/

2he 3uality System may $e com$ined 'ith JAR-15! 3uality System&

"ypes of Maintenance
Each airline develops its own program, based on manufacturer#s planning documents, but includes ad$ustments for the airline#s own operations Each aircrafts re%uires different operators and programs &'", aircraft of the same number of routine maintenance hours during the program cycle

MRO- Maintenance, Repair & Overhaul

Maintenance of aircraft usually categori(ed into

)roduct type *airframe, engine and components+ "iming and purpose of work Routine scheduled maintenance -on-routine maintenance Refurbishments Modifications

"hen, resulted into , categories

Routine scheduled maintenance

.ncludes airframe and engine checks "he most elementary is visual inspection of the aircraft before flight- /walk-around# "o ensure there are no leaks, missing rivets or cracks "ypes of checks-.n 0rades

Overnight !-1heck

Routine scheduled maintenance

&-check 1-check 2-1heck

Overnight: Operate 3 to 345 hrs4 inspection *End of working day+ to ensure the plane operating in according to OEM /s *Original E%uipment Manufacturer+ minimum list .n, e6ample installation of telephones and other devices

14

Routine scheduled maintenance

!-1heck: 2one after 375flight hours *7-8 weeks+

!n amplified preflight visual inspection of plane9s power plants, avionics and accessories

&-1heck: 2one appro6imately after 3:5 flight hours *8 to , months+

!n open inspection for preventive maintenance *e6terior wash, engine oil+ Oils filters are removed and checked, parts are lubricated and carefully e6amined

Routine scheduled maintenance

1-check: 1arried out appro6imately for every 8;;; flight hours *35 months+

.ncorporates both ! and & checks 1omponents are repaired, <lights controls are calibrated Ma$or internal mechanism are tested Other tests include minor structural inspections, compressor, flight control rigging tests, engine, compressor washes, aircraft appearance maintenance, and post-check flight tests

Routine scheduled maintenance

2-1heck: "he most intensive, appro6imately 7;, ;;; flights hours *=-> years+

1abin interiors *including seats, galleys, lavatories, cockpit, furnishings, headliners and sidewalls+ are removed to enable careful structural inspections <lights controls are e6amined and the fuel system is probed for leaks and cracks "he aircraft is stripped to its shell and rebuilt to return it to its original con

Routine scheduled maintenance

MRO activities

Engine 1ompressor washes

flight control rigging tests

-ngine Maintenance
I must leave this shop in full airworthy condition !
)6M!:-!* and )6M!:-!) at 2AP Maintenance & -ngineering )-)hec7 #angar

J28, at 2AP Maintenance & -ngineering -ngine Overhaul Sho"

TAT and profit margin considerations shall never impair quality !

-ngine MRO Providers

O-M Original -qui"ment Manufacturers .o'n facilities or acquired sho"s/
e1( ;-% Snecma% P&<% RR% etc&

Airlines

Airline -ngine Sho"s .integrated or inde"endent from airline/

e1( 2AP M&-% =0M -&M% 0ufthansa 2echni7% Air 6rance >ndustries% etc&

>nde"endents

>nde"endent -ngine Sho"s

e1( M2?% 6iat Avio% >A>% etc&

-on-routine Maintenance
2one due to unforeseen event such as accident4 !n e6ample of the first engine damage due to bird ingestion or an airframe dented by a catering truck 2one also for an aging aircraft

Refurbishments
!ny form of upgrading of cleaning, brighting, or making it fresh again4 "o renovate and upgrade the aircraft <or e6ample: 1abin upgrades and e6terior painting

Modifications
!ny form of small alteration, ad$ustment, or limitation to fulfill the aircraft#s owner4 Most modifications are carried out within the interior design, not much on the airframe and engine4 <or e6ample: .nstallation of karaoke, ) 8 and various kind of entertainment in the cabin

Overhaul of airframes
! plan where a series of seven minor overhauls and one ma$or check were conducted on aircraft "he ma$or overhaul was designed to rework the airplane to a like-new condition-to fit the bits and pieces back together to the e6actness of current manufacturing tolerances

Overhaul of engines and other components

1omponents are brought in when either operating time? condition re%uires it "he overhaul returns them to specifications laid down by engineering and manufacturer &'" when practical, engine changes are made during maintenance checks or airframe overhauls

1ontract Maintenance
@henA @hen the airline do not have the personnel and e%uipment to perform maintenance @hen serving a distant airport at which they do not have maintenance support @hyA 2ifferent types of aircraft re%uires different e6pertise from different areas Bow labor cost .mportant note: ome contracts e6tend to other functions, such as cleaning and fueling the aircraft

-1"ectation from -ngine MRO Provider

2he 2he7ey 7eychallenge challengefor foran an-ngine -ngineMRO MROProvider Provider is isto to manage managethe the$alance $alance$et'een $et'een2A2 2A2 and and)ost )ostmaintaining maintaining
Manage 'or7sco"e vs& required 2A2

)ost

3uality

Manage stoc7 level vs& required 2A2 Manage scra" re"lacement vs& re"air
Performance% Performance%6le1i$ility% 6le1i$ility%3uality 3uality

2A2

-1"ectation from -ngine MRO Provider

Relia$ility% Relia$ility% 3uality 3ualityand andS"eed S"eedare are no'adays no'adaysmore more im"ortant im"ortant than thanPrice Pricefor for the theAirline AirlineO"erator O"erator
Source( A&2& =earney

-ompletion 4ate (eliability (eputation for 3uality 1ast TAT $ow Total &rice -ustomer "ervice -onvenient "cheduling 2nnovative &ricing 1ull "ervice $ong Term &artner O M . ) / 0 * +

6actor

Relative im"ortance

MRO )hallenges
@e'er engines are $ecoming increasingly more com"le1 requiring higher levels of engineering e1"ertise Shortage of s7illed staff is one of the greatest o$stacles today for future "erformance gains among Airline O"erators >n order to reduce costs and increase surviva$ility% Airline O"erators focus on their core $usiness and reduce staff to a minimum #ighly com"etitive engine MRO situation "revents Providers from o$taining desired "rofit margins

>n general% Airline ca"a$ility to control their JAR-OPS 1&8 4 res"onsi$ilities in res"ect to engines has decreased significantly in the "ast years and 'ill "ro$a$ly continue in the near future

Stresses MRO 3uality Assurance de"artments

Added Addedres"onsi$ilities res"onsi$ilitieson on JAR-15! JAR-15!a""roved a""rovedorganisations organisationsstress stress @ational @ationalAuthorities Authoritiesand and>nternal >nternalAudit Auditto tomaintain maintain"ro"er "ro"er control control

MRO )hallenges
Airlines are for flying C >Dve got to reduce some resources in other de"artments& Oh&&fly $oysAC Bust 'ant to fly% $ut they must ta7e care of their "lanes too& >Dd $etter 7ee" close control& > guess > 'ill end u" in the hands of an MRO ProviderA > Bust ho"e it is really good C #ey "al% > have some friends in the technical de"t& 'ho ta7e real good care of me&

2ime is money& #urry u" C

My 3A friend really 7no's his "lace and his "eo"le& #eDs doing a fine Bo$& > have to hel" him more&
Authority JAR-OPS Authority JAR-15!

Mechanic

Sometimes there are Bust so many rules% so much to learn and so little time C&&& &&& and my $oss al'ays tells me to hurry u"&

#umm&&& 2hese mechanics 7no' 'hat theyDre doing% $ut are al'ays under stress& >Dd $etter tighten the control and chec7 them more often&

3A - MRO

Question 1
The aircraft maintenance, repair and overhaul (MRO sector has seen tremendous growth in recent !ears that involve cost centre within an airline, the maintenance, modification and aftermar"et servicing of commercial aircraft, engines and components.
a #riefl! e$plain in !our own words the concept of maintenance, repair and overhaul (MRO . (% mar"s b &escribe in !our own words the responsibilit! of the airline MRO operator' (( mar"s c )rom !our opinion, which is the most challenging tas" for an MRO operator and state !our reason wh!. (% mar"s

Question 2
Airliner would develops its own MRO program, based on manufacturer*s planning documents, but includes adjustments for the airline*s own operations. a &iscuss in details the four categories of Maintenance, Repair and Overhaul (MRO (( mar"s b &iscuss in !our own words significance of MRO engine maintenance . (% mar"s
c )rom !our opinion, what are the "e! success indicator

for an MRO service provider' (% mar"s

Question 3
MRO toda! has become more sophisticated in identif!ing, diagnosing and transmitting defects that require the important feature of MRO Management.
a #riefl! e$plain the difference in refurbishments and modifications in MRO. +tate some e$amples to support !our answer. (, mar"s b &iscuss in !our own words the standard e$pectations from an MRO -rovider (. mar"s c )rom !our opinion, which MRO provider would !ou prefer to service !our aircraft' +tate !our reasons (% mar"s

Question 4
One of the most critical activities for airline MRO is to stri"e a balance between suppl! and demand, as insufficient stoc" of spare parts can lead to stoc" outs and creating lost revenue opportunities.
a #riefl! discuss all the challenges that the MRO provider faces. (. mar"s b /uide MA+ that has more than 0 !ear old aircraft with %111 flight hours completed in the MRO routine scheduled maintenance. 2hich t!pes of chec"s3in grades is suitable for this aircraft. (4 mar"s c )rom !our opinion, would !ou opt to use contracted maintenance for !our airline compan!. +tate !our reasons. (5 mar"s