“AIRCRAFT MAINTENANCE & CREW

MANAGEMENT ”
Project Submitted to the IIKM B-SCHOOL [ALAGAPPA
UNIVERSITY] in partial fulfillment of the requirements for the award of
the Degree of
BACHELORS OF BUSINESS ADMINISTRATION
IN
[AIRLINE & AIRPORT MANAGEMENT]
By
Name of the Candidate
SATHISH P
209150289

Research Guide
Name of the Guide
LOKESH BABU

DIRECTORATE OF COLLABRATIVE INSTITUTIONS

IIKM B-SCHOOL
ALAGAPPA UNIVERSITY

857Poonamallee High Rd
Kilpauk, Chennai.
Tamil Nadu – 630 010
OCTOBER -2022
 DECLARATION

I hereby declare that the project entitled “AIRCRAFT

MAINTENANCE & CREW MANAGEMENT” submitted
for the B.B.A. Degree is my original work and the dissertation
has not formed the basis for the award of any degree,
associateship, fellowship or any other similar titles.

Place: CHENNAI
Date: OCTOBER-2022

SATHISH P
Signature of the Student

2
 BANAFIDE CERTIFICATE

This is to certify that the project entitled “AIRCRAFT

MAINTENANCE & CREW MANAGEMENT” is the bonafide
research work carried out by ... [SATHISH P] student of B.B.A.,
collaborative programme, Alagappa University, Karaikudi, during the
year 2021-2023, in partial fulfilment of the requirements for the
award of the Degree of Bachelors Of Business Administration and
that the project has not formed the basis for the award previously of
any degree, diploma, associate ship, fellowship or any other similar
title.

Place: CHENNAI
Date: October-2022

Signature of the Guide

3
 SUBMISSION FORM

Name Of The Candidate :

Enrolment No :
Course:
Period Of Study :
Mode Of Registration [Please :
Tick In The Respective Box]
If Through Institutions, State :
The Name & Address Of The
Collaborative Institutions
Address Of The Candidate :

Name Of The Guide :

i. Academic Qualification :
ii. Designation:
iii. Years Of Experience :
iv. Institution Where :
Working
v. Contact Address :
Date Of Submission :

Signature Of The Guide Signature Of The Candidate

Director,
Collaborative Institutions, Alagappa University

4
 CERTIFICATE

This is to certify that the project report titled “AIRCRAFT

MAINTENANCE & CREW MANAGEMENT”
submitted by
SATHISH P
REGISTER NUMBER of 209150289
BACHELORS OF BUSINESS ADMINISTRATION
[AIRLINE AND AIRPORT MANAGEMENT]
This record carried out by them. The result embodied in this
report have not been submitted to any other institutes for the
award of any degree.

CO-ORDINATOR
MS.ATHULYA R

5
 ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have

been possible without the kind support and help.
I would like to express my special gratitude and thanks to my
Teacher MR.LOKESH BABU.

The wonderful project of Educational Studies about the subject

of “AIRCRAFT MAINTENANCE & CREW
MANAGEMENT”
And
I would like to express my gratitude towards my Parents &
Friends for their kind co-operation and encouragement which
help me in completion of this project.

My thanks and appreciations also go to my collage IIKM

BUSINESS SCHOOL for developing the project and people
who have willingly helped me out with their abilities.

And my special thanks for my friends and classmates. Also

For the co-operation on doing this project.

THANKYOU ALL FOR YOUR’S CO-OPERATION.

BY
SATHISH .P

6
 ABSTRACT

Task scheduling and resource allocation problems have been the

subject of intense research over the past decades, particularly within
Operations Research. However, seldom optimization models have
been proposed to address the aircraft maintenance management
process in an integrated manner.

Besides eliciting the problems of capacity planning, parts forecasting

and inventory management, and task scheduling and resource
allocation faced by aircraft MRO companies, this paper presents a
short review on models that address each of the problems and
discusses research opportunities within this field.

Keywords:
 Aircraft Maintenance
 Capacity Planning
 Spare Parts Forecasting
 Inventory Management
 Task Scheduling
 Resource Allocation

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S.no: Contents Pg.no
1. Introduction 09
2. About Aircraft Maintenance 10
3. Maintenances 11
3.1.The Role Of Engineer
3.2.The Role Of Mechanic
4. Two Types Of Maintenance 13
5. About The Airworthiness 14
6 Key Concepts 15
7 Modern Day Aircraft Maintenance 17
8 Design & Role Of Engineer 18
9 Establishing A Maintenance Program 19
10 Development Of Maintenance Program 24
11 Process Oriented Maintenance 26
12 Maintenance Steering Group [MSG] 27
Approach
13 Maintenance Task Development 29
14 Functional Check 30
15 Maintenance Program Documents 31
16 Maintenance Interval Defined 32
17 Types Of Documentation 33
18 Conclusion And Future Research 34
19 Reference 35

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 1. INTRODUCTION

Aircraft maintenance is the performance of tasks required to

ensure the continuing airworthiness of an aircraft or aircraft part,
including overhaul, inspection, replacement, defect rectification, and
the embodiment of modifications, compliance with airworthiness
directives and repair.

Designed for cleaning narrow-body, wide-body and extra

wide-bodied aircraft
Lower fuel consumption, extended paint life and fewer corrosion
issues
Easy to use, Cost saving.

Aircraft Maintenance means the repair, maintenance, adjustment, or

inspection of Aircraft. Major repairs include major alterations to the
airframe, powerplant.

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 2. ABOUT AIRCRAFT MAINTENANCE

Aircraft maintenance is a highly-regulated field requiring a robust

regimen of :-
 Scheduled or preventive servicing,
 Inspection,
 Testing,
 Repair,
 Overhaul or modification activities.

By certified maintenance, repair and overhaul (MRO) technicians

on every aircraft in service.

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 3. MAINTENANCES

3.1. THE ROLE OF ENGINEER:-

An aircraft maintenance engineer is responsible for ensuring an
aircraft operates properly and safely.

One of the first sources of confusion, particularly among those who

are not engineers or scientists, is the distinction between science
and engineering.

This job entails:-

 Assessing repairs,
 Handling repairs,
 Performing regular inspections,
 Updating aircraft as needed.

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3.2. THE ROLE OF MECHANIC:-

Aircraft mechanics are responsible for:-

 Inspecting,
 Diagnosing,
 Repairing aircraft structural systems.

They also help maintain hydraulic and mechanical systems,

identify repair methods, and schedule routine updates. They may
be employed in the logistics or aviation industries.

The mechanic such as:-

 Technician,
 Repairer,
 Maintainer,
 On the other hand,
 Has a different problems

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 4. TWO TYPES OF MAINTENANCE

1. Unscheduled Maintenance:-
 Unscheduled maintenance occurs when there is an
unexpected issue with the aircraft that must be addressed
immediately to ensure the safety of pilots and passengers.
 While unscheduled and scheduled aircraft maintenance are
each performed in different scenarios, they can be
connected.

2. Scheduled Maintenance:-
 Scheduled aircraft maintenance is preventative
maintenance that is performed at regular intervals.
 This type of maintenance generally includes 100-hour
inspections, annual inspections, and progressive
inspections as well as preflight checks to ensure the
aircraft is airworthy and ready to be flown.

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 5. ABOUT THE AIRWORTHINESS

 Airworthiness mean ‘Aircraft Fit-To-Fly’ certificate by

engineer.
[FC]= Fitness certificate

 There are two different classifications of FAA airworthiness

certificates:-
a. Standard Airworthiness Certificate
b. Special Airworthiness Certificate.

 For an aircraft, or aircraft part (airworthiness), is the possession

of the necessary requirements for flying in safe conditions,
within allowable limits.

 Three key elements deserve special consideration:

a. Safe conditions
b. Possession of the necessary requirements
c. Allowable limits

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 6. KEY CONCEPTS

The field of aircraft maintenance management has enormous key

concepts to be elaborated as below.
They are:-
1. Reliability
2. Redesign
3. Failure rate patterns

 Reliability:-
‘A measure of the probability that an item will survive to a
specified operating age or time, under specified conditions,
without a failure’.
 No amount of maintenance can be performed to increase
the systems inherent level of designed in-level of
perfection.

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 Redesign:-
 When the reliability decreases & higher level of
‘perfection’ is desired-redesign may take place.
 Needs to be weighed if the performance improvement
justifies more maintenance & thus the increase in
maintenances cost-ideally the opposite is true.

 Failure rate patterns:-

 There are three patterns of failures for non-repairable
items, which can change with time. The failure rate or
hazard rate may be decreasing, increasing or constant.
 Decreasing Failure Rate or Non-Repairable Items.
 Constant Failure Rate or Non-Repairable Items.
 Increasing Failure Rate or Non Repairable Items.

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7. MODERN DAY AIRCRAFT MAINTENANCE

 Aircraft require preventive or corrective maintenance at frequent

intervals:-
 Kind of operation
 Environmental conditions
 Storage facilities avail
 Age and construct of aircraft

 Maintenance man-hours per flying hour:-

 Cost to maintain a particular type of aircraft

 Cost of ownership:-
 Fuel
 Wash
 Oil
 Tires etc…

 Scheduled maintenance:-
 Goal is to correct any deficiency before it occurs
 Checks cost money- labor and parts , fluids costs and loss
of passenger revenue when not flying.

 Total up all maintenance associated costs subtract from revenue

from aircraft and you get profit or loss.

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 8. DESIGN & ROLE OF ENGINEER

 We can design perfect systems on paper but we can not build

perfect systems in the real world
 Nothing is perfect
 Good, Fast, Cheap

 A design engineer may be limited from making the perfect

system by technology or the state of the art within any facet of
the design effort
 Limited by ability, technique or economics
 Economics may force a redesign with reduced tolerances,
cheaper materials and gap between
 Perfect and ‘perfect’ realism.

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 9. ESTABLISHING A MAINTENANCE
PROGRAM

A maintenance program combines the maintenance and inspection

function used to fulfil an operator / applicants total maintenance
needs.
A states regulations normally require that an operator must have a
maintenance program adequate to perform the work and qualified
competent persons to certify the maintenance and to monitor
performance.

Terminologies:-

 Airworthiness:-
A condition in which the aircraft, airframe, engine,
propeller, accessories, and components meet their type
design and are in a condition for safe operation

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 Inspection:-
 The routine performance of inspection takes at prescribed
intervals.
 The inspection must ensure the airworthiness of aircraft,
up to and including its overhaul or life-limits.

 Scheduled [routine] maintenance:-

The performance of maintenance takes at prescribed intervals.

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 Unscheduled [non-routine] maintenance:-
 The performance of maintenance takes when mechanical
irregularities occur.
 These irregularities are categorized as to whether or not
they occur during flight time.

 Structural Inspection:-
 A detailed inspection of the airframe structure that may
require special inspection techniques to determine the
continuous integrity of the airframe and its related parts.

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 Program requirements:-
Basic requirements of a maintenance program which will,
include the following:-
 Inspection
 Scheduled Maintenance
 Un Scheduled Maintenance
 Overhaul And Repair
 Structural Inspection

 Manuals:-
 Instructions and standards for unscheduled maintenance
should be in the operator or applicants technical manuals.
 The manuals must contain procedures to be followed when
using these manuals and recording scheduled and
unscheduled maintenance.

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 Approval:-
 Maintenance programs are approved by issue of operations
specifications or by direct approval of the maintenance
program document.
 The approved document should describe the scope of the
program and reference manuals and other technical data.
 Details of the program must also be included in the
operator applicants manual.

 Operator or Applicants Organization:-

 The complexity of the organization
 The aircraft
 The experience of the personnel
 The number of personnel

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 10. DEVELOPMENT OF MAINTENANCE
PROGRAMS

 Introduction:-
 The maintenance is as old as the world from the ancient
times every industry has to survive by maintenance its
equipment in proper conditions.

 Under the economic pressure most airlines currently

experiences, there is no margin to do too must or not
enough of maintenance.

 Customers demands high regularity punctuality and safety.

 It is all about finding a balance in the maintenance

program to be able to control costs and to deliver what the
customers expect.

 To actively work with the maintenance program and to

continuously evaluate the same is of these reason utterly
important.

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11.MAINTENANCE STEERING GEOUP [MSG]
APPROACH

 In 1968 the maintenance steering group [MSG] was created with

a mandate to formulate decision logic process used for
development of the initial scheduled maintenances for new
aircraft.

 The group was composed of participants from various aviation

bodies, including:-

 The Air Transport Association [ATA]

 Airlines
 Aircraft Manufactures
 Suppliers
 Federal Aviation Administration [FAA] Representatives.

 The basic goal of MSG-3 is to identify maintenance tasks which

are both effective and efficient in enabling a new aircraft to be
designed and operated in a manner which achieves a satisfactory
level of safety and reliability throughout its life.

 The maintenance tasks were derived from one of three

processes:-

1. Hard-time
2. On-condition
3. Condition-monitoring or some combination of the three
processes.

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 Drawbacks of MGS-2

 Does not take the economic view into the considerations.

Simply maintains aircraft at any cost.
 Does not treat hidden failure to pilots: and electronic
failures, fatigue inside the structure etc...
 Is a bottom-up approach requiring more staff
 The definition in MSG-2 contradicts themselves
 Does not take the modern corrosion prevention approach
into account

 Advantages of MSG-3

 Top-down process
 Reduced maintenance costs
 Fewer maintenance tasks
 Some tasks are carried out of economic and others for
safety reason
 Eliminates emotions

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 12.PROCESS ORIENTED MAINTENANCE

In general, hard time means the removal of an item at a predetermined

interval, usually specified in either so many flight hours or so many
flight cycles. In some cases the hard time interval may be in calendar
time.
Condition monitoring involves the monitoring of:-
 Failure rate
 Removal rate

The three oriented maintenance processes are discussed below in

detail:-
 On-condition maintenance
 Condition monitoring
 Hard time process

 On-Condition Maintenance:-
A type of aircraft maintenance in which parts are replaced only
when their condition appears no longer airworthy, instead of at
predetermined intervals of operation.

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 Condition monitoring
The Condition monitoring is a process for system, components, or
appliances that have neither hard time nor on-condition
maintenance as their primary maintenance process

 Hard time process

A hard time component is a component that requires a specific
action at a specific interval like overhaul, refurbishment, bench
check, etc.

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 13. MAINTENANCE TASK DEVELOPMENT

MSG-3 is the current method used for developing the scheduled

maintenance tasks and intervals which will be acceptable.
They are:-
1. Regulation Authorities
2. Operators
3. Manufactures

The remaining maintenance that is non-scheduled or non-

routine maintenance consist of maintenance action to correct
discrepancies notes during scheduled maintenance tasks.

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 14. FUNCTIONAL CHECK

 The quantitative checks to determine if one or more functions of an

item perform within specified limits

 They are three levels of inspections to determine if an item is

fulfilling its intended purpose as the following:-
 General visual inspection [GVI]
 Detailed inspection [DI]
 Special detailed inspection [SDI]
 Restoration :-
 Reworking, replacement of parts or cleaning necessary
to return an item to a specified standard.
 Discard :-
 The removal from service of an item at a specified life
limits.

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 15.MAINTENANCE PROGRAM DOCUMENTS

Maintenance programme is a document containing the maintenance

requirements tasks that need to be carried out on an aircraft in order to
ensure its continuing airworthiness.

The supplemental inspection of tasks are detailed in The Aircraft

Certification Maintenance Requirement [CRM] And Airworthiness
Limitations [AWL] Documents.

They are:-
 Certification Maintenance Requirements [CMR]
 Airworthiness Limitations [AWL]
 Operators Approved Maintenance Program

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 16. MAINTENANCE INTERVAL DEFINED

Aviation maintenance professionals perform B maintenance checks

approximately every 6-8 months.

It takes about 160-180 labor hours, depending on the aircraft, and can
be completed within 1–3 days at an airport hangar.

Maintenance manuals are available from aircraft manufacturers or

commercial vendors with revisions for maintaining your aircraft.

Maintenance interval defined:-

 Inspection
 Annual inspection
 100 hour inspection
 Other inspection program
 Altimeter system inspection
 Preventive maintenance
 Repairs and alterations
 Letter check maintenance program
 Phased maintenance program

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 17. TYPES OF DOCUMENTATION

Aircraft Documentation means all logs, manuals, certificates, data and

inspection, modification, repair, and overhaul records which are
required to be maintained with respect to the Aircraft under the
Maintenance Program or by the Relevant Aviation Authority.
They are:-
 Airplane Maintenance Manual
 Fault Isolation Manual
 Fault Reporting Manual
 Components And Vendors
 Illustrated Parts Catalogue
 Storage And Recovery Document
 Structural Repair Manual [SRM]
 Maintenance Planning Data Document [MPD]
 Schematic Diagram Manual [SDM]
 Wiring Diagram Manual
 Master Minimum Equipment List
 Dispatch Deviation Guide
 Configuration Deviation List
 Task Cards [TC]
 Service Bulletins, Service Letters And Maintenance Tips.

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 18. CONCLUSION AND FUTURE RESEARCH
This paper presents the aircraft maintenance problem from the
perspective of independent MRO companies, and divides it into three
main sub-problems:
 Capacity Planning Of Manpower To Face Uncertain Demand
 Spare Parts Forecasting And Inventory Management
 Task Scheduling And Resource

 Aircraft Maintenance means the repair, maintenance,

adjustment, or inspection of Aircraft. Major repairs include
major alterations to the airframe, powerplant are maintenance
area.

 Lower fuel consumption, extended paint life and fewer

corrosion issues & Easy to use, Cost saving.

 All aircraft maintenance systems products are under continual

development and we are working hard to find ways to improve
operational efficiency for our present and future customers.

 Aircraft engineering and maintenance need to be familiar with

any components in aircraft.

 No way for any default in maintenance whether in preventive or

corrective maintenance routine.

 Maintenance of aircraft classified into levels.

 Determining lifetime of the aircraft is very important.

 A maintenance programme is a combination of management

procedures as well as scheduled maintenance tasks.

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 19. REFERENCE

 Adida E, Joshi P (2009) A robust optimisation approach to

project scheduling and resource allocation. Int J Serv Oper
Informatics 4:169–193. doi: 10.1504/IJSOI.2009.023421

 Ahire S, Greenwood G, Gupta A, Terwilliger M (2000)

Workforce-constrained Preventive Maintenance Scheduling
Using Evolution Strategies. Decis Sci 31:833–859.
doi:10.1111/j.1540-5915.2000.tb00945.x

 Atasoy B, Güllü R, Tan T (2012) Optimal inventory policies

with non-stationary supply disruptions and advance supply
information. Decis Support Syst 53:269–281.
doi:10.1016/j.dss.2012.01.005

 Bertsimas D, Gupta S, Lulli G (2014) Dynamic resource

allocation: A flexible and tractable modeling framework. Eur J
Oper Res 236:14–26. doi: 10.1016/j.ejor.2013.10.063

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“I HOPE THAT YOU ENJOYED THIS
PRESENTATION”

“THANK YOU FOR YOUR TIME”

-THE END-

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