Appendix 1 EDR Environmental Deterioration Rating EICAS Engine Indicating and Crew Alerting System EROPS Extended Range Operations ETOPS Extended Two Engine Operations EWIS Electrical Wiring Interconnection System EZAP Enhanced Zonal Analysis Procedure FAA Federal Aviation Administration FAR Federal Aviation Regulations FC Functional Check FCK Functional Check FD Fatigue Damage FEC Failure Effect Category FH Flight Hours FLT Flight FMEA Failure Mode and Effects Analysis FOEB Flight Operations Evaluation Board FSDO Flight Standards District Office FTS Fuel Tank Safety GFRP Glass Fiber Reinforced Plastic GV General Visual GVI General Visual Inspection HIRF High Intensity Radiated Fields ICA Instructions for Continuing Airworthiness ICAO International Civil Aviation Organization IP Issue Paper ISC Industry Steering Committee IMRBPB International Maintenance Review Board Policy Board JAA Joint Aviation Authorities JAR Joint Airworthiness Requirement JOEB Joint Operations Evaluation Board L/HIRF Lightning/High Intensity Radiated Field LU Lubrication Task MEA Maintenance Engineering Analysis MMEL Master Minimum Equipment List MFG Manufacturer MEL Minimum Equipment List MTB Maintenance Type Board Process MTBR Maintenance Type Board Process Report MPD Maintenance Planning Data Document MPIG Maintenance Program Industry Group MPP Maintenance Program Proposal MRB Maintenance Review Board MRBPB Maintenance Review Board Policy Board MRB Report Maintenance Review Board Report Page 2
Appendix 1 MSC Maintenance Steering Committee MSG-1 Maintenance Steering Group - 1st Task Force MSG-2 Maintenance Steering Group - 2nd Task Force MSG-3 Maintenance Steering Group - 3rd Task Force MSI Maintenance Significant Item MTBF Mean Time Between Failure MTBUR Mean Time Between Unscheduled Removal MWG Maintenance Working Group NDI Non-destructive Inspection NDT Non-destructive Test OEM Original Equipment Manufacturer OPC Operational Check PI Principal Inspector PMMEL Proposed Master Minimum Equipment List PPH Policy and Procedures Handbook PSE Principal Structural Element R/I Remove and Install RF Radiated Frequency RMP Recommended Maintenance Process (RMP) RS Restoration Task RST Restoration SATO Statistical Analysis Tasking Optimization SDI Special Detailed Inspection SID Supplemental Inspection Document SFAR Special Federal Aviation Regulation SIP Structural Inspection Procedure SSA System Safety Assessment SSI Structural Significant Item SSID Supplemental Structural Inspection Document SVC Service Task STWG Structures Working Group SWG Structures Working Group TCH Type Certificate Holder TBD To Be Determined TCDS Type Certificate Data Sheet UV Ultra-Violet VC Visual Check Task VCK Visual Check WG Work Group ZA Zonal Analysis ZIP Zonal Inspection Program ZLWG Zonal Working Group ZWG Zonal Working Group
Appendix 2 APPENDIX 2. IP 44 DEFINITIONS
a. Confidence Level. The likelihood that the overall fleet performance lies within the range specified by the sample fleet performance. The confidence level is usually expressed as a percentage.
b. Nonroutine Task. A task is nonroutine when it is not a planned/scheduled task coming from the operator’s/manufacturer’s maintenance program.
c. Nonmetallics. Any structural material made from fibrous or laminated components bonded together by a medium. Materials such as graphite epoxy, boron epoxy, fiberglass, kevlar epoxy, acrylics and the like are nonmetallics. Nonmetallics include adhesives used to join other metallic or nonmetallic structural materials.
d. Line Maintenance. Routine check, inspection and malfunction rectification performed en-route and at base stations during transit, turn-around or night stop.
e. Pilot Report (also known as PIREP). Suspected or known malfunctions, or unsatisfactory conditions that are entered by the flightcrew into the aircraft log and require maintenance action.
f. Qualified FAA MRB Chairperson. An Airworthiness inspector with working knowledge of the Maintenance Review Board (MRB) process must have system/structures training on particular aircraft and have MSG formal training.
g. Unscheduled Maintenance. Maintenance performed to restore an item to a satisfactory condition by providing correction of a known or suspected malfunction and/or defect.
h. Evolution/Optimization. Task through the management of data is a means to assure the continued applicability and effectiveness of the task while improving the integrity of the process.
i. Risk Management. The systematic application of management policies, procedures, and practices to the tasks of identifying, analyzing, evaluating, treating and monitoring risk.
j. Safety Management. The application of engineering and management principles, criteria and techniques to optimize safety. It is an integrated and comprehensive engineering effort.
k. Structural Significant Items (SSI). Any detail, element, or assembly that contributes significantly to carrying flight, ground, pressure or control loads, and whose failure could affect the structural integrity necessary for the safety of the aircraft.
Appendix 3 APPENDIX 3. POLICIES AND PROCEDURES HANDBOOK FORMAT This appendix intends to provide standardized and harmonized policy in the development of a proper policy and procedures handbook (PPH). It is encouraged that all industry applicant’s PPH documents be developed containing the same basic data and information, as applicable, to provide for a complete, consistent, and quality process.
Regulatory authority and industry experience has indicated that the following information is expected in each PPH, as applicable, for the successful latest version of the Maintenance Steering Group process and development of a Maintenance Review Board Report:
SCHEDULED MAINTENANCE DEVELOPMENT Contents of PPH I Approval & Acceptance Lette rs or Signature Page II Record of Revisions III List of Effective Pages IV History of Changes Table of Contents List of Figures List of Tables Highlights of Significant PPH Changes
1. Introduction
1.1 Purpose
1.2 Background
1.3 Scope & Objective
1.4 Regulatory Requirements
1.5 MSG Guidelines
1.6 Revision Process Policy
1.7 Temporary Revisions Process
1.8 Program Organization Program Work Schedule Page 1
Appendix 3
1.9 Main Principles and Design Standards
1.10 Aircraft Utilization Assumptions
1.11 Establishing Task Intervals (Frequencies)
1.11.1 Systems & Powerplants Task Interval Determination
1.11.2 Zonal Inspection Task Interval Determination
1.11.3 Structures Task Interval Determination
1.11.4 Task Review Procedures
1.11.4.1 General
1.11.4.2 Factors to be considered
1.11.4.3 ISC & MRB Responsibilities
1.11.4.4 Manufacturer Responsibilities
1.11.4.5 Evaluation Criteria
1.11.4.6 Lubrication Tasks
1.11.4.7 Servicing Tasks
1.11.4.8 Operational Check
1.11.4.9 Inspection Tasks (General Visual, Detailed, Special Detailed)
1.11.4.10 Functional Check
1.11.4.11 Restoration or Discard
1.11.4.12 Structure/Zonal Inspections
1.11.4.13 Task Interval Review Report
1.12 IP 44 MRB Optimization Process
2. Organization and Administration
2.1 Industry Participation
2.1.1 General
2.1.2 Intellectual Property Management Page 2
Appendix 3
2.1.3 Communications, Inte rnal and External
2.1.4 Industry Steering Committee (ISC)
2.1.5 Working Groups (WG)
2.1.6 OEM/TCH
2.1.7 Partners, Suppliers & Vendors
2.1.8 Certification and Design personnel
2.2 FAA & Other Regulatory Authority Participation & Functions
2.2.1 General
2.2.2 Regulatory Authority Ma intenance Review Board
2.2.3 Regulatory Authority Members and Advisors
2.2.4 Foreign Regulatory Authorities
2.2.5 Aircraft Certification office personnel
2.3 Documentation
2.3.1 MRB Report Revisions Prior to Entry into Service
2.3.2 Latest version of MSG Analysis Procedure
2.4 Organization of Meetings
2.4.1 ISC & WG Meeting Reports
2.4.2 ISC & WG Action Item Lists
2.4.2 Acceptance & Timely Distribution of Reports and Lists
2.5 Meeting Reports
2.5.1 Standardization and Harmonization of Required Data for WG Meeting Reports
2.5.2 Standardization and Harmonization of Required Data for ISC Meeting Reports
2.6 Supplemental Presentations Page 3
Appendix 3
3. Systems and Powerplant Analysis Procedures
3.1 General
3.1.1 Handling and Tracking of Task Transfers to Zonal
3.1.2 Handling and Tracking of Task Transfers amongst Systems and Powerplant WGs
3.2 Procedural Steps
3.2.1 Maintenance Significant Item (MSI) List (Appendix E)
3.2.2 Maintenance Significant Item Selection Form
3.2.3 The Systems Functional Description (SDF) Form
3.2.4 Component Supplier & Maintainability and Reliability Data (MDR) Form
3.2.5 Design Features
3.2.6 The Functional Failure Analysis (FFA) Form
3.2.7 The Failure Effect Questions (FEQ) Form
3.2.8 The Task Selection Questions (TSQ) Form
3.2.9 Task Summary
3.3 Analysis Forms
3.4 Responsibilities
3.4.1 OEM/TCH
3.4.2 Partners, Suppliers & Vendors
3.4.3 Working Groups
3.4.4 Industry Steering Committee
3.5 Analysis Guidelines
3.6 Lightning/HIRF Protection System Analysis Procedures
3.6.1 Introduction
3.6.2 Propose for Consideration of Process Revision
3.6.3 Proposal Page 4
Appendix 3
3.6.4 Revised Process Overview
3.6.5 Proposed Process
3.6.5.1 LHWG Process for Connector
3.6.5.2 LHWG Process for Connector Analysis -Fuselage
3.6.5.3 Maintenance Inspection of Wing Tanks
3.6.6 Lightning/ HIRF Forms
3.6.7 Preliminary Level A (Catastrophic) and B (Hazardous), C (Major) Items
3.7 Certification Maintenance Requirements (CMRs)
3.7.1 CMR Process
3.7.2 Certification Maintenance Coordination Committee (CMCC)
3.7.3 Documentation and Handling of CMRs
3.7.4 ISC & MRB CMR Policy and Procedures
4. Structural Analysis Procedures
4.1 General
4.2 Procedural Steps
4.3 Identification of Significan t Structure Item (SSI) or Other Structural Selection
4.4 Environmental Deterioration
4.4.1 Timely Detection Matrix
4.4.2 Susceptibility Matrix
4.4.3 Ground Rules for EDR
4.4.4 Use of ED Analysis Process
4.4.5 Galvanic Corrosion Procedures & Charts
4.4.6 Corrosion Protection and Control Program
4.5 Accidental Damage Analysis Process
4.5.1 Timely Detection Matrix Page 5
Appendix 3
4.5.2 Susceptibility and Residual Strength Matrix
4.5.3 Ground Rules for ADR
4.5.4 Use of AD Analysis Process
4.6 Fatigue Damage Analysis Process
4.6.1 Type Certification Interface
4.6.1.1 Airworthiness Limitations Items (ALI)
4.6.2 Crack Growth Rate
4.6.3 Residual Strength
4.6.4 Crack Delectability
4.6.5 FD Inspection Threshold
4.6.6 Feasibility of an FD Sampling Program
4.6.7 Selecting Inspection Intervals for FD
4.7 Composite Structure (Nonmetallic)
4.7.1 Nonmetallic Materials
4.7.2 Structural Composition
4.7.3 Accidental Damage
4.7.4 Environmental Deterioration
4.7.5 Fatigue Damage
4.7.6 Analysis Forms (nonmetallic)—Re fer to section 4-9 for all forms
4.8 Program Implementation Guidelines
4.9 Analysis Forms
4.9.1 Structure Rating Form
4.10 Responsibilities
4.11 Analysis Considerations
4.12 Glossary Page 6
Appendix 3
5. Zonal Analysis Procedures
5.1 General
5.2 Zonal Analysis Procedures – General
5.3 Zonal Analysis General Rules
5.3.1 Enhanced Zonal Analysis Ground Rules (EWIS/EZAP)
5.4 Responsibilities
5.4.1 Handling and Tracking of Task Transfers to Zonal
5.4.2 Handling and Tracking of Tasks Rejected by Zonal
5.5 Flow Diagram and Procedural Steps
5.6 Analysis Forms
5.6.1 Form—Title Page and Zonal Task Summary
5.6.2 Form—Transferred MSIs and SSIs
5.6.3 Form—Zone Contents
5.6.4 Form—Panel Access
5.6.5 Form—Zonal Tasks
5.6.6 Form—Zonal Analysis
5.6.7 Form—Enhanced Zonal Analysis
5.6.8 Form—Zonal Task Consolidation
5.7 Zone Diagrams
5.7.1 Aircraft Zones
6. Operator Purchased Standard Options
6.1 General
6.2 List of Items
7. Training
7.1 Policy and Procedures Training Page 7