Chr-A320 Family Heavy Maintenance Project Management

Highlight A: Heavy maintenance working schedule and control
1) Preparation and work package analysis for Heavy Maintenance ( C check)

2) Pre-inspection for aircraft condition ( Preliminary check) If applicable.

3) Communication and Liaison before C check incoming

4) Aircraft input to the C check
a. Phase 01----incoming
b. Phase 02---- removal/access
c. Phase 03---- inspection
d. Phase 04/05 ---- repair/modification/Non-routine handling
e. Phase 06---- Re-installation
f. Phase 07---- Functional test and final assembly
g. Phase 08---- close up and redelivery
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Highlight B: A320 aircraft heavy maintenance potential risk

1) A320 family both wing top skin corrosion
2) A320 family rib 5 inspection and modification
3) A320 family SB A320-57-1154 and A320-57-1155 inspection and
modification.
4) A320 family lavatory floor pan heavy corrosion in the lavatory wet zone

When above major inspection/modification items affect to each AIRBUS
A320 aircraft, it risks raising C check turn around time (T.A.T)
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Highlight C: A320 aircraft heavy maintenance cost saving and re-
adjustment of T.A.T.
1) Detailed analysis of GTA details, such as the cap of Non-routine
manhours, materials, and obligations of both parties.
2) Deep, specific analysis of the work package, such as customized MP
tasks and work scope.
3) Combine work schedules and make materials delivery a priority. Closely
monitor milestones and benchmarks along the duration of the entire
project.
4) Negotiate the final division of non-routine labor and additional work
requests.
5) In case outstanding issues will impact delivery target, the schedule
sequence and milestone will be movable and match the final target.

Highlight A:
Heavy maintenance working schedule and control
1.Preparation and work package analysis for Heavy Maintenance ( C check)
Deeply review the datum aircraft heavy maintenance work package. clearly
catch key points
a. major routine tasks
b. major access zones
c. major repair /modifications
d. open Non-routine/ADD
e. closed or open loop components repair ( LDG,ENG or APU, THS).
Materials status control.
a. Routine materials status
b. Non-routine/ADD materials status
c. Modification /repair kit or special tooling required if any.
d. Off wing OCCM or major components repair /OVH T.A.T or redelivery
schedule.
GTA (contract) review
a. The fixed price and cap of non-routine labor, consumable materials,
expendable and peculiar materials ( BFE etc)
b. Obligations of both parties understood; Attention to responsibility of
materials purchase , special tooling loan and T.A.T.
c. Attention to how well the aircraft is leasing - which will impact the PMA parts
usage or reimbursement requirement. It is very important issue for
customers.
Aircraft basic information
a. share and provide airplane technical data and information,
such as type of oil, fluid, MTOW, BFE data etc.
Review the C check flow chart. ( It applicable for MRO PM or on-site rep)
a. Milestone set up.
I b. initial inspection phase and due date. Important for entire schedule.
c. Repair/ mod due date and re-installation start
d. Power on/hydraulic on/weighting/engine run/test flight

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2. Pre-inspection for aircraft condition ( Preliminary check) If applicable.

Depends on operators or MRO experience, mainly focuses on structure and
cabin issues. Improves the layover quality and avoids significant structural
damage, the pre-inspection is necessary.
Obtain accurate part numbers and quantities to order peculiar materials.
Consider the layover increase risk
Order necessary materials/tooling if structural damage is found.

The pre-inspection is not applicable for every C check. It is better for 6Y or 12 Y
check or cabin refurbishment.
3. Communication and Liaison preceding C check

C check working schedule discussion and correction with Planning or MRO
( It applicable for MRO project Manager and on-site rep as well).

Account for layover information such as materials, tooling, T.A.T etc. Very
important for MRO PM or Airline On-site rep. Technically, it is the final
opportunity to brief the project before aircraft are incoming.

If Airline on-site rep, you may pay careful attention to the following:
a. Minimum fuel quantity and outstation fuel agency handling.
b. Contact MRO for first working day arrangement
c. Update airlines Non-routine and ADD status and inform MRO.
4. Aircraft input to the C check
Phase 01----Aircraft incoming
a. Share technical information with project team in first daily meeting
b. Acquire the working schedule and emphasize key points ( Milestone or
potential points)
c. Fix both parties materials resource coordinator agenda and
communication paths.

Phase 02 ---- Removal and Access
a. Based on the work package analysis , trace the process and focus on the
key working zone ( Fwd, Aft galley aisle floor beam, top skin, rear spar,
floor pan of LAV. Floor beam under cargo ball mat etc. )
Note: Important! Based on your knowledge and experience, you may
catch key points and push our MRO to follow them in its priorities.
b. Key working zone inspection without removal/access. - Such as both wing
top skin, rear spar , T/R surface or wiremash corrsoion and de-lamination.
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Phase 03----- Inspection
a. Continue following and monitoring key area working processes. Request report
on daily basis.
b. in case of any outstanding finding, especially for structures, immediately
work with team for measurement, report, and liaison with vendor.
Moreover, attention to whether the entire schedule will be impacted.
c. Attention to materials request.
Note: Important! Have to review item by item. First of all, you may
know if the missing materials are critical or not, next to verify the
leading time will match the schedule.
d. We will Work closely with your QC and Materials resource to identify the
critical missing parts, leading time, delivery date, any re-installation
impact etc.
e. Meanwhile, both parties should consider two solutions for missing
materials, one way is to order anew, one way is to repair. It is better for time
and cost savings. Moreover, the schedule will not be impacted due to missing
materials.

Phase 04 and 05----- Repair/modification/non-routine handling
a. Attention to the major repair /modification process and to avoid any impact
for final hydraulic on and power on.
b. Pay more attention to the interface between major modification or repairs. It
always happens in ageing aircrafts heavy maintenance. Major repair
interface may change the jacking CG or affect jacking procedure.
Note: Important! Jacking loan need 5 days at least from HAM airbus. It
represents potential risk for T.A.T

c. Set up the deadline for materials delivery and feedback materials status
with your team.
Note: Technically, the mass of missing materials requests will be reported
from production after the inspection phase is done. - Especially for
China mainland MROs. The phase 04/05 is a good opportunity to
follow and trace the missing materials.

Phase 06----- Reinstallation and Non-routine handling
a. Push the materials availiability and fulfill the milestone.
Note: Delayed materials cause cost waste.
b. Attention and monitoring key non-routine task processing, it will impact
reinstallation schedule.

Phase 07----functional test and final assembly
a. Fulfill the power on and hydraulic on.
b. Technical logic for final test sequence. - Especially for aircraft
LDG swing, weighting, fuel on-board check, engine run.
Note: At C check final phase, you need to with an MRO PM for key
issues, not only consideration for materials supply. Final working flow
also needs be discussed and reviewed. If applicable, the key workflow
will be enhanced.
Phase 08----- close up and redelivery
a. If on-site rep for airlines, inform flight operation of delivery date and request
for ferry flight schedule in advance.
b. Ask flight dispatch for ballasting and fuel quantity.
c. make a cross index for incoming non-routine and inform MCC in advanced.
d. Make a ADD records and extention records , inform MCC and planning
department in advance if applicable.

Highlight B:
A320 aircraft heavy maintenance potential risk
1.A320 family both wing top skin corrosion
Inspection and findings must be as earlier as possible.
1) No extra access required for such inspection zone, the inspection
must be done once aircraft is incoming.
2) If in case finding, polish and blend out will be followed and
measured. The step shall be finished at first day.
3) If corrosion is out of limits, a structural engineer needs to be involved
immediately, make a grid for the damage area, and report to
AIRBUS promptly.

Note: Long delays will be incurred If the top skin corrosion cannot
not be found at first phase. Major impacts as following:
a. damage report and AIRBUS inquiry.
b. oversized fasteners seeking and order
c. special jacking procedure and jacks loan if reinforce plate
required.

In summary, the top skin corrosion is a major issue leading to long delay.
Early inspection/report and fasteners estimate/ordering are important. If
advice is followed, the entire repair T.A.T can be deducted 5 days at least.
2.A320 family rib 5 inspection and modification
This is AD requirement for each AIRBUS aircraft. For ageing aircraft, it is
a potential risk for aircraft redelivery
a. Inspection must be first priority once LDG removed.
b. Bore inspection and blend out must be careful. If crack found,
structural engineer must be involved immediately and report to
AIRBUS.
c. Special tooling and reamer need be loaned from AIRBUS. Some
airlines also need AIRBUS on-site advisor to support.
Note: reamer goes in slowly and controls size carefully to ensure
the crack is eliminated and the bore inner diameter is within
limit.
d. If crack remains and the bores inner diameter is out of limit, the
fitting must be replaced by AIRBUS working party. Entire repair T.A.T is
14 days.
3.A320 family SB A320-57-1154 and A320-57-1155 inspection and
Modification.
This is recommended for each aircraft , especially ageing aircraft.
a. special NDT tooling must be prepared before C check layover.
b. modification kits must be available before C check.
c. No more extra access inspection area, the inspection has to be
performed once aircraft is incoming.
d. If found, the concerned area damage limits need to be
verified immediately. If out of limit, oversized fasteners need be
estimated and ordered. Meanwhile, structural engineers need to be
involved and report to AIRBUS.
Note: If above findings happened, you may coordinate with MRO to readjust
the schedule. Because Top skin repair and Two SBs repair
Will be seriously interfered.
4.A320 family lavatory floor pan heavy corrosion in the lavatory wet
zone
The floor pan heavy corrosion will incur extra removal or access and
impact cabin restoration process.
a. If floor pan leading time is long it will impact entire T.A.T.
b. If corrosion or crack heavy, the underlying floor beam will incur
corrosion. The extra removal and access is required.

Highlight C:
A320 aircraft heavy maintenance cost saving and re-
adjustment of T.A.T.
1.Detailed analysis of the GTA details, such as the cap of Non-routine
manhour, materials, and obligation of both parties.
Attention to the cap of Non-routine manhour definitions, It is better to
discuss the above charges in the final phase. Only if you carefully review
the routine task card and understand the contract may you know the
non-routine resource and how much labor you should pay for.
Attention to the cap of materials price and routine task cards involved
zone or area, you may know how much materials cost need to be paid.
Attention to the obligation of both parties, you may know the key
obligations such as tooling loans, warranty, redelivery etc.
2.Deeply understand and analyze the work package, such as customized
MP tasks and major work scope.
Attention to the major access and major routine task cards, such as
LDG,ENG,THS removal, Cargo loading removal, cabin floor panel etc,
you may clearly figure out the work sequence and milestones.
Attention for preliminary check, especially for structure inspection and
CPCP tasks ( MRB5,8 or CMR) , you may estimate the potential risk and
easily trace the key points.
Attention for Off-wing ( OCCM or hard time control) components
requirement, one way you can follow the materials status, another way
you will find close or open loop repair T.A.T.
Attention to routine task cards working zone, you may know how much
the above charge would be incurred.
3.Combine work schedule processing, make materials delivery a priority
and closely monitor milestones of the entire project.
Whatever C check duration, you have to give attention to the materials
delivery time and schedule. It can save operator cost directly and can
save the layover time.
Attention to the schedule process, provides enough stress to MRO and
controls the non-routine materials raise. Based on your knowledge and
experience, you may focus on the key missing materials who will impact
entire project milestones.
If any key missing materials cannot match the milestone, you may
consider moving the schedule sequence and try to fulfill the final
delivery target or reduce delay time. For example, If top skin are
fasteners missing, you need to move the final phase tasks forward to
avoid time waste.

4. Negotiate the final labor of non-routine and additional work requests.
You have to have figure out or estimate what non-routine or additional
tasks will occur above charge. The handling process and result needs to
be closely monitored. Finally you will catch up the key point and
negotiate with MRO.
5.In case outstanding issues will impact delivery targets, the schedule
sequence and milestone could be movable and match the final target.

It depend on your experience and knowledge. If outstanding issue
occurred, you may clearly figure out whats major work zone or task will
be postponed. What tasks can be moveable or adjusted. The time need
must be carefully reviewed and estimated. In this phase , task
combination is first priority.
Technically, this is general instruction for AIRBUS A320 family common C
check. This instruction is a little bit different with leasing aircraft delivery or
redelivery check. Major requirement will be as followed:
1) Work package analysis and estimate
2) Materials status confirmation and follow up
3) Enough stress for MRO and control key milestone
4) Any schedule arrangement or adjustment will fulfill final redelivery
target.


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Highlight A: Heavy maintenance working schedule and control

1) Preparation and work package analysis for Heavy Maintenance ( C check)

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