Appendix 2 Page 1 (and 2) APPENDIX 2. EVOLUTION/OPTIMIZATION 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. Evolution/Optimization. Task performed through the management of data as a means to assure the continued applicability and effectiveness of the task, while improving the integrity of the process.
c. Line Maintenance. Routine check, inspection, and malfunction rectification performed en-route and at base stations during transit, turn-around, or night stop.
d. 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.
e. Non-Routine Task. A task is non-routine when it is not a planned/scheduled task coming from the operator’s/manufacturer’s maintenance program.
f. Pilot Report (PIREP). Suspected or known malfunctions or unsatisfactory conditions that are entered by the flightcrew into the aircraft log and require maintenance action.
g. Qualified Federal Aviation Administration (FAA) Maintenance Review Board (MRB) Chairperson. An airworthiness inspector with working knowledge of the MRB process must have system/structures training on particular aircraft and have Maintenance Steering Group—3rd Task Force (MSG-3) formal training.
h. Risk Management (RM). The systematic application of management policies, procedures, and practices to the tasks of identifying, analyzing, evaluating, treating, and monitoring risk.
i. Safety Management. The application of engineering and management principles, criteria, and techniques to optimize safety. It is an integrated and comprehensive engineering effort.
j. Structural Significant Item (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.
k. Unscheduled Maintenance. Maintenance performed to restore an item to a satisfactory condition by correcting a known or suspected malfunction and/or defect.
Appendix 3 APPENDIX 3. POLICY AND PROCEDURES HANDBOOK (PPH) FORMAT This appendix intends to provide standardized and harmonized policy in the development of a PPH for a new product. It is encouraged that all industry applicants’ PPH documents be developed containing the same basic data and information, as applicable, to provide for a complete, consistent, and quality process. It is not required that existing PPHs be revised to meet these standards.
Regulatory authorities and industry experience have indicated that the following information is expected in each PPH, as applicable, for the successful latest version of the Maintenance Steering Group (MSG) process and development of a Maintenance Review Board Report (MRBR).
SCHEDULED MAINTENANCE DEVELOPMENT Contents of PPH I Approval and Acceptance Le tters or Signature Page II Record of Revisions III List of Effective Pages (LEP) 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 and Objective
1.4 Regulatory Requirements
1.5 MSG Guidelines
1.6 Revision Process Policy
1.7 Temporary Revisions Process
Appendix 3
1.8 Program Organization Program Work Schedule
1.9 Main Principles and Design Standards
1.10 Aircraft Utilization Assumptions
1.11 Establishing Task Intervals (Frequencies)
1.11.1 Systems and 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 Industry Steering Committee (ISC) and Maintenance Review Board (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 Issue Paper (IP) 44, MRB Evolu tion/Optimization Guidelines
2. Organization and Administration
2.1 Industry Participation
2.1.1 General
Appendix 3
2.1.2 Intellectual Property Management
2.1.3 Communications, Inte rnal and External
2.1.4 Industry Steering Committee (ISC)
2.1.5 Working Groups (WG)
2.1.6 Original Equipment Manufacturer (O EM)/Type-Certificate Holder (TCH)
2.1.7 Partners, Suppliers, and Vendors
2.1.8 Certification and Design Personnel
2.2 Federal Aviation Administration (FAA) and Other Regulatory Authority Participation and Functions
2.2.1 General
2.2.2 Regulatory Authority MRB
2.2.3 Regulatory Authority Members and Advisors
2.2.4 Foreign Regulatory Authorities
2.2.5 Aircraft Certification Office (ACO) Personnel
2.3 Documentation
2.3.1 MRBR Revisions Prior to Entry into Service
2.3.2 Latest Version of MSG Analysis Procedure
2.4 Organization of Meetings
2.4.1 ISC and WG Meeting Reports
2.4.2 ISC and WG Action Item Lists
2.4.2 Acceptance and Timely Distri bution 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
Appendix 3
2.6 Supplemental Presentations
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 and 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, and Vendors
3.4.3 WGs
3.4.4 ISC
3.5 Analysis Guidelines
3.6 Lightning/High Intensity Radiated Fiel d (L/HIRF) Protection System Analysis Procedures
3.6.1 Introduction
Appendix 3
3.6.2 Proposal for Consideration of Process Revision
3.6.3 Revised Process Overview
3.6.4 Proposed Process
3.6.4.1 L/HIRF Working Group (LHWG) Process for Connector
3.6.4.2 LHWG Process for Connector Analysis–Fuselage
3.6.4.3 Maintenance Inspection of Wing Tanks
3.6.5 L/HIRF Forms
3.6.6 Preliminary Level A (Catastrophic), B (Hazardous), and C (Major) Items
3.7 Certification Maintenance Requirements (CMR)
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 and MRB CMR Policy and Procedures
4. Structural Analysis Procedures
4.1 General
4.2 Procedural Steps
4.3 Identification of Structural Significant Item (SSI) or Other Structural Selection
4.4 Environmental Deterioration (ED)
4.4.1 Timely Detection Matrix
4.4.2 Susceptibility Matrix
4.4.3 Ground Rules for Environmental Deterioration Rating (EDR)
4.4.4 Use of ED Analysis Process
4.4.5 Galvanic Corrosion Procedures and Charts
4.4.6 Corrosion Protection and Control Program
Appendix 3
4.5 Accidental Damage ( AD) Analysis Process
4.5.1 Timely Detection Matrix
4.5.2 Susceptibility and Residual Strength Matrix
4.5.3 Ground Rules for Accidental Damage Rating (ADR)
4.5.4 Use of AD Analysis Process
4.6 Fatigue Damage (FD) Analysis Process
4.6.1 Type Certification Interface
4.6.1.1 Airworthiness Limitation Items (ALI)
4.6.2 Crack Growth Rate
4.6.3 Residual Strength
4.6.4 Crack Detectability
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)
4.8 Program Implementation Guidelines
4.9 Analysis Forms
4.9.1 Structure Rating Form
4.10 Responsibilities
Appendix 3
4.11 Analysis Considerations
4.12 Glossary
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 Rule s (Electrical Wiring Interconnection System (EWIS)/Enhanced Zonal Analysis Procedure (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
Appendix 3
7. Training
7.1 Policy and Procedures Training
7.2 MSG Analysis Training
7.3 Airplane General Familiarization Training
7.4 (Aircraft Model) Airp lane Detailed Training
8. MRBR—Procedures and Format
8.1 Purpose
8.2 MRBR Proposal
8.2.1 Development of MRBR Proposal Concurrent to MSG Process
8.2.2 Contents
8.3 MRBR
8.3.1 Contents
8.3.2 Multiple Primary Critical Systems
8.3.3 Approval Process
8.4 MRB Item Numbering Scheme Ground Rules
8.4.1 MRB Item Numbering Scheme for Sy stems, Structures and Zonal Tasks
8.4.1.1 MRB Policy and Rules for Syst ems/Powerplant Requirements
8.4.1.2 MRB Policy and Rules for Structures Requirements
8.4.1.3 MRB Policy and Rules for Zonal Requirements Appendix A Air Transport Association of Amer ica (ATA) Latest Version of MSG Document (Currently Applied Revision) Appendix B PPH Acronyms and Abbreviations Appendix C ISC, MRB and WGs Appendix D (Aircraft Model) Master Minimum Equipment List (MMEL) Appendix E MSI and Analysis List Items Appendix F SSI List or Applicable Document
Appendix 3 Page 9 (and 10) Appendix G Fuel Tank Safety Guidelines Appendix H Glossary and Definitions Appendix I Advisory Circulars (AC) and Regulatory Documents Appendix J Policy Letters and IPs Appendix K Temporary Revision Process Appendix L IP 44 MRB Optimization Process References Active Page Record Revision Record