Week 9 AMT 4202 Midterm Lecture No. 3

TECHNICAL SERVICES
FOR ENGINEERING
Introduction
Introduction
The aviation industry is currently debating the necessity of an
engineering component within airlines. Historically, airlines
played a pivotal role in determining aircraft specifications and
design, but recent trends have shifted the responsibility for
aircraft design and development to airframe and engine
manufacturers. Consequently, many airlines have downsized or
eliminated their engineering staff. However, there remain
compelling reasons to retain engineering expertise within
airlines.
Introduction
This chapter explores the essential role of engineering in aviation,
emphasizing the importance of maintenance engineers who ensure
the continued reliability and safety of aviation systems. While
various engineering specialties exist, the focus in an airline
context is on "maintenance engineers" who blend engineering
knowledge with technical expertise to develop and apply
maintenance programs effectively. The organization and functions
of airline engineering departments vary, but their key role is to
support maintenance activities and provide analytical and
troubleshooting assistance to address complex technical
challenges within the industry
Makeup of Engineering
The airline engineering department comprises experienced
individuals from the maintenance organization.
Specialized staff within the department cover various

equipment types, including avionics, electrical, hydraulic,
pneumatic, power plant, structures, and mechanical systems.
Some airlines may further divide specializations, such as

avionics into communications and navigation, or mechanical
systems into flight controls and hydraulics.
Mechanics and Engineers
Some airlines employ mechanics-only engineering
departments, while others opt for exclusively degreed
engineers.
Mechanics excel in system details, regulations, and fleet

idiosyncrasies but lack analytical skills.
Engineering graduates often lack practical aircraft

knowledge.
Mechanics
The Crucial Role of Mechanics and Technicians in Aviation:
Mechanics and technicians are fundamental to aviation, specializing in

avionics or mechanical systems.
They are indispensable for shop, hangar maintenance, and third-party

maintenance organizations.
Their training equips them with a deep understanding of system operations

and standardized troubleshooting, fault isolation, and repair procedures.
Engineers
"Engineer" refers to those with academic engineering degrees, who undergo distinct
training from mechanics.
Engineers receive comprehensive education in science, engineering basics,

reasoning, statistics, and problem-solving, specializing in specific engineering
disciplines.
Engineers are capable problem solvers, equipped to tackle complex aviation issues
beyond standard mechanics' procedures.
It's vital for engineers to possess not only engineering knowledge but also a deep
understanding of aircraft systems for effective problem resolution.
Engineering Department Functions
Purpose of the Engineering Department
Preparation, study, and analysis of maintenance operations
Evaluation of maintenance requirements
Establishment of maintenance programs
Upgrading Aircraft Systems
Assessment of suggested modifications
Potential incorporation into the fleet
Facilitating Equipment and Facility Handling
Preparing units for new equipment
Ensuring smooth facility operations
Comprehensive Maintenance Support
Assistance in all maintenance-related aspects
Development of Aircraft Maintenance Programs
Aircraft maintenance programs are crucial for ensuring the safety and reliability of aircraft.
These programs are initially provided by industry working groups and aircraft manufacturers.
Initial Maintenance Program
Each airplane model comes with an initial maintenance program.

This program is a recommended starting point for new operators and equipment.
Operators can make adjustments based on their unique needs and operational conditions.
Customization of Maintenance Programs
Operators must tailor the initial maintenance program to their specific requirements.
The manufacturer produces an FAA approved MRB report and a maintenance planning
document. The airline's engineering department is responsible for organizing maintenance tasks
according to factors such as time, space, personnel, fleet schedules, and overall capabilities.
Develop technical policies and procedures manual for M&E
Add a little bPurpose: To create a comprehensive manual for M&E operations.
Components: Organizational structure, responsibilities, maps, procedures.
Collaboration: Engineering leads with inputs from other M&E units.
it of body text.
Manual Content
Covers all aspects of M&E organization and responsibilities.
Identifies organizational structure and key personnel.
Detailed procedures for work execution, management, inspection, and release.
Regulatory Compliance
FAA Requirements: Minimum requirements defined in FAR 121.369.
Emphasize Safety: Consider additional policies for complete instructions.
Adherence to regulations is crucial.
Manual Formats
Flexible Options: Single document, separate documents, or multiple volumes.
Adapt to Organizational Needs: Choose the format that suits your needs.
Evaluate changes in the maintenance program
Problem Recognition:
Maintenance program issues can arise
Ineffective or inadequate individual tasks
Potential need to reinstate MRB tasks
Adjusting Task Intervals:
Shortening or extending repetitive task intervals
Aiming for improved system/component performance
Reducing in-service failures
Responsibility:
Engineering staff plays a pivotal role
Data collection by the reliability organization
Problem analysis by engineering
Evaluate changes in aircraft or system
configuration
Reporting in aviation involves communication of modifications and improvements.
Three main types of reporting: Service Bulletins (SBs), Service Letters (SLs), and
Airworthiness Directives (ADs).
SBs and SLs are manufacturer recommendations, not mandatory.
Airlines can choose to incorporate or ignore SBs and SLs.
Airworthiness Directives (ADs) are mandatory, issued by the FAA to address safety
or airworthiness issues.
Evaluate changes in aircraft or system
configuration
Compliance with ADs is non-negotiable.
The engineering department evaluates the feasibility of incorporating

modifications.
Cost-benefit analysis is used to assess the value of modifications.
Engineering Orders (EOs) provide detailed instructions for modifications.
Compliance with ADs ensures safety and airworthiness in aviation.

Evaluation of new aircraft added to the fleet
Engine Evaluation Hangar and Facilities
Outstation and Personnel Parts and Storage
Technology Assessment Industry Experience
Compatibility with Current Maintenance
Ground Support Equipment (GSE)

Evaluation of used aircraft added to the fleet
If the airline is contemplating the purchase or
lease of used airplanes from another airline or
leasing organization, other items must be
considered in addition to the above items relating
to equipment differences from the existing fleet.
These items would include the following
information:
The current configuration of the airplane
Engine type
Maintenance program and check the schedule
that the current operator is using
Status of modifications (ADs and SBs)
Evaluation of used aircraft added to the fleet
Also, these items would include the following
information:
1. Are these requirements the same as, similar to, or
different from your airline’s current equipment?
2. How will this affect training, maintenance
support, material support, outstation activities,
etc.?
3. If airplanes are to be leased, what modification
and configuration standards must be met by the
operator; and by the lessor?
4. What configuration should the airplane be in at
the termination of the lease?
Evaluation of new ground support equipment
On a smaller scale, the engineering department
will also be called upon to evaluate the need for
new equipment in support of aircraft added to
the fleet. This would include tools, test
equipment, stands, electric and pneumatic
carts, heaters, tow bars, tractors, etc. Some
existing equipment may or may not be usable
with the new airplane models (purchased or
leased). In some cases, the GSE, though usable,
may not be available in sufficient quantity to
serve the increased fleet size.
Development of new facilities for M&E
At times, it is necessary for the airline to build new facilities or expand
existing ones to support new equipment, airline expansion, or modernization
efforts. This would include such projects as hangars, engine test facilities,
component shops, storage facilities for various types of equipment, and
storage for special parts.
Engineering will have considerable input into the design in terms of
requirements. A hangar, a workshop, or any other facility must be designed
for the express use of the airline and the M&E organizations that will occupy it.
Therefore, the engineering department will act as a liaison between the users
and the designers and builders to ensure that the finished product is
acceptable.
Issuance of Engineering Orders
Any work not included in these standard checks
must be assigned by engineering order. Some
airlines may call this document by another name,
such as work order, technical order, or engineering
authorization (EA). This EO is developed by
engineering, with inputs from appropriate work
centers, to define the scope of the job and schedule
the work. Work performed as a result of SBs, SLs,
ADs, and all work resulting from evaluation of
problems defined by reliability investigations or QC
reports, will be issued on an engineering order.
Maintenance Checks
Different checks (A, B, C, and D) are performed at varying intervals.
Larger airlines can schedule "C" checks as a continuous process.
Smaller airlines need to divide "C" checks into manageable phases due to limited
resources.
An annual "C" check can be divided into phases (C1, C2, C3, and C4).
Each phase is conducted separately over several months to distribute the workload
evenly.
Continuous Personnel Utilization
This approach ensures checks are completed within specified time limits and stabilizes
airline workload.
Task Selection and Packaging
The engineering department selects tasks, packages them into check units, and ensures
all task limits are met.
Scheduling checks for individual aircraft is handled by the production planning and
control department.
Task Cards
Detailed maintenance tasks require task cards for mechanics.

Task cards are either provided by aircraft manufacturers, written by the
airline, or a combination of both.
Engineering is responsible for developing, assembling, and maintaining task
cards.
Provide assistance in troubleshooting difficult
problems
Routine Challenges in Daily Work:
Mechanics commonly face predictable issues in their daily tasks on the line, in
the hangar, and in shops, demanding familiar solutions.
Troubleshooting Expertise in Action:

Occasionally, more intricate problems arise, requiring mechanics to employ
their troubleshooting skills for resolution.
Last Resort Engineering Aid:

In challenging situations beyond a mechanic's expertise, engineering
provides support as a supplementary resource, not a substitute for
maintenance duties.
Other Engineering Functions
Broad Expertise in Training and Resources:
Engineering shares its technical proficiency with diverse M&E organizations, aiding
in training, materials, and the technical library.
Technical Authority within the Organization:

Recognized as the technical experts, the engineering team is accessible to offer
technical assistance to anyone within the airline seeking help.
Extensive Tech Assistance:

Engineers, extending beyond their core duties, offer valuable technical
support throughout the airline, catering to diverse needs.
Engineering Order Preparations
Initiating EOs:
Engineering launches EOs for tasks beyond standard maintenance, driven by
alerts, workforce needs, or directives like ADs or SBs.
Diverse EO Paths:
EO execution varies based on work complexity, involving Planning for
modifications or direct issuance for changes in programs, processes, parts, or
training.
Eight-Step Process:
The EO process includes decision-making, analysis, resource
identification, coordination, issuance, and closure, with fleet-wide EOs
closed after PP&C addresses the entire fleet.

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TECHNICAL SERVICES

Specialized staff within the department cover various

Some airlines may further divide specializations, such as

Mechanics excel in system details, regulations, and fleet

Engineering graduates often lack practical aircraft

Mechanics and technicians are fundamental to aviation, specializing in

They are indispensable for shop, hangar maintenance, and third-party

Their training equips them with a deep understanding of system operations

Engineers receive comprehensive education in science, engineering basics,

Initial Maintenance Program

Each airplane model comes with an initial maintenance program.

Customization of Maintenance Programs

SBs and SLs are manufacturer recommendations, not mandatory.

Airlines can choose to incorporate or ignore SBs and SLs.

The engineering department evaluates the feasibility of incorporating

Cost-benefit analysis is used to assess the value of modifications.

Engineering Orders (EOs) provide detailed instructions for modifications.

Compliance with ADs ensures safety and airworthiness in aviation.

Engine Evaluation Hangar and Facilities

Outstation and Personnel Parts and Storage

Technology Assessment Industry Experience

Compatibility with Current Maintenance

Ground Support Equipment (GSE)

Detailed maintenance tasks require task cards for mechanics.

Troubleshooting Expertise in Action:

Last Resort Engineering Aid:

Technical Authority within the Organization:

Extensive Tech Assistance:

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