Maintenance programs have a material impact on how an airline operates, its costs, and its revenue.
Airlines have a choice with regards to Maintenance Programs – use the Original Equipment Manufacturer (OEM)’s MRBR/MPD or customize it and optimize for their unique operation and environment.
Maintenance Program optimization is a commonly employed strategy that has contributed to increased profitability without compromising safety.
The benefits of a fully optimized maintenance program are accessible by packaging and optimizing maintenance to:
- Take full advantage of planned maintenance events and schedule tasks for common access – reducing the frequency with which maintenance tasks require access to or removal by technicians of an assembly, part or panel
- Perform maintenance at its highest effective interval
- Adjust program requirements to address reliability drivers
- Move maintenance effort out of operational line stations and into controlled hangar environments
- Simplify maintenance packages to reduce the planning burden and take advantage of aircraft access
- Develop a lowest cost check structure for life of the unit, taking into account the fleet life cycle
Together, these initiatives generate benefits by way of six value drivers:
Reducing the number of maintenance units (aircraft) on the ground or in the hangar results in more aircraft available to fly and earn revenue. A SeaTec optimized program for a regional airline brought 1 additional aircraft onto the flight schedule.
Optimized Maintenance Task content and check intervals reduces maintenance and engineering labor hours / costs. For another airline, the SeaTec optimized program reduced the number of C Checks which yielded a 20% maintenance cost saving per aircraft for the life of each aircraft.
Remaining compliant with ‘one size fits all’ MRB programs requires a significant investment in infrastructure and resources. Underinvestment can lead to overruns. Simplification reduces complexity and costs.
Robust data analysis informs program enhancements and reduces maintenance effort which improves aircraft reliability and availability.
Optimization of all checks reduces the utilization of scarce line and hangar resources and addresses bottlenecks in MRO maintenance execution.
Reductions in maintenance touch time directly reduces human factors risks.
FAA REQUIREMENTS AND EXPECTATIONS
For airlines regulated by the FAA, Advisory Circular No.120-16(X) Air Carrier Maintenance Programs describes the mandated scope and content of an air carrier’s aircraft maintenance programs.
Use of the Original Equipment Manufacturer (OEM)’s MRBR/MPD is mandated for the first year of operation for any new fleet added to an operators OpSpec. One year is specified to collect the minimum data required to support an operator’s Continuing Analysis and Surveillance System (CASS) program which amongst other things, ensures maintenance decisions are driven by a consistent baseline of data.
After one year, AC 120-16(X) Chapter 6 requires an operator to maintain an effective program customized to their unique operation using specific data analysis. This is often misinterpreted as meaning the MRBR/MPD and subsequent revisions are the most effective and optimized program, however, the exact opposite can be true.
HOW CAN AN OPTIMIZED MAINTENANCE PROGRAM HELP YOUR AIRLINE?
Any aircraft operator – commercial passenger, private passenger, cargo, or defense – can benefit from an optimized maintenance program. The scale of the benefit varies and is typically a function of five factors:
- Fleet size
- Fleet configuration
- Fleet utilization
- Operational environment and conditions
- Experience of the Maintenance and Engineering teams with program optimization
Any operator that is not doing maintenance at the highest effective level or has flight operations constrained or otherwise negatively impacted by maintenance should consider maintenance program optimization.
SeaTec is an industry leader in developing and optimizing Maintenance, Reliability and Predictive Programs.
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