Par 5-1 Page 23 CHAPTER 5. MAINTENANCE REVIEW BOARD REPORT (MRBR) APPROVAL
5-1. INITIAL MRBR APPROVAL PROCESS.
a. MRBR Proposal. The Industry Steering Committee (ISC) chairperson forwards the MRBR proposal to the Original Equipment Manufacturer (OEM)/type-certificate holder (TCH)’s representative(s) and may invite the OEM/TCH to discuss the comments or findings. The OEM/TCH must present the ISC-proposed MRBR, as recommended, to the Federal Aviation Administration (FAA) for review as part of the instructions for continued airworthiness (ICA).
Following ISC final review, the OEM/TCH submits a formal letter and the MRBR proposal to the Maintenance Review Board (MRB) chairperson for review and approval.
b. FAA Approval Process. Concurrent with MRBR approval, the MRB chairperson will forward a copy of the MRBR with an approval recommendation to the Aircraft Maintenance Division, AFS-300, for their concurrence. The AFS-300 representative concurs with or rejects the MRBR and returns it to the assigned Aircraft Evaluation Group (AEG). If AFS-300 concurs, the MRB chairperson sends a letter of approval, along with the signed approval page of the MRBR to the OEM/TCH (ISC cochair). Refer to Figures 5-1, Maintenance Review Board Report Letter of Approval, and 5-2, Maintenance Review Board Report Approval Page, below.
Should AFS-300 reject the MRBR, the assigned AEG MRB chairperson will return the report to the OEM/TCH for corrections and resubmit. The chairperson returns the corrected report to AFS-300 for their concurrence. Normally, the entire FAA approval process occurs within 90 calendar-days, unless corrections are required. Approval by foreign regulatory authorities will normally occur concurrently with FAA approval. The OEM/TCH is responsible for publishing and distributing the initial and revised MRBR and any supporting documents in a format acceptable to the Administrator.
5-2. NATIONAL AVIATION AUTHORITY (NAA) APPROVAL OF THE MRBR. There may be a need to identify national regulatory differences that are not compatible with, acceptable to, or applicable to all regulatory authorities. In this case, use an appendix to or specified section of the MRBR to list these differences, with the respective regulatory authority approving each difference. If the FAA is the validating authority for a foreign MRB, then a separate appendix to or specified section of the MRBR will identify regulatory differences.
5-3. PROPOSED INITIAL MRBR DISAPPROVAL PROCESS. The OEM/TCH must coordinate disapproval of an MRBR proposal with the MRB chairperson so that the ISC chairperson receives written notification of such action. The disapproval letter will include the specific reason(s) for the disapproval and suggested guidance to make the MRBR proposal approvable.
5-4. MRBR IMPLEMENTATION. Operators of the aircraft type should implement the initial MRBR in accordance with established procedures. The MRBR requirements are not an operator maintenance program. After FAA approval, the requirements become a baseline or framework around which each operator can develop its own individual aircraft maintenance program.
Aircraft/engine design and performance help form the MRBR requirements. The oversight of an operator’s program is the responsibility of the local regulatory authority. MRBR revisions are encouraged but are not mandatory inclusions in an operator’s approved maintenance program.
Page 24 Par 5-4 The FAA recommends that the operator’s program incorporate MRBR revisions associated with type design changes. The local regulatory authority must approve and/or accept all maintenance program revisions.
FIGURE 5-1. MAINTENANCE REVIEW BOARD REPORT LETTER OF APPROVAL
XXX Region 345 Regulation Alley Flight Standards Division Anytown, ST 12345-6789 XXX Aircraft Evaluation Group, XXX-AEG
XX/XX/XXXX
Mr. Gary Gordon Model 500 ISC Co-Chairman The ABC Aviation Company 123 Airport Avenue Anytown, ST 12345-6789
Dear Mr. Gordon:
The Federal Aviation Administration (FAA) has reviewed and approved the ABC Aviation Model 500 Maintenance Review Board Report (MRBR), original issue, dated Dec 10, 2013.
This report outlines the minimum scheduled tasking/interval requirements to be used in the development of an airworthiness maintenance/inspection program for the airframe, engines, systems and components of the ABC Aviation Model 500 aircraft. The exception to this approval is appendix XXX, Airworthiness Limitations, which is the responsibility of the appropriate Aircraft Certification Office (ACO).
The requirements in this report have been developed using Maintenance Steering Group - 3rd Task Force (MSG-3) Version 2011.1.
The FAA hereby approves that this report be used by U.S. certificated air carriers and U.S.-certificated operators of the Model 500 aircraft.
Sincerely, //s// Alan Able FAA Model 500 MRB Chairman XXX Aircraft Evaluation Group cc:
Howard Hughes, Industry Steering Committee (ISC) Chairperson, FlyByNight Airline, Inc.
Ida Innes, European Aviation Safety Agency (EASA) Model 500 MRB Chairperson Jacob Jefferies, Transport Canada Civil Aviation (TCCA) Model 500 MRB Chairperson
Par 5-4 Page 25 (and 26) FIGURE 5-2. MAINTENANCE REVIEW BOARD REPORT APPROVAL PAGE
Model 500 Maintenance Review Board Report (MRBR) Federal Aviation Administration (FAA) Approval Page This report outlines the minimum scheduled tasking/interval requirements to be used in the development of an airworthiness maintenance/inspection program for the airframe, engines, systems and components of the ABC Aviation Model 500 aircraft.
The requirements in this report have been developed using Maintenance Steering Group -3rd Task Force (MSG-3) Version 2011.1.
The FAA hereby approves that this report be used by U.S.-certificated air carriers (and/or U.S.-certificated operators) of the Model 500 aircraft.
Signed:____________________________ Date:_______________ Alan Able, FAA Model 500 Maintenance Review Board (MRB) Chairperson XXX Aircraft Evaluation Group (AEG) Federal Aviation Administration
Par 6-1 Page 27 CHAPTER 6. MAINTENANCE REVIEW BOARD REPORT (MRBR) REVISIONS,
FORMAT, AND CONTENT
6-1. MRBR ANNUAL REVIEW. Because the MRBR is intended to be an up-to-date, dynamic document, the Original Equipment Manufacturer (OEM)/type-certificate holder (TCH), Industry Steering Committee (ISC), and the Maintenance Review Board (MRB) chairperson should annually conduct a joint MRBR review to determine any need for a revision. The MRB chairperson should document results of these reviews for inclusion in the MRB historical file.
a. Proposed Changes. If needed, the OEM/TCH, ISC and MRB will convene to evaluate any proposed changes. Submit all proposed changes with supporting data to the MRB chairperson. Approval or disapproval of the proposed changes will be processed in the same manner as outlined for the MRBR approval/disapproval process.
b. Aircraft Maintenance Division, AFS-300, Review. AFS-300 review/concurrence of all revised MRBRs is required when changed text matter of the report affects Federal Aviation Administration (FAA) policy. If there is any doubt, submit the MRBR for review and concurrence by AFS-300. Technical changes to revised MRBRs do not need to be submitted for AFS-300 concurrence.
c. Multiple Approvals. If more than one regulatory authority approves an MRBR, each approving authority will evaluate proposed changes (per Appendix 4, Figure 5, Letter of Confirmation Template) before approval by the FAA. If the FAA is the validating authority, the MRB chairperson will provide a letter of confirmation (per Appendix 4, Figure 5) to the host National Aviation Authority (NAA).
6-2. TEMPORARY REVISIONS. If temporary revisions are needed, the OEM/TCH, ISC and MRB will convene in a timely manner to evaluate any proposed changes. Submit all proposed changes with supporting data to the MRB chairperson. Temporary revisions should be processed expeditiously, but in the same manner as outlined for the MRBR approval/nonapproval process.
Specifically identify and incorporate all temporary revisions during the next MRBR review process. If the need for a temporary revision arises while the FAA is reviewing an MRBR revision proposal, the MRB chairperson should review the temporary revision and decide if it should be incorporated in the major revision (which would require that the major revision be returned to the OEM/TCH for incorporation) or may be incorporated during the next major revision cycle.
6-3. RECOMMENDATIONS FOR COMPLETING THE REPORT. Each MRBR should be entitled, “Maintenance Review Board Report (MRBR) OEM name, aircraft model #,” and, at minimum, should contain the following, as appropriate:
a. Title Page. Containing the title of the MRBR and the report number, if any.
b. Table of Contents.
c. Approval Page. Containing the following statements:
Page 28 Par 6-3
(1) “This report outlines the minimum scheduled tasking/interval requirements to be used in the development of an airworthiness maintenance/inspection program for the airframe, engines, systems and components of the (aircraft make, model, and series (M/M/S)).”
(2) “The requirements in this report have been developed using (the current MSG revision or an alternative procedure, as agreed upon by the FAA, ISC, or WG).”
(3) “The FAA hereby approves that this report be used by U.S.-certificated air carriers (and/or U.S.-certificated operators) of the (aircraft M/M/S) aircraft.” (Insert page for each foreign regulatory authority approval, as applicable.)
NOTE: Chapter 5 of this advisory circular (AC) contains sample approval letters.
d. Record of Revisions.
e. Summary of Changes.
f. List of Effective Pages (LEP). Including the revision status and corresponding dates.
g. ISC/MRB Personnel Listing. Both a list of those persons who initially developed the MRBR and a current listing of personnel serving on the ISC/MRB should be provided (including their organizational affiliations and the capacity in which they serve).
h. The MRBR Preamble. The following information should be included in the preamble of each MRB report: “This report outlines the minimum scheduled tasking/interval requirements to be used in the development of a maintenance/inspection program for the airframe, engines (on-aircraft), systems, components, and appliances, of (aircraft M/M/S). These MRBR requirements are a basis from which each operator develops its own maintenance/inspection program.”
i. Acronyms. Define all acronyms in the MRBR. Appendix 1, Acronym/Abbreviation Listing for the Maintenance Review Board Report (MRBR), contains a reference list of acronyms that may appear in the MRBR, but this list is not comprehensive or complete.
j. Definitions. Include definitions of technical terms in the MRBR. Whenever possible, use industry-accepted definitions, such as those found in the Air Transport Association of America’s (ATA) latest version of the MSG document and the Common Support Data Dictionary (CSDD).
k. Applicability. The MRBR must identify the specific aircraft M/M/S. New options/modifications that cause changes to the MSG analysis will be added to the MRBR.
l. Analysis of Maintenance Significant Items (MSI) and Structural Significant Items (SSI). Analyze all MSIs and SSIs and select intervals without regard for established inspections. If a task is determined to be a safety task or applicable cost-effective task, select the appropriate tasking interval.
Par 6-3 Page 29
m. Checks and Intervals. Once the analysis of the tasks is complete, the OEM/TCH may choose to group tasks into checks performed at various intervals.
(1) The MRBR will provide guidance regarding the means to optimize the minimum scheduled tasking/interval requirements to a level higher than that provided by initial requirements in the MRBR. This guidance will be unique to the aircraft model.
(2) Optimization guidance should consider the content of like checks or other related inspections and their repetitive intervals. A determined series or sequence of specified checks or other related inspections must be completed and the resultant data found satisfactory before optimization of that type of check/inspection. Include in this section of the MRBR the description, type of checks/inspections, and their intervals.
n. Maintenance Requirement Rules. Include the following general requirements in the MRBR:
(1) The OEM/TCH optimization procedures of the MRBR, as described in the OEM/TCH Policy and Procedures Handbook (PPH). (Refer to Chapter 12, Implementation and Optimization of Tasking Intervals, for details on requirements.)
(2) That an operator’s maintenance/inspection program, based on the MRBR, can then be escalated, based on satisfactory substantiation by the operator and review and approval by its appropriate regulatory authority, or in accordance with the operator’s FAA-approved reliability program.
(3) That task interval parameters expressed in the MRBR may be converted to an individual operator’s desired units, provided that this conversion does not result in the operator exceeding the initial requirements of the MRBR.
(4) That the use of nondestructive inspection (NDI) methods, such as X-ray, ultrasonic, eddy current, and radioisotope, or alternative processes that the manufacturer approves, can provide an alternative to the methods this report prescribes. Each operator should notify its regulatory authority of the use of an acceptable alternative method.
NOTE: Within this report, the terms “check” and “inspection” are not intended to imply a level of skill required to accomplish a task.
(5) That life-limited items must be retired in accordance with the limits established in the engine or aircraft Type Certificate Data Sheets (TCDS) or the airworthiness limitations (AL) section of the engine or aircraft OEM/TCH instructions for continued airworthiness (ICA).
(6) A provision that, after the accumulation of industry service experience, either the ISC or MRB chairperson may request changes to the requirements of this MRBR.
(7) A restriction that Failure Effect Category (FEC) 5 or 8 safety tasks cannot be deleted or escalated without the approval of the MRB chairperson. Additionally, those Category 5 and 8 tasks involving either fuel tank safety (FTS) or the electrical wiring
Page 30 Par 6-3 interconnection system (EWIS)/enhanced zonal analysis procedure (EZAP) programs may not be deleted or escalated without approval from the Aircraft Certification Office (ACO).
o. System/Powerplant Requirement Rules. The FAA recommends that the following requirements be addressed in the system/powerplant requirement rules section of the MRBR.
(1) A statement that MSG-3 logic (specifying the revision) was used to develop an on-aircraft minimum scheduled tasking/interval requirement. With the exception of life-limited items, this process does not normally include detailed shop maintenance procedures.
(2) That the OEM/TCH provides a listing of identified candidate MSIs as the start of the analysis process. Those identified MSIs for which no task was selected must be included as part of the MRBR.
(3) A requirement that each candidate MSI that the OEM/TCH identifies is subjected to MSG analysis. This process results in the identification of maintenance tasks that are contained in this report. Provide a listing, or other record, as specified in the PPH, for MSIs with no tasks identified.
p. Structural Program Rules. The OEM/TCH develops structural inspection requirement rules to meet the inspection requirements for damage-tolerance (DT). The types of damage considered during structural requirement development are Environmental Deterioration (ED) (corrosion, stress corrosion), Accidental Damage (AD), and fatigue damage (FD). Some forms of ED are age-related; therefore, calendar intervals control inspections for this type of deterioration.
The required structural requirements section incorporates these calendar inspections, plus the requirements for detecting other types of ED, AD, and FD. The structural requirement rules section of the MRBR recommends the following contents:
(1) All aircraft in an operator’s fleet, or group of operators’ fleets, are subject to the provisions of this report. These requirements include external and internal inspections; structural sampling and age-exploration programs; corrosion prevention and control programs; and additional supplemental structural inspections that may be required for fatigue-related items. The initial check intervals for the Structural Inspection Program (SIP) may be expressed in terms of calendar time, flight cycles, or flight-hours. Do not optimize a repeat inspection interval until at least one aircraft in an operator’s fleet or group of operators’ fleets has been inspected within the initially defined interval listed in the MRBR.
(2) All changes to structural inspection items listed in the AL section require FAA engineering approval. Structural inspection limitations listed in the OEM/TCH’s AL section will be referenced in an MRBR appendix by document number.
Par 6-3 Page 31
(3) The Structural Program should include requirements to maintain composite structural details, elements, or assemblies whose failure could affect the structural integrity necessary for the safety of the aircraft. These requirements should take into account that composite structures may be damaged by accidental impact or aging deterioration, and that those composite structures degrade in a different way than metallic structures. Composite structure will be analyzed to create a minimum initial scheduled maintenance/inspection requirements. All structural items will be categorized as either an SSI or an “Other Structure.” (The SSI/Principal Structural Elements (PSE) list is provided by the OEM/TCH in a separate specified document.)
(4) SSIs must not be confused with PSEs (as described in Title 14 of the Code of Federal Regulations (14 CFR) part 25, § 25.571); however, the SSIs must address all PSEs.
q. Zonal Program Rules. The Zonal Inspection Program (ZIP) provides for the consolidation of a number of General Visual Inspection (GVI) tasks for each zone. A zonal inspection may include GVI tasks derived from MSI and SSI lists. An MSI/SSI task that is in the ZIP must be cross-referenced with supporting documentation and located in the appendix of the MRBR, indicating that an MSI/SSI is being accomplished by one or more zonal tasks. Likewise, the zonal item must be cross-referenced as an MSI/SSI task to ensure content and accountability.
Include the following contents of the Zonal Procedure Rules section of the MRBR:
NOTE: FEC 5 or 8 safety tasks are not candidates for zonal requirements.
(1) The ZIP contains a series of GVI tasks generated from standard zonal analysis procedures. Detailed inspection (DET) and Special Detailed Inspection (SDI) are not to be contained in the ZIP. Zonal inspection requirements apply only to zones.
(2) The ZIP contains GVI tasks derived from EZAPs as well as standard zonal analysis procedures.
(a) Identify zones that both contain electrical wiring and may contain combustible material. For those zones, perform an enhanced zonal analysis that permits the identification of stand-alone inspection tasks that allow appropriate attention to be given to deterioration of installed wiring and EWISs.
(b) EWIS tasks derived during the EZAP process will be identified as GVI, DET, or restoration (RS) tasks. The ZIP will not contain stand-alone EWIS tasks. These special, dedicated tasks reside in ATA 20 of the Systems/Powerplant section of the MRBR, and do not have an FEC.
(c) Uniquely identify all EZAP-derived stand-alone tasks as GVI, DET, or RST in the EZAP analysis for traceability during future changes. This prevents inadvertent deletion or escalation of an EZAP-derived stand-alone task without proper consideration of the risk basis for the task and its interval. All escalations must go through the appropriate FAA oversight office.
(d) The latest version of the MSG analysis develops Lightning/High Intensity Radiated Field (L/HIRF) tasks. The ZIP will not contain stand-alone L/HIRF tasks. These special, dedicated tasks should reside in a separate section of the MRBR. Uniquely identify all L/HIRF tasks.
Page 32 Par 6-3
(3) Access to zones should be easy to accomplish and should not require the use of special tools. Normally, the inspection aids include a flashlight and/or inspection mirror. Inspect the entire visible contents of the zone for obvious damage, security of installation, and general condition, including corrosion and leaks. Refer to the latest version of the MSG document for a definition of GVI.
(4) The following zones do not contain system installations but receive adequate surveillance from other maintenance or structural inspections tasks. Accordingly, the inspection requirements in the ZIP do not specify these zones. (Insert listing of the zones not specified in the ZIP or in other document as specified.) (Insert aircraft zone diagram sheets or in other document as specified.)
r. Appendices. The following is a list of possible appendices that may apply to MRBRs.
• Identification of aircraft zones.
• Extended Operations (ETOPS) requirements.
• All acronyms/abbreviations used in the MRBR.
• Definitions of specific terms, processes, and inspections identified in the MRBR.
• NAA Requirements. An appendix (or appendices), as needed, for each regulatory authority will identify national differences, as mandated by the respective authorities (and approved or accepted by them).
• Other items, as applicable.
Par 7-1 Page 33 (and 34) CHAPTER 7. MAINTENANCE REVIEW BOARD POLICY BOARDS (MRBPB)
7-1. FEDERAL AVIATION ADMINISTRATION (FAA) MRBPB.
a. Purpose of the MRBPB. The MRBPB advocates the standardization of Maintenance Review Board (MRB) policy and procedures and provides a structured forum for discussions leading to the development of national and international recommendations regarding all MRB activities. The MRBPB develops FAA/Aircraft Evaluation Group (AEG) positions for standardized guidance on issues that arise from the MRB/Air Transport Association of America (ATA) latest version of the Maintenance Steering Group (MSG) process. Continued development of standardized MRB policies, procedures, and guidance promotes harmonization within the respective FAA AEG offices and participating industry groups.
b. Meetings. Membership includes a designee from the Aircraft Maintenance Division, AFS-300, and one designee from each AEG office. The MRBPB normally meets at least twice a year, with one meeting just before the International Maintenance Review Board Policy Board (IMRBPB). Additional meetings may be held via electronic media. It is the responsibility of the MRBPB to develop harmonized issue papers, procedures, and guidance. It also produces FAA guidance for issue papers recommended for implementation by the IMRBPB. The MRBPB participates in international meetings on MRB policy issues with other regulatory authorities.
7-2. IMRBPB.
a. Function of the IMRBPB. The IMRBPB is a system for the continuing development of policies, procedures, and guidance for the use of personnel operating under the purview of various MRBs. The IMRBPB provides a process of promoting harmonization with other regulatory authorities throughout the world; the IMRBPB advocates the standardization of MRB policy and procedures. The IMRBPB also provides a structured forum for discussions leading to the development of national and international policy regarding all MRB activities. The ATA and the Maintenance Programs Industry Group (MPIG) under the ATA Airworthiness Committee represent the industry at the IMRBPB meeting. The committee is also open to input from the aviation industry.
b. Composition of the IMRBPB. The IMRBPB convenes once a year.
Industry/regulatory discussions are a portion of the meeting. Industry representation should be limited to appropriate representatives dealing with the discussion topics. The meeting venue will normally rotate among the IMRBPB members.
c. IMRBPB Documents. The IMRBPB maintains an issue paper list with associated documents, such as minutes of meetings, action item lists, substantiation documents, and associated IMRBPB policy decisions. The IMRBPB only addresses issues related to the MRB/MSG processes and uses the latest revisions of the following guidance.
• Advisory Circular (AC) 121-22;
• European Aviation Safety Agency (EASA) Document # WI.MRB.00002-001, Maintenance Review Board Team; and
• Transport Canada Transport Publication (TP) 13850, Scheduled Maintenance Instruction Development Process Manual.