U.S. Department of Transportation Federal Aviation Administration Advisory Circular AC NO: 121-22A DATE: 3l7l97
MAINTENANCE REVIEW BOARD
PROCEDURES Initiated by: AFS-330
U.S. Department of Transportation Federal Aviation Administration Advisory Circular Subject: MAINTENANCE REVIEW BOARD Date: 3/7/97 PROCEDURES Initiated by: AFS-330 AC No: 12%22A Change:
1. PURPOSE. This advisory circular (AC) provides guidelines that may be used by industry during its development and revision of the initial minimum scheduled maintenance/inspection requirements for derivative or newly type-certificated transport category aircraft and powerplants for submittal to the Federal Aviation Administration (FAA) for approval. These initial minimum scheduled maintenance/inspection requirements are referred to in this AC as the Maintenance Review Board Report (MRBR). The requirements, after approval by the FAA, become a base or framework around which each air carrier develops its own individual maintenance program.
NOTE: Mandatory terms used in this AC, such as “must,” and “shall,” are used only in the sense of ensuring the applicability of these particular methods of compliance when the acceptable means of compliance described herein is used. This AC does not change regulatory requirements and does not authorize changes in, or deviations from, regulatory requirements.
2. CANCELLATION. AC 121-22, Maintenance Review Board, dated January 12, 1977, is cancelled.
3. RELATED REGULATIONS. Title 14 of the Code of Federal Regulations (14 CFR) parts 21, 23, .25, 27, 29, 33, 35, 121, 135; ss 21.50, 23.1529, 25.571, 25.1309, 25.1529, 27.1529, 29.1529, 33.4, 35.4,
121.25,121.45, and 135.11.
4. RELATED READING MATERIAL. Airline/Manufacturer Maintenance Program Development Document, MSG-3, Revision 2, may be obtained from the Air Transport Association of America (ATA), at l-800-497-3326, ext. 950 (U.S. and Canada), 410-490-7951, ext. 950 (overseas), or FAX: 410-206-9789.
c-4%74* Thomas C. Accardi Director, Flight Standards Service
AC 121922A 317197 (THIS PAGE INTENTIONALLY LEFT BLANK)
317197 AC 121922A
CONTENTS Page No.
CHAPTER 1. GENERAL
1. Background .............................................................................................................................
2. Maintenance Review Board Report .......................................................................................
3. Document Time Delivery Guidelines ....................................................................................
4. Instructions for Continued Airworthiness .............................................................................
5 . - 10. Reserved .......................................................................................................................
CHAPTER 2. INDUSTRY PARTICIPATION
11. General ..................................................................................................................................
12. Industry Steering Committee ...............................................................................................
13. Working Groups ...................................................................................................................
14. Manufacturer .........................................................................................................................
15 . - 25. Reserved .....................................................................................................................
CHAPTER 3. FAA PARTICIPATION
26. General ..................................................................................................................................
27. Maintenance Review Board .................................................................................................
28. MRB Members .....................................................................................................................
29. FAA WG Advisors ...............................................................................................................
30. Other Regulatory Authorities ...............................................................................................
31 . - 35. Reserved .....................................................................................................................
CHAPTER 4. MRBR APPROVAL
36. MRBR Approval Process .....................................................................................................
37. Other Regulatory Authority Approval of the MRBR .........................................................
38. Nonapproval Process of the Proposed MRBR or Revision ................................................
39. MRBR or Revision Implementation ....................................................................................
40 . - 45. Reserved .....................................................................................................................
CHAPTER 5. MRBR REVISIONS
46. Annual Review .....................................................................................................................
47 . - 55. Reserved .....................................................................................................................
CHAPTER 6. RECOMMENDED MRBR FORMAT AND CONTENT
56. Recommendations .................................................................................................................
57 . - 65. Reserved .....................................................................................................................
APPENDIX 1. POLICY AND PROCEDURES HANDBOOK (PPH) (2 pages) ..............................
APPENDIX 2. SUGGESTED ACRONYM LISTING FOR THE MRBR (2 pages) .......................
APPENDIX 3. SCHEDULED MAINTENANCE TASK DEVELOPMENT’(1 page) .....................
APPENDIX 3a. SCHEDULED MAINTENANCE TASK DEVELOPMENT and INSTRUCTIONS for CONTINUED AIRWORTHINESS PROCESS (1 page) .........................
7 7 7 7 7 9 9 11 14 1 1 1 2 i
AC 121-22A 317197 (THIS PAGE INTENTIONALLY LEFT BLANK) ii
317197 AC 121122A CHAPTER 1. GENERAL
1. BACKGROUND. The development of maintenance programs has a long history dating back to Aeronautical Bulletin 7E of May 15, 1930. The process of developing maintenance programs for new aircraft and powerplants has evolved from one in which each air carrier proposed its own unique program to one in which the FAA and industry work together to develop the initial minimum scheduled maintenance/inspection requirements for new aircraft and/or powerplants. Early experience in the development of initial scheduled maintenance/inspection requirements revealed that a program of effective maintenance tasks could be developed through the use of logical analysis and decision processes. In 1968, a maintenance requirements decision and analysis logic was developed by an industry team called the Maintenance Steering Group-1st Task Force (MSG-1).
a. MSG-1. MSG.1 procedures were used by the FAA and industry to develop the initial minimum scheduled maintenance/inspection recommendations for the B-747 aircraft and its powerplants. A later task force utilized the experience gained on the B-747 project to update the MSG.1 procedures so that a universal document could be applicable for future newly type-certificated aircraft and/or powerplants. This document was called the Maintenance Steering Group-2nd Task Force (MSG-2) document.
b. MSG-2. MSG-2 procedures were used to develop the initial minimum scheduled maintenance/ inspection recommendations for aircraft/powerplants of the 1970’s. In 1980, the combined efforts of the FAA, the Air Transport Association of America (ATA), U.S. and European aircraft and engine manufacturers, and U.S. and foreign airlines generated new decision logic and analysis procedures contained in a new document called Maintenance Steering Group-3rd Task Force (MSG-3).
c. MSG-3. In 1987, after using MSG-3 analysis procedures on a number of new aircraft and powerplants in the first half of the 1980’s, the airline industry decided that the benefits of the experience gained during those years should be used to improve the document for future applications. Thus, Revision 1 to MSG.3 was developed.
d. MSG-3Rl. The FAA and industry have been using MSG-3Rl since 1988 for the development of current and future aircraft and powerplant MRBR’s.
e. MSG-3R2. The FAA and industry have been using MSG-3R2 since 1993 for current and future aircraft and powerplant MRBR’s.
2. MAINTENANCE REVIEW BOARD REPORT.
a. An MRBR is prepared for aircraft intended for air carrier use according to the following guidelines.
An MRBR is normally not prepared for transport category aircraft having a maximum certificated takeoff weight of 12,500 pounds or less. For transport category aircraft having a maximum certificated takeoff weight of more than 12,500 pounds but not more than 33,000 pounds, a Maintenance Review Board (MRB) is sometimes convened and an MRBR generated. However, for transport category aircraft of more than 33,000 pounds maximum certificated takeoff weight, an MRB is normally convened and an MRBR generated as an expeditious means of complying in part with the maintenance instruction requirements of Appendix H to 14 CFR part 25. It is a means, in part, of developing Instructions for Continued Airworthiness, as required by § 25.1529.
b. An MRBR contains the initial minimum scheduled maintenance/inspection requirements for a particular transport category aircraft and on-wing engine program, but does not establish off-wing engine maintenance programs required by the Regulations. It should be developed in accordance with these guidelines and is not to be confused with, or thought of, as a maintenance program. After approval by the FAA, the requirements become a base or framework around which each air carrier develops its own individual maintenance program.
Although maintenance programs vary widely from one air carrier to another, the initial requirements for Par 1 Page 1
AC 121922A 317197 a particular type of aircraft will be the same for all. An air carrier’s total maintenance program (methods used to implement these requirements) must be approved by the FAA through operations specifications.
3. DOCUMENT TIME DELIVERY GUIDELINES. The time allotments for delivery and return of the various documents mentioned in this AC are intended to be used as a general guide. These allotments have been included as an approximation of the time needed by the various groups to process the material.
4. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS. A flow chart, outlining the relationships between the various documents, including the MRBR, involved in the creation of the Instructions for Continued Airworthiness, is contained in Appendix 3a.
5. - 10. RESERVED.
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3m97 AC 121922A CHAPTER 2. INDUSTRY PARTICIPATION
11. GENERAL. The most recent logic process should be used for the development of MRBR’s. Although MRBR’s were once developed by combining MSG.2 and MSG-3 analysis procedures, this method has proved to be impractical today. And since many problems have been identified from using this method, the FAA has responded with a policy stating that the latest MSG analysis procedures must be used for the development of MRBR’s for all new or derivative aircraft. This policy, however, will be implemented on a case-bycase basis.
12. INDUSTRY STEERING COMMITTEE (ISC). The ISC membership should comprise representatives from aircraft, engine, propeller, and appliance manufacturers and intended air carriers. The ISC’s role is to develop and establish policy with regard to procedural matters for the development of the proposed MRBR, to direct the activities of the working groups (WG), and to prepare the MRBR proposal. It is also the function and responsibility of the ISC, under the direction of the ISC Chairperson, to perform the following functions:
a. Determine the number and type of WG’s that will be necessary, and then organize those groups.
b. Provide the MRB Chairperson with a list of the various types of WG’s, the name and affiliation of each WG member, and any changes as they occur.
c. Develop and approve the Policy and Procedures Handbook (PPH) and forward it to the manufacturer for review and for transmittal to the MRB Chairperson. Further comments developed through this review process will be directed to the manufacturer by the FAA. (Guidance to be used during development can be found in Appendix 1).
d. Arrange for necessary technical and MSG.3 training of all ISC and WG members and FAA advisors.
e. Invite the MRB Chairperson and selected MRB members to ISC meetings.
f. Invite other regulatory authorities to ISC meetings, with coordination of the MRB Chairperson.*
g. Attend MRB meetings.
h. Review all WG analyses and presentations.
i. Identify ISC changes to WG proposals in the ISC meeting minutes.
j. Provide supporting technical data/analysis for the proposed MRBR.
k. Document and present the proposed MRBR to the manufacturer.
1. Review and provide comments on proposed revisions to the MRBR.
13. WORKING GROUPS. WG’s are to comprise representatives of the manufacturer air carrier and should be chaired by an industry representative appointed by the ISC. The should assign FAA personnel to act as advisors to each WG. FAA WG advisors should FAA engineering/design certification branches as well as appropriate personnel from AFS( ities include the following functions:
and the purchaser/ MRB Chairperson include staff from WG’ s responsibil-
craft using the latest revision of the MSG.3 process.
b. Establish sampling requirements when MSG.3 analysis determines that such sampling is applicable and effective in the identification of the cause of failure. These failures could have an adverse effect on the continued airworthiness or safety of the aircraft.
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AC 121-222 317197
14. MANUFACTURER. The manufacturer should perform the following functions:
a. Receive the draft PPH from the ISC, and after review, transmit it to the MRB Chairperson.
b. Provide general familiarization training for the MRB, ISC, and WG’s.
c. Provide the ISC with an initial list of Maintenance Significant Items (MSI) and Structural Significant Items (SSI), with sufficient data to support the reason each item was selected.
d. Provide industry WG’s with sufficient technical data to support the analysis of MSI’s and SSI’s in a timely and adequate fashion.
e. Provide the ISC and appropriate WG’s (in a timely manner) with information concerning certification issues and resolutions regarding proposed tasks originating from the certification process, such as airworthiness limitation items or certification maintenance requirements (CMR).
f. Ensure that the manufacturer’s manual(s) contain(s) information covering the on-aircraft systems/ powerplant tasks listed in the FAA MRBR.
g. Participate in ISC and WG activities.
h. Submit the MRBR Proposal to the MRB Chairperson at least 90 days prior to scheduled approval.
For engines where discretionary sampling/analytical inspections are conducted by a manufacturer/air carrier, on an opportunity basis, the following procedures apply:
(1) The manufacturer/air carrier shall notify the regulatory authority, in a timely manner, of the time and place of the inspection, in order to permit regulatory authority participation. When regulatory authority attendance is not possible, the manufacturer/air carrier must provide a copy of the inspection report to the regulatory authority.
(2) Subsequent to the first three inspections of the complete product or modules after introduction into service, further regulatory authority participation will be determined on a case-by-case basis on technical issues only.
NOTE: The Flight Standards offke responsible for coordinating FAA attendance at powerplant/auxiliary power unit (APU) opportunity inspections will be the Manager, Aircraft Evaluation Group, BOS-AEG.
15. - 25. RESERVED.
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317197 AC 121122A CHAPTER 3. FAA PARTICIPATION
26. GENERAL. This AC is designed around the maintenance/inspection development concepts embodied in MSG-3, as revised. To accomplish the development of an MRBR proposal in an orderly manner, the FAA should establish an MRB and select WG advisors, as described in this chapter. When the aircraft manufacturer formally notifies the Aircraft Evaluation Group (AEG) manager of the controlling FAA directorate of its intention to develop an MRB proposal, the AEG manager will assign a qualified person as MRB Chairperson to manage the MRB for the FAA. MRB members are to be selected by the MRB Chairperson with Washington Headquarters, AFS-330 concurrence. MRB member(s) assigned to engine and propeller WG’s will be selected by the Manager, Aircraft Evaluation Group, BOS-AEG, in coordination with the MRB Chairperson.
27. MAINTENANCE REVIEW BOARD. The MRB supports the development of an industry proposal or report containing the initial minimum scheduled maintenance/inspection requirements for a derivative or newly type-certificated transport category aircraft and its powerplants. The MRB also acts on the MRBR proposal or revision IAW these procedures. The MRB should include qualified FAA Flight Standards inspector personnel and engineering representatives from the controlling FAA directorate, as members to the board.
The MRB Chairperson shall assign MRB members to work as advisors to the industry WG’s. It is also the function and responsibility of the MRB, under the direction and management of the MRB Chairperson, to perform the following functions:
a. Determine the number and type of FAA personnel that are necessary, and then organize them.
b. Provide the ISC Chairperson with a list of FAA personnel names, their affiliations, assignments, and changes as they occur.
c. Invite other authorities, in coordination with the AEG manager and the aircraft manufacturer, to participate in the MRB, and coordinate the activities of other regulatory authorities through their representatives.
d. Obtain letters of confirmation between the FAA and each participating regulatory authority, and inform the ISC Chairperson of participating regulatory authorities.
e. Establish and maintain a file of all MRB proceedings for the MRB historical file.
f. Establish the extent of regulatory authority participation and assignment of WG advisors.
g. Brief other regulatory authorities regarding MRB policy and procedures before and during the MRB process.
h. Accept the PPH, following a review by participating regulatory authorities, within 30 days of receipt.
i. Coordinate all MRB activities and associated matters with the ISC Chairperson.
j. Ensure that the manufacturer provides the necessary technical and MSG.3 training to MRB members and WG advisors.
k. Attend ISC meetings.
1. Ensure that the appropriate regulatory authority is in attendance at all WG meetings.
m. Offer advice to the ISC and the WG’s.
n. Invite the ISC Chairperson and selected ISC members to the MRB meetings.
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AC 121922A 317197
o. Review reports from previous ISC meetings (if applicable) and from the WG members.
p. Discuss potential problem areas and controversy with other regulatory authority management.
q. Approve the MRBR, and revisions, IAW established MRBR and revision procedures.
28. MRB MEMBERS. MRB members are expected to perform the following functions:
a. Provide guidance to the FAA WG advisors and WG members.
b. Direct FAA WG advisors in assigned WG.
c. Attend MRB meetings.
d. Attend ISC meetings, as invited by the ISC Chairperson.
e. Review WG meeting minutes and provide progress reports to the MRB Chairperson before the next scheduled ISC meeting. This review will contain an assessment of WG activities, including a notification of any controversy for potential problem areas.
29. FAA WG ADVISORS. FAA WG advisors are expected to perform the following functions:
a. Attend WG meetings and provide advice to the WG members.
b. Attend MRB meetings.
c. Provide progress reports to the MRB member assigned to the WG before the next scheduled ISC meeting. This report will contain an assessment of WG activities, including notification of any controversy or potential problem NOTE: FAA WG advisors must include FAA engineering/design certification staff.
30. OTHER REGULATORY AUTHORITIES. Other regulatory authorities normally will perform the following functions:
a. Participate in the MRB and/or WG activities, as provided by the letter of confirmation between the regulatory authority and the FAA.
b. Attend ISC meetings by invitation from the ISC Chairperson and concurrence of the MRB Chairperson.
c. Notify the ISC Chairperson, via the MRB Chairperson, of any national regulatory differences before compiling the MRBR proposal.
d. Acknowledge approval of the MRBR in the manner outlined in the letter of confirmation, and in the PPH.
e. Review WG meeting minutes and provide, to the MRB Chairperson, an assessment or notification of any controversial or potential problem areas before the next .scheduled ISC meeting.
NOTE 1: If multiple regulatory authority participation is required, it should be conducted through the use of common standards and joint authority representation.
NOTE 2: When the role of the host authority is limited due to the lack of personnel or other reasons, the MRB Chairperson may seek more involvement of other regulatory authorities as MRB members1 WG advisors.
NOTE 3: Generic terms or terminology should be used when dealing with various regulatory rule requirements (for example, “Regulations or other national regulatory requirements”).
31. - 35. RESERVED.
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317197 AC 121922A CHAPTER 4. MRBR APPROVAL
36. MRBR APPROVAL PROCESS. The ISC Chairperson forwards the proposed MRBR to the manufacturer’s representative(s), and may invite the manufacturer to discuss the proposal. The manufacturer must present the proposed MRBR, as recommended or with revisions, to the FAA for approval as part of the Instructions for Continued Airworthiness. The manufacturer transmits the proposed MRBR to the MRB Chairperson for review and for approval and for submittal to AFS-300 for concurrence. Normally, the FAA approval process occurs within a time frame of no more than 90 days. Approval by other regulatory authorities will normally occur concurrently with that of the FAA. The manufacturer is responsible for publishing and distributing initial and revised MRBR’s and any supporting documents.
37. OTHER REGULATORY AUTHORITY APPROVAL OF THE MRBR. There may be a need to identify national regulatory differences that are not compatible, acceptable, or applicable to all regulatory authorities. When this condition exists, an appendix to the MRBR may be used to list these differences, with each being approved by the respective regulatory authority.
38. NON-APPROVAL PROCESS OF THE PROPOSED MRBR OR REVISION. The manufacturer shall coordinate non-approval of either the MRBR or revision with the MRB Chairperson, so that the ISC Chairperson may be notified in writing of such action. The non-approval letter shall include the specific reason(s) for the non-approval, and suggested guidance to make the MRBR proposal or revision approval.
39. MRBR OR REVISION IMPLEMENTATION. Air Carriers of the aircraft type should implement the MRBR, or revisions thereto, IAW established procedures. For air carriers of similar aircraft, and dependent on a particular air carrier’s qualifications and overall maintenance experience, adjustments to initial maintenance program intervals may be approved by the air carrier’s corresponding regulatory authority.
40. - 45. RESERVED.
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