U.S. Department of Transportation Federal Aviation Administration Advisory Circular Subject: Maintenance Review Board Report Maintenance Type Board, and OEM/TCH Inspection Program Procedures Date: 10/29/10 Initiated by: AFS-300 AC No: 121-22B Change:
FOREWORD This advisory circular (AC) provides guidelines that industry may use to develop and revise the minimum scheduled interval/tasking requirements for derivative or newly type-certificated aircraft and powerplants for Federal Aviation Administration (FAA) approval. This AC refers to these minimum scheduled interval/tasking requirements as the Maintenance Review Board Report (MRBR), Maintenance Type Board. After FAA approval, the requirements become a basis upon which operators develop their own individual maintenance programs. The report will become a living report for each type-certificate holder.
Use this AC to standardize development, implementation, and update of FAA-approved minimum scheduled maintenance/inspection requirements.
ORIGINAL SIGNED BY /s/ John W. McGraw for John M. Allen Director, Flight Standards Service
CONTENTS Paragraph Page CHAPTER 1. CREATING AND USING MAINTENANCE/INSPECTION REQUIREMENTS.1
1-1. Purpose1
1-2. Cancellation1
1-3. Related Title 14 of the Code of Federal Regulations (14 CFR)1
1-4. Audience1
1-5. Use of This AC1
1-6. Related FAA Orders (current editions)2
1-7. Related FAA Advisory Circ ulars (current editions)2
1-8. Other Reading Materi al (current Editions)3
CHAPTER 2. MAINTENANCE PROGRAM OVERVIEW5
2-1. Timeline of Maintenance Steering Group (MSG) Actions5
2-2. Maintenance Review Board Report7
2-3. MRB Report Proposal Delivery Schedule Guidelines8
2-4. Minimum Scheduled Interv al/Tasking Requirements8
2-5. Certification Maintenance Requirements (CMR)8
CHAPTER 3. INDUSTRY PARTICIPATION11
3-1. Industry Steering Committee11
3-2. ISC Functions11
3-3. MSG Working Groups12
3-4. OEM/TCH Functions12
CHAPTER 4. FAA PARTICIPATION15
4-1. United States OEM/TCH15
4-2. Foreign OEM/TCH17
4-3. Maintenance Review Board17
4-4. Maintenance Review Board Members19
4-5. FAA Maintenance Working Group Advisors20
4-6 Foreign Regulatory Authorities20
CHAPTER 5. MRB REPORT APPROVAL23
5-1. Initial Maintenance Review Bo ard Report (MRBR) Approval Process23
5-2. Foreign Regulatory Authority Approval of the MRB Report23
5-3. Proposed Initial MRBR Disapproval Process23
5-4. Maintenance Review Board Report Implementation23
CHAPTER 6. MRB REPORT REVISIONS, FORMAT, AND CONTENT27
6-1. MRB Report Annual Review27
6-2. Temporary Revisions......................................................................................................2 7
6-3. Recommendations for Completing the Report27
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CONTENTS (Continued) Paragraph Page
CHAPTER 7. MRB POLICY BOARD33
7-1. FAA Maintenance Review Board Policy Board (MRBPB)33
7-2. International Maintenance Review Board Policy Board33
CHAPTER 8. MAINTENANCE TYPE BOARDS PROCESS35
8-1. General35
8-2. MTB Process Applicability35
8-3. MTB Audit Process35
8-4. MTB Report36
8-5. Policy and Procedures Handbook36
8-6. OEM/TCH Representatives37
8-7. Regulatory Authorit ies Responsibility38
CHAPTER 9. OEM/TCH RECOMMENDED MAINTENANCE PROCESS41
9-1. General41
9-2. Recommended Maintenance Process41
9-3. Recommended Maintenance Process Audits41
9-4. Scheduled Maintenance Instruction41
CHAPTER 10. MRBR LOW UTILIZATION MAINTENANCE REQUIREMENTS43
10-1. General43
10-2. Applicability43
10-3. Requirements43
CHAPTER 11. FLIGHTCREWS ACCOMPLISHING MAINTENANCE45
11-1. General45
11-2. Applicability45
CHAPTER 12. INTERNATIONAL MAINTENANCE REVIEW BOARD POLICY BOARD
ISSUE PAPER 4447
12-1. Introduction47
12-2. Purpose47
12-3. Policy Description47
12-4. Responsibilities49
12-5. Data Quality49
12-6. Data Integrity51
12-7. Data Review52
12-8. Data Correlation52
CHAPTER 13. STATISTICAL ANALYSIS TASKING OPTIMIZATION55
13-1. General55
13-2. Applicability55
13-3. Operator Participation55
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iii (and iv) CONTENTS (Continued) Paragraph Page APPENDIX 1. ACRONYM/ABBREVIATION LISTING FOR THE
MRB REPORT (3 Pages)1
APPENDIX 2. IP 44 DEFINITIONS (1 Page)1
APPENDIX 3. POLICIES AND PROCEDURES HANDBOOK FORMAT (9 Pages)1
APPENDIX 4. RELEVANT FLOWCHARTS AND LETTERS (4 Pages)1
LIST OF FIGURES
Figure 2-1. MRB Process Flowchart7
Figure 2-2. Certification Maintenance Requirement and MRB Process Interface9
Figure 4-1. Letter to AFS-300 to Establish An MRB16
Figure 5-1. MRBR Letter of Approval24
Figure 5-2. MRBR Approval Page25
Figure 8-1. Maintenance Type Board Flowchart37
Par 1-1 Page 1 CHAPTER 1. CREATING AND USING MAINTENANCE/
INSPECTION REQUIREMENTS
1-1. PURPOSE. This advisory circular (AC) provides guidelines that industry may use to develop and revise the minimum scheduled interval/tasking requirements for derivative, or newly type-certificated aircraft and powerplants for Federal Aviation Administration (FAA) approval.
This AC refers to these minimum scheduled interval/tasking requirements as the Maintenance Review Board Report (MRBR) Maintenance Type Board (MTB). After FAA approval, the requirements become a basis upon which operators develop their own individual maintenance programs. The report will become a living report for each type-certificate holder (TCH).
1-2. CANCELLATION. This AC cancels AC 121-22A, Maintenance Review Board Procedures, dated March 7, 1997.
1-3. RELATED TITLE 14 OF THE CODE OF FEDERAL REGULATIONS (14 CFR).
Parts 21, 23, 25, 27, 29, 33, 35, 91, 119, 121, 129, and 135 apply.
1-4. AUDIENCE. Guidance in this AC pertains to FAA personnel, air operators, air carriers, and original equipment manufacturer (OEM)/TCH and their vendors involved in the development of the MRBR process.
1-5. USE OF THIS AC. This AC is not mandatory and is not the only means to comply with the regulations. The FAA issues this AC for guidance and to outline a method of compliance. A person may elect to follow an alternative method, provided the FAA finds it to be an acceptable means of complying with the applicable requirements of 14 CFR. If you use the methods described in this AC you must follow them in all respects. The FAA derived these guidelines from regulatory authorities and aviation industry experience. This AC is primarily designed to provide advice and recommendations for the standardized development, implementation, and update of FAA-approved minimum scheduled maintenance/inspection requirements NOTE: This AC uses the term “must” only in the sense of ensuring the applicability of these particular methods of compliance when operators use the acceptable means of compliance described herein. This AC does not change regulatory requirements and does not authorize changes in, or deviations from, regulatory requirements.
1-6. RELATED FAA ORDERS (current editions).
• Order 1100.5, FAA Organization—Field.
• Order 8100.5, Aircraft Certification Service Mission, Responsibilities, Relationships, and Programs.
• Order 8110.4, Type Certification.
• Order 8110.54, Instructions for Continued Airworthiness Responsibilities, Requirements, and Contents.
• Order 8900.1, Flight Standards Information Management System.
• Order 8300.12, Corrosion Prevention and Control Programs.
• Order 8430.21, Flight Standards Division, Aircraft Certification Division and Aircraft Evaluation Group Responsibilities.
1-7. RELATED FAA ACs (current editions).
• AC 20-107, Composites Aircraft Structure.
• AC 20-136, Protection of Aircraft Electrical/Electronic Systems Against the Indirect Effects of Lightning.
• AC 20-158, The Certification of Aircraft Electrical and Electronic Systems for Operation in the High-Intensity Radiated Fields (HIRF) Environment.
• AC 23-1309-1, System Safety Analysis and Assessment for Part 23 Airplanes.
• AC 25-19, Certification Maintenance Requirements.
• AC 25-27, Development of Transport Category Airplane Electrical Wiring Interconnection Systems Instructions for Continued Airworthiness Using an Enhanced Zonal Analysis Procedure.
• AC 27-1, Certification of Normal Category Rotorcraft.
• AC 29-2, Certification of Transport Category Rotorcraft.
• AC 33.4-3, Instructions for Continued Airworthiness, Aircraft Engine High Intensity Radiated Fields (HIRF) and Lightning Protection Features.
• AC 120-42, Extended Operations (ETOPS and Polar Operations).
1-8. RELATED READING MATERIAL (current editions).
• CMH-17, Composites Materials Handbook.
• Evolution/Optimization Guidelines, International Maintenance Review Board Policy Board Issue Paper 44.
• Transport Canada TP 13850, Schedule Maintenance Instruction Development Process Manual.
Page 2 Par 1-6
• ATA MSG-3, Operator/Manufacturer Scheduled Maintenance Development, current edition available from:
Air Transport Association of America (ATA), 1301 Pennsylvania Avenue N.W., Suite 1100 Washington, DC 20004–1707 1-800-497-3326 Ext. 950 Par 1-8 Page 3 (and 4)
CHAPTER 2. MAINTENANCE PROGRAM OVERVIEW
2-1. TIMELINE OF MAINTENANCE STEERING GROUP (MSG) ACTIONS.
a. History. The development of maintenance programs dates to Aeronautical Bulletin 7E of May 15, 1930. The process of developing maintenance programs for new aircraft and aircraft engines has evolved from one in which each air carrier proposed its own unique program to a collaborative effort in which the Federal Aviation Administration (FAA), associated foreign regulatory authorities, and industry collaborated to develop the initial minimum scheduled maintenance/inspection requirements for new and derivative aircraft, aircraft engines, and propellers. Early experience in the development of initial scheduled maintenance/inspection requirements revealed that through the use of logical analysis and decision processes, it was possible to develop a program of applicable and effective maintenance tasks. In 1968 the Maintenance Steering Group—1st Task Force developed maintenance requirements decision and analysis logic.
b. Role of the Maintenance Steering Group. In 2006, the Air Transportation Association of America (ATA) MSG was named the Maintenance Programs Industry Group (MPIG), while the latest version of MSG still retained the same original title. ATA coordinates, and industry chairs the MPIG; it assumed the same duties as the original MSG task force. MPIG meets annually, or as required, to review issues submitted by industry and the regulatory authorities affecting the latest version of MSG and institute improvements or any necessary evolutionary changes due to revised regulatory requirements or advances in industry technology.
(1) Handbook—Maintenance Evaluation and Program Development, MSG-1 (July 10, 1968). The FAA and industry used MSG-1 procedures to develop the initial minimum scheduled maintenance/inspection recommendations for the B-747-100 aircraft and its engines.
A task force later used the experience gained on the B-747-100 project to update the MSG-1 procedures so that a universal document could be made applicable for future newly typecertificated aircraft and/or engines. This document was called the Maintenance Steering Group— 2nd Task Force (MSG-2) document.
(2) Specification Maintenance Program Development, MSG-2 (January 8, 1970).
In the 1970s, the FAA and industry used the MSG-2 procedures to develop the initial minimum scheduled maintenance/inspection recommendations for aircraft and engines. In 1980, the combined efforts of the FAA, ATA interval/tasking requirements, United States 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.
(3) Airline/Manufacturer Maintenance Program Development Document MSG-3, Original Revision (September 30, 1980). In 1987, after applying MSG-3 analysis procedures on a number of new aircraft and engines in the first half of the 1980s, 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.
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(4) Airline/Manufacturer Maintenance Program Development Document MSG-3, Revision 1 (March 31, 1988). The FAA and industry began applying MSG-3 Revision 1 in 1988 for the ongoing development of new aircraft and aircraft engine Maintenance Review Board (MRB) Report (MRBR) documents.
(5) Airline/Manufacturer Maintenance Program Development Document MSG-3, Revision 2 (September 12, 1993). Further refinements made to the MSG-3 Revision 1 analysis resulted in Revision 2 to MSG-3. In 1993, the FAA and industry began applying MSG-3 R2 for development of new and derivative aircraft and engine MRBR documents.
(6) ATA MSG-3 Operator/Manufacturer Scheduled Maintenance Program Development, Revision 2001 (March 2000). This version was reformatted into an electronic document to adapt to the use of computer technology.
(7) ATA MSG-3 Operator/Maintenance Program Development, Revision 2001.1 (February 2001). To include the large corporate aircraft and aging large transport legacy aircraft segment in the MSG-3 process, the FAA and industry began using MSG-3 Revision 2001.1 in 2001. This revision introduced significant changes including inspection definitions, corrected terminology, and expanded wording on safety/emergency equipment. Also, with the advent in the manufacturer development of more technologically advanced fly-by-wire aircraft and to improve safety of the legacy transport aircraft, it became necessary to introduce sections on enhanced zonal analysis procedures (EZAP) and Lightning/High Intensity Radiated Field (L/HIRF) protection.
(8) ATA MSG-3 Operator/Manufacturer Scheduled Maintenance Development, Revision 2002.1 (March 2002). Significant changes at this revision included recording of all assumptions, consideration of all vendor recommendations, procedures for fault-tolerant systems, Master Minimum Equipment List considerations, and the inclusion of analysis of nonmetallic structures.
(9) ATA MSG-3 Operator/Manufacturer Scheduled Maintenance Development, Revision 2003.1 (March 2003). Most significant changes added three-letter task abbreviations/acronyms, further revised fault-tolerant systems procedures, definition changes for fault-tolerant systems, and further clarification of definition of safety/emergency systems or equipment.
(10) ATA MSG-3 Operator/Manufacturer Scheduled Maintenance Development.
Revision 2005.1 (March 2005). Changes introduced in this version added the need to identify design features that affect fuel tank safety, defined differentiation of Structural Significant Items and Principal Structural Elements, corrected the relation of fatigue damage (FD) to nonmetallic materials, revised EZAP to reflect recommendations from FAA’s Aging Transport Systems Rulemaking Advisory Committee’s on aging wiring and added definition for electrical wiring interconnection system.
(11) ATA MSG-3 Operator/Manufacturer Scheduled Maintenance Development.
Revision 2007.1 (April 2007). Changes introduced in this version expanded text to better define and consider structural wear damage. This change added text and a flow chart to better define Page 6 Par 2-1