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Boeing Mistake Prevention

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Steven Galvin
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Module 5 activity 5.4 1. Discuss the three categories of tasks in your own words
a. Routine tasks are those that must be completed regularly on all aircraft.
b. Variable Routine tasks are similar to routine tasks but vary by aircraft. They can include SB and AD that are specific to models of aircraft.
c. non-routine tasks are unscheduled maintenance tasks that are discovered as a result of conducting routine tasks. 2. Research a Phase Check on an aircraft of any airline and write about the way the airline performs the Phase Check.
American Airlines conducts Daily Checks, A checks, B checks, and C checks.
Daily checks are conducted every 2-3 days and it is visually inspected, taking approximately two man hours. The log book is checked for any maintenance needs.
A checks are more detailed and are performed every 7-9 days. It takes approximately 10-20 man hours.
B checks are even more thorough. It is accomplished every 2 months, which is usually between 500-600 flight hours. In addition to visual checks, a series of systems and operational checks are performed. These checks are conducted in a hangar in one of seven cities. The B check takes approximately 100 hours on narrow body aircraft and 200-300 hours on wide body.
C checks are the most thorough. The aircraft goes through a series of checks inspections and overhaul work. The c check is performed in one of the airlines heavy maintenance facilities in Tulsa, OK or Fort Worth, TX. There are 3 types of C checks done depending on the style of aircraft. 2 types are used on narrow body planes. A light C check is done every 15-18 months and takes 2,100 man hours. Every fourth light c check becomes a Heavy C check and takes 20,000-30,000 man hours.
The wide body C check are all Heavy C checks. They are done every 24-30 months and take approximately 10,000 man hours. (American Airlines, 2011)

3. Describe some necessary elements that PP&C must arrange for in order to execute the PP&C package.
a. Locate and secure hangar space needed to conduct the maintenance
b. Obtain a release of the airplane from operations. Downtime must be scheduled in coordination with operations to ensure the aircraft is available for maintenance. The airplane may be needed by operations to meet the flying schedule.
c. Arrange for and schedule the washing of the aircraft. Aircraft require cleaning to prevent corrosion and should be done in conjunction with major maintenance to reduce downtime and aid in the inspection process.
d. Secure tow vehicles and manpower needed to move the airplane to the wash rack and into the hangar.
e. Ensure all parts and supplies needed are on hand. This will eliminate unnecessary delays in the accomplishment of maintenance.
f. Ensure delivery of those parts and supplies to the hangar at the time needed.
g. Identify manpower and skills needed for the check. The necessary personnel must be scheduled and available to avoid delays. (Kinnison & Siddiqui, 2013)

4. Outline the three functions of Production Planning & Control (PP&C) Department.
1. Forecasting- Concerned with the future workload of the M&E organization.
a. Ensure PP&C and M&E are up to date on changes and ready to adjust their processes and procedures.
b. Long term forecasts- 5-10 years. These planned changes affect maintenance and engineering activities, scheduling, budgeting, training, manpower, and facilities. Long term forecasts accommodated growing or shrinking airlines.
c. Short term forecasts- 1-2 years. More detailed forecasts with definitive plans. Focused on actual manpower and budget numbers. Schedules for checks and modifications are finalized.
d. Intermediate forecasts- 2-5 years. Used by larger airlines. (Kinnison & Siddiqui, 2013)
2. Planning-Deals with day to day activities with the purpose to deliver airworthy vehicles to the flight department in time to meet the flight schedule. Planning takes the engineering package and plans, schedules, and adjusts the work for each aircraft. (Kinnison & Siddiqui, 2013) a. Line maintenance activities b. Hangar maintenance activities c. Shop Maintenance activities.
3. Control- Adjusts to variations in the plan. a. Non-routine tasks b. Parts/supplies/manpower/facilitiy availability
c. Provides feedback to Planning activity for more accurate forecast in the future (Kinnison & Siddiqui, 2013)

5. Explain the elements that the Aviation Maintenance Manager needs to know to adjust future planning.
a. Exact amount of time to complete each task
b. Amount of time lost waiting for parts, supplies, and tooling
c. Downtime for unusual circumstances.
d. Exact additional time spent on non-routine findings
e. Variation in manpower availability
f. Lost time due to parts robbing for other jobs. (Kinnison & Siddiqui, 2013)
References
American Airlines. (2011, December). Aircraft Maintenance Procedures Fact Sheet. Retrieved from https://www.aa.com/content/images/aboutUs/newsroom/fs_aircraft_maintenance_procedures.pdf Kinnison, H.A. & Siddiqui, T. (2013). Aviation Maintenance Management, Second Edition. New York, Ny. McGraw-Hill Education. Kindle Edition

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