Aircraft Reliability

Improvement and Maintenance

Cost Optimization
PIC Claimable

25 - 29 January 2016, Singapore

About The Trainer
Mr. S.Nadeem Ahmed has 20 years plus of diverse engineering experience in Industrial sectors as a Mechanical
Engineer with Manufacturing and Engineering MRO Industry. For the past 15 years, he has worked with PK
Engineering MRO facility on Maintenance Repair, Overhaul, Testing and Evaluation of Turbo Machinery
including Aero and Aero derivative Gas Turbine Power Plants and has diversified experience on General
Electric, Rolls Royce and Pratt & Whitney Machines. As an international conference speaker & trainer
globally addressing Gas Turbine Power Plants, Rotating equipment, Reliability engineering & lean Six Sigma
topics, he has also trained numerous professionals in the same area within and outside his organization.
Nadeem has also provisioned Process companies (Power Generation, Oil and Gas etc) on Effective Reliability
Improvement Programs, Maintenance Management Strategies, Lean Maintenance and Six Sigma Process
Improvement Strategies integrating the same with reliability solutions. He holds a Masters in Mechanical
Engineering with Major in Thermal Power Systems Engineering, is a Certified Six Sigma Master Black Belt from USA & is well
versed with the Quality, Six Sigma and Power Plant Equipment Reliability Analysis Softwares. He has also conducted training for the
following companies : Lao Airlines, Miat Mongolian Airlines, ST Aerospace Supplies Pte Ltd, Air Niugini Limited, Myanmar
Airways International, Berjaya Air Sdn Bhd and Brunei Department of Civil Aviation.

About The Organizer

T.U.N International was formed with the objective of truly understanding the needs of each
individual organizations training requirements. Our strength lies in our ability to listen to our
clients, understand their unique business issues and assisting them to deliver the appropriate
training solution based on the business challenges in the current market situation.
Our vision is to be the No. 1 preferred training provider for all corporate companies by
providing an innovative approach to your training requirements. We facilitate a training
solution that is not only cost effective, but tailored to yield maximum benefits. We deeply value our working relationship
with our clients and constantly dedicate ourselves to exceed your expectations of us. Besides customizing in-house training
solutions for corporate companies, we also offer public courses and conferences in various industries.

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

Aircraft Reliability Improvement and Maintenance Cost Optimization

25 - 29 January 2016, Singapore
This course is focused on aircraft reliability programs as part of the operators maintenance program, with emphasis on
issues related to maintenance cost analysis. Asset Management Concept as applied to Aircraft, its structure and components will be discussed in detail. Maintenance strategy and various concepts may reduce cost, but they need to be
integrated to ensure high reliability levels. Continued compliance with the regulatory requirements, while fulfilling the
challenges of cost reductions and effective maintenance programs, is of paramount importance. Regulatory Authorities
and Operators should be on the same level of understanding.
Within a 5-day period you will be provided with guidance for the implementation of RCM based Reliability Programs
and you will focus on the monitoring task and the relevance of the efficiency of the Maintenance Program, in order to
fulfill the regulatory requirements and to avoid unnecessary maintenance cost. Case studies with practical examples will
complement this course.
Continuing airworthiness is to be delivered by the aircraft Manufacturer for the establishment of an approved aircraft
operators aircraft maintenance program and must contain the necessary details, including frequencies, of all maintenance required to be carried out for a safe and economical aircraft operation. Implementation of such aircraft maintenance program requires the preparation and planning of the maintenance tasks. These tasks are normally based upon
the Maintenance Review Board Report and the Manufacturers Maintenance Planning Recommendation as detailed in
the Maintenance Planning Document (MPD). In order to establish an operators maintenance program, the tasks and
periods (interval/ frequencies) at which each part of the aircraft, engines, APUs, components, accessories, equipment,
instruments, electrical and communication apparatus, and associated systems and installations should be inspected.
Such implementation includes the periods at which items as appropriate should be checked, cleaned, lubricated, replenished, adjusted and tested as well.
This course will be focused on RCM based approach, integration of Heavy Maintenance of airframe , Engines and
LRUs / components. Practical exercises on individual critical components will supplement the course.
Training Methodology
The training will be facilitated using modern techniques supported by case studies from real aviation environment. The
operator reliability program development and implementation will be discussed in detail. The Analysis tools application
to maintenance, reliability and failure analysis of aircraft, its systems, components and structures will be exercised with
mini workshop within the sessions. The audiences are requested to bring their laptops to exercise analysis softwares with
their own Aircraft / Engine data. In addition Aircraft Maintenance cost trends / breakdowns will be discussed in detail.
Key Learning Outcomes

Aircraft Basics, Design Philosophy and Applications.

Aircraft Operator reliability Program .Practical management
of Aero Engines Components
Maintenance Cost optimization for new and aged aircraft
Aircraft Risk management in relation to repair and maintenance
Warranty and Insurances related to aircraft reliability.
RCM based Reliability Strategies , Criticality Analysis
Understanding Maintenance Services agreements with
OEMs and MROs for higher reliability

Course Benefits

Who Should Attend

Airworthiness Inspectors from Civil Aviation Authorities

Airline Maintenance Management Personnel
Service or Design Engineering Personnel
Technical Support Staff
MRO Line and Base Maintenance Staff
Workshop Personnel
Maintenance Planning Personnel
Fleet Managers

Quality Assurance Personnel

Maintenance Program Engineers
Reliability Engineers
Technical Staff from Leasing Companies

Understanding the Operational and Maintenance Philosophy

of Aircraft
Reliability Improvement strategies or Aircraft systems , Components, Engines
RCM based Strategies for critical components , Failures
Analysis
FMECA for Aircraft Systems , Engines , Components &
Defining Criticality
Maintenance Cost reductions through reliability Improvement
Aircraft heavy maintenance integration with reliability Programs.
Aero Engine reliability / Design trends / Up-Gradations in
technology
ETOPs requirements thorough understanding and integration in Aircraft reliability program.

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

Aircraft Reliability Improvement and Maintenance Cost Optimization

25 - 29 January 2016, Singapore
Course Outline
Day 1

General Introduction to Reliability

What is Reliability
Asset Management Concept
Regulatory Requirements EASA , FAA
Explanation of Appendix I to AMC
Contents of the Maintenance
Types of Maintenance Strategies
Reliability Programme
Pooling Arrangements
FAA Advisory Circular AC 120-79
Purpose of the advisory circular
EASA Vs FAA Requirements, Comparisons

Day 2

Failure Considerations and Reliability Analysis

Definitions, Philosophy
Fail Safe Design Concept
System Configuration and Redundancy
Non Redundant Single Path System
Redundant Parallel System, Multiple Path System
Life Cycle Process, Classification of Failures
Probability (Qualitative and Quantitative)
Safety Objective
RCM Based Strategies , FMECA , FRCA
MSG, MSG-2 Maintenance Process and Decision Logic
MSG-3 Maintenance Tasks and Decision Logic
Failure Effect Categorization
Time-to-Failure, Failure scenarios
Unscheduled Removals
Data Collection
Prime sources of Information
Data Collection System
Information Sources and Data Collected
Process Flow Diagram
Pilot Reports and Repeaters
Delays and Cancellations
Component Removals and Failures, Cannibalization
Service Difficulty / Occurrence Report
Structural Irregularity Report
Types of Data in Aircraft Operation
Data Analysis Techniques, Six Sigma Tools
Weibull Analysis , Distribution Fitting for Datas
Reporting Schemes
Data Display and Reporting
Monthly Fleet Reliability Report
Fleet Performance Report, Statistics Summary
NFF, Statistics, Variations
Critical Failure Report ,
Technical Delays and Cancellations
Dispatch Reliability, Delays and Cancellation per 100 Departures
Engine in-flight Shutdowns and Unscheduled Removals
ETOPs requirements
Fleet Corrective Action Status
Active Risk Analysis and Matrix for Aircraft Systems, Components and Engines.

Day 3

Reliability Data Monitoring

Performance Measurement and Parameters
Alert Definitions, Status, Exceptions
Airplane Alerts ,
Structures Reliability
Upper Control Limits & Establishment
Revision of Control Limits
Examples
Maintenance Program Implementation
Source documents (AD, SBs, ARB, APD, CMR etc.)
Operators Maintenance Program, General Requirements
Scheduled Maintenance (Check Intervals, Thresholds,
Sample Checks, Permitted Variation etc.)
Task / Function Codes (ATA Spec 100)
Logistics and Man hour planning aspects (Access Panels,
Zones, Skills, Tool and Equipment, Material etc.)
Maintenance Task Packaging (Blocked Checks, Equalized
Programs, Phased Programmes)
Maintenance Task Cards , CMMS , SAP Based
Maintenance Program Implementation and Development
(Staggered Implementation Plan , Service Experience, Periodic Review, Amendments, Interval Escalations etc.)
Maintenance KPIs , Monitoring and Control
Lean Maintenance Concepts and integration with existing
programs.
Maintenance Cost
Direct and Indirect Cost Associated with Aircraft
Maintenance Cost Baselines
Industry values for A380, B777, B747, B737, A340 / 330 /
310 etc.
Maintenance Contracts Cost Aspects
Maintenance Cost Reporting, Analysis
Cost Benefit Model, Change Proposals
Cost Analysis
Repair Vs Replacement Decisions

Day 4

Practical Workshops / Case Studies

Reliability Improvement (Example)
Reliability Program Development (Complete Exercise )
Regulatory Requirements for Continued Airworthiness
Continued Airworthiness Management Organizations
Recent reliability related Aviation Incidents.

Day 5

Workshops / Case Studies

FMP , FHA , MCPH variations Discussions & Understandings

Reliability Analysis of agreements
Maintenance Planning (Case Study)
Maintenance Cost Analysis for
A380, B777, B747, B737, A340 / 330 / 310 etc.
Discussion on overhaul Scope for Engines / Components.
LTSAs for Wet lease and Dry lease with end acquisitions pitfalls
Conclusion

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

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Aircraft Reliability Improvement and

Maintenance Cost Optimization
25 - 29 January 2016, Singapore

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T.U.N INTERNATIONAL reserves the right to replace or modify the advertised speakers/topics should there be circumstances beyond the control of the organizers before the event. Any
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TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG