PREVENTIVE MAINTENANCE

SCHEDULE IN PAKISTAN INTERNATIONAL LINES

[Document subtitle] SECTION : D

BATCH : 2011-12

DATE : 2ND NOVEMBER 2015

SUBMITTED TO : SYED MUNAWER HASAN

GROUP MEMBERS

S.NO NAME ROLL NO.

1 MUHAMMAD ADNAN ME-009

2 SYED MOIZ ME-012

3 KASHAN AKRAM SHEIKH ME-020

4 MUHAMMAD ZAIN ME-038

5 ASAD AKTHER NAQVI ME-048

6 OVAIS MAHFOOZ ME-082

7 ASAD SIDDIQUI ME-090

8 BILAWAL MAHER ME-092

9 USMAN ARSHAD ME-093

10 MUNEER ALI ME-096

11 MUHAMMAD ARIF ME-149

12 AHMED NAWAZ ME-156

ABOUT PIA In 1946, Quaid-e-Azam Muhammed Ali Jinnah realized the need for a flag carrier for the prospective country and requested financial help from a wealthy businessman Mirza Ahmad Ispahani and Adamjee Haji Dawood for this purpose. Around that time, a new airline 'Orient Airways’ was registered in Calcutta on 23 October 1946. On 7 June 1954, Orient Airways started its operations. On 11 March 1955, Orient Airways merged with the government's proposed airline, becoming Pakistan International Airlines Corporation.

FLEETS PIA's fleets of modern aircraft are spacious, comfortable, and designed to get you to your destination safely.

Boeing 777

The Boeing 777 family comprises of long-range, wide-body twin-engine airplanes. PIA was the first airline in the world to operate all the three variants of the 777 family: 777-200LR, 777-200ER and 777-300ER, all of them are well loved by PIA's seasoned travelers for their spaciousness and comfort. PIA also holds the privilege of being the launch customer for 777-200LR, one of PIA’s aircraft which holds the record for the longest commercial jet flight in aviation history.

Boeing 747

The Boeing 747, often referred to as “Jumbo Jet”, is amongst the world's most iconic and recognizable jet airplanes. This 4 engine long haul wide-body airplane has a two-deck configuration. PIA operates one variant of 747 family i.e. 747-300. At present due to its

capacity, 747-300 fleet is mostly deployed to cater high density requirements like carrying intending pilgrims to and from Saudi Arabia.

Airbus A310

The Airbus A310 is a medium to long range wide-body airplane providing a spacious interior to its travelers. PIA has deployed the A310-300 fleet on Far East, Regional as well as Domestic routes.

Airbus A320

The Airbus A320 is one of the world's favorite narrow-body short/medium haul jet airplane. By virtue of right-sized fuselage, it enhances comfort for passengers and at the same time enjoys the reputation of fuel-efficient aircraft. A320 aircraft mostly serve its domestic and regional routes.

ATR42

This modern technology turbo prop is the latest type inducted in PIA’s fleet. PIA’s fleet of ATR42-500 and ATR72-500 aircraft is configured in comfortable two class seating arrangement. This aircraft has enabled the airline to provide its valued customers the most convenient way to fly to far flung and remote destinations of the country which are sparsely served by other means of transport.

MAJOR COMPONENTS OF PLANE An airplane is a semi-cop structure that is aerofoil shaped so as to assist lifting.

MANUFACTURERS:

Plane:

Boeing (American company)

Airbus (conglomerate of Germany, France etc)

Engine: Three engine manufacturers with whom PIA deals are:

General Electric

Pratt and Whitney

Rolls Royce

MAIN PLANE PARTS

Control surfaces: Moveable surfaces on an airplane’s wings and tail allow a pilot to maneuver an airplane and control its attitude or orientation. In light of the adoption of nautical terms, the motion about the airplane’s longitudinal axis is called “roll”; motion about its lateral axis is referred to as “pitch.” Finally, an airplane moves about its vertical axis in a motion, which is termed “yaw”—that is, a horizontal (left and right) movement of the airplane’s nose. The three motions of the airplane (roll, pitch, and yaw) are controlled by three control surfaces. Roll is controlled by the ailerons; pitch is controlled by the elevators; yaw is controlled by the rudder.

The three motions of the airplane (roll, pitch, and yaw) are controlled by three control surfaces. Roll is controlled by the ailerons; pitch is controlled by the elevators; yaw is controlled by the rudder. There are three major control surfaces:

Ailerons

Ailerons control roll about the longitudinal axis. The ailerons are attached to the outboard trailing edge of each wing and move in the opposite direction from each other

Moving the control wheel to the right causes the right aileron to deflect upward and the left aileron to deflect downward.

Rudder

The rudder controls movement of the airplane about its vertical axis. This motion is called yaw. Like the other primary control surfaces, the rudder is a movable surface hinged to a fixed surface, in this case, to the vertical stabilizer, or fin. Moving the left or right rudder pedal controls the rudder.

When the rudder is deflected into the airflow, a horizontal force is exerted in the

opposite direction.

By pushing the left pedal, the rudder moves left. This alters the airflow around the

vertical stabilizer/rudder, and creates a sideward lift that moves the tail to the right and

yaws the nose of the airplane to the left.

Elevator

The elevator controls pitch about the lateral axis. Like the ailerons on small airplanes, the elevator is connected to the control column in the cockpit by a series of mechanical linkages. Aft movement of the control column deflects the trailing edge of the elevator surface up. This is usually referred to as up elevator.

Engines: There are two types of engine in an aircraft:

Main engine The main engine provides the main thrust power for the aircraft and is also used to get bleed air. A turbofan engine is much the same as a turbojet, but with an enlarged fan at the front that provides thrust in much the same way as a ducted propeller, resulting in improved fuel-efficiency.

Auxiliary Power Unit (APU) The APU is used for electrical power and to start the main engine. It provides power (electric, pneumatic, or hydraulic, depending on the design) to start the aircraft's main engines. This allows the cabin to be comfortable while the passengers are boarding before the aircraft's engines are started. Electrical power is used to run systems for preflight checks. This function can also be used, on some aircraft, as a backup in flight in case of engine or hydraulic failure.

BRAKING SYSTEM: The braking system of a plane is made up of three major parts:

The spoilers: are present on the wings and are lifted up to provide air-drag.

The turbine thrust reversal: is used to reverse the high velocity exhaust gases to provide braking.

The brakes of landing gear: are disc brakes and are used to stop the landing gear.

LIFT AUGMENTATION DEVICES:

Slats and flaps These are used during takeoff to assist lifting by increasing the area of the aero foil

shape. CGC= Center Gravity Control: is used to move fuel and maintain the C.G point

MOTIONS OF PLANE: There are three motions of a plane: Apart from Yawing, Pitching, Rolling some other motions related to aircraft are:

Mooring : is the fixing of a plane in case of storms

Towing: is the puling of plane when engine power is killed

Taxing: is the movement of plane on land using engine power

Shoring : is supporting the plane on jacks Yawing and rolling is done together to decrease the radius of rotation

LOADS ON AN AIRCRAFT: There are the following main loads on an aircraft:

Pressurization loads

Aerial loads

Bending loads

Tensile loads

Compressive loads

AIRCRAFT MAINTENANCE PROPER AIRCRAFT MAINTENANCE IS ESSENTIAL FOR KEEPING AIRCRAFT AND AIRCRAFT PARTS IN OPTIMAL CONDITION, AND ENSURING THE SAFETY OF PILOTS, CREW, AND PASSENGERS.

Maintenance is required for three principal reasons: Operational: To keep the aircraft in a serviceable and reliable condition so as to

generate revenue.

Value Retention: To maintain the current and future value of the aircraft by minimizing

the physical deterioration of the aircraft throughout its life.

Regulatory Requirements: The condition and the maintenance of aircraft are regulated

by the aviation authorities of the jurisdiction in which the aircraft is registered. Such

requirements establish standards for repair, periodic overhauls, and alteration by

requiring that the owner or operator establish an airworthiness maintenance and

inspection program to be carried out by certified individuals qualified to issue an

airworthiness certificate.

Repair stations and maintenance technicians perform maintenance and inspections on aircraft. The Federal Aviation Administration is responsible for certifying the repair stations and aircraft maintenance technicians (AMTs).

Repair stations are certified under FAR Part 145. AMTs are certified under FAR Part 65.FAR Part 43 details the standards regarding the maintenance, preventative maintenance, and alterations of aircraft and aircraft articles and systems.

ROUTINE MAINTENANCE TASKS

Maintenance of aircraft is a comprehensive, ongoing process. The entire aircraft needs to be examined, maintained, and have the necessary parts replaced to uphold the safety standards.

Aircraft are required to be maintained after a certain period of calendar time or flight hours or flight cycles. Also, some aircraft articles have a specific life (flight cycle) limit, and need to be replaced immediately upon reaching the maximum use requirements.

Besides the aircraft articles that are due for replacement, all other parts need to be checked for faults or faulty performance. Because of the noise of testing different systems, working long hours, and the expectations of maintaining high safety standards, being an AMT can be a stressful job.

Here are just some of the routine maintenance tasks performed by an AMT’s in Pakistan international Airlines:

cleaning aircraft and components

application of corrosion prevention compound

lubricating parts

draining and troubleshooting fuel systems

checking and servicing hydraulic and pneumatic systems

replacing components

inspecting for general wear and tear

A newer field of aircraft maintenance is working in avionics, which deals with electronic systems. These parts are vital for navigation and communications, and include radar, instruments, computer systems, radio communications, and global positions systems (GPS).

A strong knowledge of wiring and technical skills is required for working in avionics maintenance.

PREVENTIVE MAINTENANCE SCHEDULE PIA clientele comprises of large numbers of international operators and its experience of over

50 years enables to find the right solutions for all operational and maintenance needs. PIA’s

highly qualified engineering personnel offer comprehensive engineering services, backed up by

excellent equipment and systems. They have sufficient aircraft support dock installations in the

hangars, as well as trained manpower and tooling, to undertake simultaneous work on various

types of aircraft in pia fleet, around the clock.

Preventive maintenance for the air crafts are carried out in different intervals, which are specially needed to be carried out for larger aircrafts. All aircraft have periodic inspections, aircraft have to go through an extensive inspection process, also referred to as “checks.” There are several checks that need to be done according to calendar dates, flight hours, or flight cycles. A flight cycle is one flight, with a take-off and landing.AMTs maintain specific areas of aircraft depending on their certification and rating. The different aircraft ratings are airframe (the aircraft body, such as the tail, fuselage, wings, and landing gear), power plant (engines and propellers), and avionics (electrical systems and instruments).Most AMTs hold a dual airframe and power plant FAA certification, and are referred to as A&P mechanics.

PIA is performing preventive maintenance program on regular and satisfactorily basis. PIA is fulfilling the 10 elements required of an air carrier maintenance program. These 10 elements are:

Airworthiness responsibility

Air carrier maintenance manual

Air carrier maintenance organization

Accomplishment and approval of maintenance and alterations

Maintenance schedule

Required Inspection Items

Maintenance recordkeeping system

Contract maintenance

Personnel training

Continuing Analysis and Surveillance System (CASS)

In PIA we found out that maintenance department categorized the intervals with letters from A to D. A-check is a light routine inspection. On the opposite end of the spectrum, a D-check is the most intensive, long-term check.

A-checks are performed at around 500 flight hours (FH). This is a routine check, to make sure everything is functioning safely and efficiently. It can usually be completed overnight at an airport gate, and can even be delayed if an aircraft meets certain predetermined conditions.

B-checks are more extensive than a checks, but can also be completed overnight.

C-checks require aircraft to be docked at a hangar or repair station for detailed inspections. These are generally performed every 12-18 months, depending on the type of aircraft and the manufacturer’s specifications.

D-checks are done approximately every 4-5 years, and are the most intensive, time-consuming aircraft inspection. The aircraft needs to have every fastener, nut, wire, hinge, and component inspected, repaired, maintained, or replaced.

B777-200/ 300

Service Inspection time

Line Checks Transit (Outstation & Base)

Service Check 1 After 250 flight hours Service Check2 After 500 flight hours

Routine checks

A 75days/1000FH

C 750 days

Major Checks

Mid-D -

D 3000 Days

C of MR issuance As per PCAA ANO 0001 Requirement

B747-300

Service Inspection time

Line Checks Transit (Outstation & Base)

Daily Check 36elphrs Weekly Check Not exceeding 8 elp days

Routine checks

A Not exceeding 600 flight hours

C 6000 flight hours/18 months

Major Checks

Mid-D -

D 6 Years

C of MR issuance As per PCAA ANO 0001 Requirement

B747-200

Service Inspection time

Line Checks Transit (Outstation & Base)

Daily Check 36elphrs Weekly Check Not exceeding 8 elp days

Routine checks

A Not exceeding 600flight hours

C 6000 flight hours/18 months

Major Checks

Mid-D -

D 6 Years

C of MR issuance As per PCAA ANO 0001 Requirement

A310-300

Service Inspection time

Line Checks Transit (Outstation & Base)

Daily Check 36elphrs Weekly Check 8 calendar days

Routine checks

A 500flight hours /04 months

C 6000 flight hours/24 months

Major Checks

Mid-D 6 Yearly

D 12 Years

C of MR issuance As per PCAA ANO 0001 Requirement

B737-300

Service Inspection time

Line Checks Transit (Outstation & Base) ( Preflight elapsed 12 hrs at Base)

Turnaround (First flight from KHI, LHR, ISB, PEW)

Routine checks

A 250flight hours

C 4000 flight hours/15 months

Major Checks

Mid-D -

D 24000 flight hours

C of MR issuance As per PCAA ANO 0001 Requirement

INSPECTIONS

Ageing Aircraft Corrosion Prevention and Control Program (CPCP)

Supplemental Structural Inspection (SSI)

STRUCTURE REPAIR SHOP: In structure repair shop certain components like nose cowl, nose etc. are repaired. First the damaged area is removed than a piece of part confirming the shape of the damaged area is machined and attached with blind rivets. A similar piece of plate is than cut and machined and is riveted by blind rivets on to the part. Everything is done as per manual instruction. Aluminum for most of the skin actually is ALCLAD used, which is a special type of aluminum alloy. Most of rivets and structure is made of DURAL, which is other aluminum based alloy, and parts subject to higher stress are made of steel, Nimonic and titanium like engines parts. Many aircraft have also parts made of composite materials (commonly named as plastic) used as streamliners.

TOOL STORE:

The aviation maintenance technician (AMT) spends a major portion of each day using a wide variety of hand tools to accomplish maintenance tasks. PIA tool store contains following tools:

Spanner

Wrench

Jigs

Fixture

Ratchet

Speed Handle

Socket

Feeler gage

Micrometer Screw gage

Vernier Caliper

Screw driver

Hammers

REPAIR STRUCTURE IN PIA

The FAA classifies repairs into two categories. Major and minor. Following is the FAA’s definition of both:

Major repair means a repair:

That, if improperly done, might appreciably affect weight, balance, structural strength, performance, power plant operation, flight characteristics, or other qualities affecting airworthiness; or

That is not done according to accepted practices or cannot be done by elementary operations.

Minor repair means a repair other than a major repair.

Aircraft Structural Repairs

Structural repairs are made to aircraft that have sustained damage to the structure. There are several ways an aircraft structure can be damaged. It is usually caused by ground service equipment, maintenance stands, bird strikes, or lightning strikes.

Component repairs

Component repairs range from simple part replacements to an entire overhaul. If a component fails to operate properly, it is removed from the aircraft and replaced by one the does operate properly. The component is disassembled, cleaned inspected, repaired, reassembled, tested, and returned to service.

Systems Repairs

Some repairs to aircraft systems (i.e., hydraulic, pneumatic, fuel, etc.) simply consist of replacing a part or component. The faulty part is removed and replaced with a new part.

Engine Repairs

Some limited repairs can be done while the engine is on the aircraft. Those repairs usually consist of parts replacements.

Avionics Repairs

Avionics repairs are treated a bit differently than other components because of their delicate circuit boards and small fragile electrical or electronic parts.

General Flow Chart of How the Repairs & Alteration decisions are made

SAFETY AND MAINTENANCE

The primary goal of the aviation industry is to maintain airplane and helicopter safety

standards and protect the interests of the mechanics, flight crew, and passengers.

Problems with the aircraft or aircraft components can also lead to safety risks. These problems include electrical, mechanical or hydraulic component failures. They also include metal fatigue that result in cracks, or materials that become delaminated or corroded. These risks are minimized by the continuous inspections performed on the aircraft and all aircraft articles.

What happens when maintenance is conducted improperly………….

These problems include electrical, mechanical or hydraulic component failures. They also include metal fatigue that result in cracks, or materials that become delaminated or corroded.

These risks are minimized by the continuous inspections performed on the aircraft and all aircraft articles.

Sadly, the circumstances of each new accident are often remarkably similar to those of previous accidents. What it means that the concerned authorities are not taking advantage of the lessons learned from previous such tragedies that could help them avoid making same mistakes.

What is needed to be done…………

Continuous maintenance re-training;

Create mechanisms for reporting, investigate reports, and provide legal protections to the people who informed them

Human factors training for management and technicians/engineers.

From organizational point of view

Training and selection of appropriate personnel.

Quality of resources as distributed.

Organizational Structure.

Opportunities for career development.

From individual point of view

Knowledge and skill of personnel.

Quality of resources on hangar floor.

Work environment.

Morale & personalities of employee.

Name Muhammad Zain

Roll No ME-038

Sec D

Conclusion Here, I would like to appreciate the efforts made by my group members and especially towards

staff of PIA to help us study and analyze their maintenance schedule in a very short interval of

time.

Preventive Maintenance Our core objective of this visit lies with preventive maintenance. The term “preventive

maintenance” commonly refers to the practice of regularly servicing equipment on a pre-

determined schedule so that it does not develop catastrophic failures.

“Nothing lasts forever”, so the saying goes, but with some care and regular servicing and

maintenance, products can provide normal anticipated operation. What I believe from the

course of plant maintenance throughout this semester and from practical exposure, preventive

maintenance

Extends the useful lifecycle of assets decreasing the need for capital replacements.

Enhances the efficiency of equipment keeping them running more efficiently and

lowering power expenses.

Enhances the performance of assets by increasing uptime.

Enhances customer (internal or external) service because maintenance teams have

less unplanned maintenance and can respond quicker to new problems.

Contributes positively to the reputation of companies

Maintenance at PIA Now towards the maintenance program at PIA, here it means the preservation, inspection,

overhaul, and repair of aircraft, including the replacement of parts. The purpose of

maintenance is to ensure that the aircraft remains airworthy throughout its operational life.

Although maintenance requirements vary for different types of aircraft, from our study we got

that some aircraft need maintenance every 25 hours or less of flying time, and minor

maintenance at least every 100 hours while others are scheduled to be checked over years.

PIA is performing maintenance program on regular and satisfactorily basis. PIA is fulfilling the

required specifications of an air carrier maintenance program.

Keeping in mind the responsibility, keeping maintenance manual up to date, technically stable

Schedule, Necessary tools and equipment Record keeping and database system are the major

aspects and for these an effective maintenance organization is primary objective.

Repairs and alterations are carried out side by side with maintenance, conducted in tool shops

or in hanger based on type of operation needed. The procedure includes

Testing

Replacing with appropriate part

Detections

Alterations

Back into operation

My recommendations

Over 80% (plus) of our accidents are due to Human Error. To understand the human

contribution to major accidents and disasters, organizational and management factors have to

be taken into account.

What management should do at PIA? Introduce policy provided its development and implementation.

Organization with effective communications, the promotion of competence at all levels

the

Planning to minimize risks by setting bench marks.

Auditing and performance review from lowest to higher grade

What can maintenance technicians do? For aviation professionals, proper training and safety awareness is imperative for flying and

maintaining aircraft.

Learning about and adhering to sound risk management practices can help prevent

common errors that can lead to tragic consequences.

Understand the safety hazards associated with human fatigue and strive to eliminate

fatigue contributors in your life.

Pay particular attention to the safety and security of the items that undergo

maintenance and any surrounding components that may have been disconnected or

loosened (possibly to ease access) during that maintenance.

Carefully follow manufacturers’ instructions to ensure that the work is completed as

Be thorough when performing routine inspections. Ensure that items needing

immediate attention are addressed rather than deferred.

Name Syed Moiz

Roll No ME-012

Sec D

Conclusion It is responsibility and duty of an airline to perform preventive maintenance for airplanes not

only to bring reliability but also to secure hundreds of passengers’ precious lives. Using statistics

of death and injuries as compared to road and sea, air travel is considered the safest way to

travel and to keep its reliability an airline has to perform strict preventive maintenance.

Furthermore, country aviation authority has to keep check and balance.

Preventive maintenance is considered to be simple or minor preservation operations and the

replacement of small standard parts, not involving complex assembly operations. It is the

activity performed in some routine or regularly scheduled fashion designed to keep equipment

in an existing state, prevent deterioration or failure, and identify work of a corrective nature to

keep equipment from causing non-productive time in any capacity.

PIA is performing preventive maintenance program on regular and satisfactorily basis. PIA is

fulfilling the 10 elements required of an air carrier maintenance program. These 10 elements

are:

1. Airworthiness responsibility

2. Air carrier maintenance manual

3. Air carrier maintenance organization

4. Accomplishment and approval of maintenance and alterations

5. Maintenance schedule

6. Required Inspection Items

7. Maintenance recordkeeping system

8. Contract maintenance

9. Personnel training

PIA preventive maintenance program comprises on a large basis.

After completion of flight hours, removal, installation, and repair of landing gear tires and shock cords; servicing landing gear shock struts by adding oil, air, or both; servicing gear wheel bearings; replacing defective safety wiring or cotter keys; lubrication not requiring disassembly other than removal of nonstructural items such as cover plates, cowlings, and

fairings; making simple fabric patches not requiring rib stitching or the removal of structural parts or control surfaces.

Replenishing hydraulic fluid in the hydraulic reservoir; refinishing decorative coating of fuselage, balloon baskets, wings, tail group surfaces (excluding balanced control surfaces), fairings, cowlings, landing gear, cabin, or flight deck interior when removal or disassembly of any primary structure or operating system is not required; applying preservative or protective material to components where no disassembly of any primary structure or operating system is involved and where such coating is not prohibited or is not contrary to good practices; repairing upholstery and decorative furnishings of the cabin, flight deck, or balloon basket interior when the repair does not require disassembly of any primary structure or operating system or interfere with an operating system or affect the primary structure of the aircraft; making small, simple repairs to fairings, nonstructural cover plates, cowlings, and small patches and reinforcements not changing the contour to interfere with proper air flow; replacing side windows where that work does not interfere with the structure or any operating system such as controls, electrical equipment, etc. Replacing safety belts, seats or seat parts with replacement parts approved for the aircraft, not involving disassembly of any primary structure or operating system, bulbs, reflectors, and lenses of position and landing lights. Replacing wheels and skis where no weight-and-balance computation is involved; replacing any cowling not requiring removal of the propeller or disconnection of flight controls; replacing or cleaning spark plugs and setting of spark plug gap clearance; replacing any hose connection, except hydraulic connections; however, prefabricated fuel lines may be replaced. The interchange of balloon baskets and burners on envelopes when the basket or burner is designated as interchangeable in the balloon type certificate data and the baskets and burners are specifically designed for quick removal and installation; adjustment of nonstructural standard fasteners incidental to operations. Inspection and maintenance tasks prescribed and specifically identified as preventive maintenance in a primary category aircraft type certificate or supplemental type certificate holders approved special inspection and preventive maintenance program when accomplished on a primary category aircraft.

Name Syed Mohammad Asad akhter

Roll No ME-048

Sec D

Conclusion We are very thankful to Pakistan International Airlines that they provided us with necessary requirements and data to achieve our target.

Preventive Maintenance

Preventive maintenance is planned maintenance of plant and equipment that is designed to improve equipment life and avoid any unplanned maintenance activity. PM includes painting, lubrication, cleaning, adjusting, and minor component replacement to extend the life of equipment and facilities. Its purpose is to minimize breakdowns and excessive depreciation. Neither equipment nor facilities should be allowed to go to the breaking point. In its simplest form, preventive maintenance can be compared to the service schedule for an automobile.

Five Important Reasons Preventative Maintenance Makes Perfect Sense

Preventative Maintenance, these two words alone imply the benefit of this practice, but many in the industrial industry abide by the “if it isn’t broke, don’t fix it” rule. Below are five important reasons that Preventative Maintenance makes sense.

Plant Safety- In order to avoid injuries to your equipment operators, it is important that the

equipment used is maintained at the highest standards. Regularly scheduled preventative

maintenance can confirm that the machine is working properly and avoid emergency situations

and outages.

Efficiency- Preventative maintenance assures the efficiency and speed of your equipment. Over

time normal wear and tear can result in diminishing efficiency.

Immediate Savings- For many reasons, money can be saved when conducting preventative vs.

emergency maintenance. One, preventative maintenance costs less to facilitate than a large

repair or replacement.

Long-term Savings-During an emergency shutdown situation, the immediacy required can cause

both parts and labor to be priced at a premium, if they are available at all.

Time Savings- Preventative maintenance procedures, for the most part, take less time to

complete than emergency repairs and replacements. Also, because you can plan for equipment

outages during maintenance, you can avoid an outage when you need the machine the most.

Maintenance at PIA

Maintenance in Airline is industry is very important as it is directly related to the passenger’s

life. There are some standards of Civil Aviation Authority Pakistan that must be followed by

Pakistan International Airlines in order to keep them in service. Pakistan International Airlines

have their own preventive maintenance schedule according to which they perform

maintenance of their aircrafts.

The maintenance of aircrafts due after some flying hours. PIA preventive maintenance program

comprises on a large basis. After completion of flight hours, removal, installation, and repair of

landing gear tires and shock cords; servicing landing gear shock struts by adding oil, air, or

both; servicing gear wheel bearings; replacing defective safety wiring or cotter keys;

lubrication not requiring disassembly other than removal of nonstructural items such as cover

plates, cowlings, and airings; making simple fabric patches not requiring rib stitching or

the removal of structural parts or control surfaces.

There are four checks of each air crafts namely: A, B, C and D. A and B perform on a short

interval of time and are different for different aircrafts. C and D are known as major checks of

an aircrafts and depends on the flying cycles whereas A and B depends on the number of days

in operations. If D check is applied twice on any aircraft it means that now aircraft should be

scrap.

Steps for the betterments in Maintenance related issues

They should improve their skills in order to wind up their work with in time.

They should provide proper uniform to the workers as they work without the care of

their dresses.

In case of inconvenience in terms of new issues, appropriate authorities should be

approached.

Name Kashan Akram

Roll No ME-020

Sec D

Conclusion We visited Pakistan International Airlines (PIA) for the purpose of studying preventive

maintenance schedule as asked in the assignment. Throughout the course we came forward

different strategies that are applied in industries for the maintenance of their equipment. Here

in Aviation we usually carry out preventive maintenance which is scheduled to be carried out

either after every flight or after some particular intervals of time.

Types of Maintenance

Breakdown Maintenance: Waiting until equipment fails before repairing or servicing it

Preventive Maintenance (PM): (Time-based or run-based) Periodically inspecting, servicing, Cleaning, or replacing parts to

prevent sudden failure. On-line monitoring of equipment in order to use important/expensive

parts to the limit of their serviceable life

Corrective or Predictive Maintenance: Improving equipment and its components so that preventive maintenance can be carried out

reliably

Benefits of Preventive Maintenance

“…the cost of breakdown maintenance is usually much greater than preventive

maintenance.”

Keeps equipment in good condition to prevent large problems

Extends the useful life of equipment

Finds small problems before they become big ones

Is an excellent training tool for technicians?

Helps eliminate rework/scrap and reduces process variability

Keeps equipment safer

Parts stocking levels can be optimized

Greatly reduces unplanned downtime

Base Maintenance

PIA clientele comprises of large numbers of international operators and its experience of over 50 years enables to find the right solutions for all operational and maintenance needs. PIA’s highly qualified engineering personnel offer comprehensive engineering services, backed up by excellent equipment and systems. They have sufficient aircraft support dock installations in the hangars, as well as trained manpower and tooling, to undertake simultaneous work on various types of aircraft in PIA fleet, around the clock. Inspection and maintenance tasks prescribed and specifically identified as preventive maintenance in a primary category aircraft type certificate or supplemental type certificate holders approved special inspection and preventive maintenance program when accomplished on a primary category aircraft. In PIA the maintenance department has categorized the checking intervals with letters from A to D. A-check being a light routine inspection and a D-check being the most intensive long-term check.

A-checks are performed at 500 flight hours (FH). This is a routine check, to make sure everything is functioning safely and efficiently.

B-checks are more extensive than A-checks and can also be completed overnight.

C-checks require aircraft to be docked at hanger or repair station for detailed inspections. These are generally performed every 12-18 months.

D-checks are done approximately every 4-5 years, and are the most intensive, time-consuming aircraft inspection.

Suggestions for betterment

There should be proper arrangements for visitors.

Those who visits engineering stations must be provided with necessary PPE’s.

Hierarchy of management should be followed

Employees should be encourage to compete at all levels

There should be a proper costume for engineers as well as for technicians without which

they should be banned to enter in the engineering workplace.

Name Muneer Ali

Roll No ME-096

Sec D

Conclusion

Maintenance is inspection, overhaul, repair, preservation and replacement of parts.

Preventive maintenance can be defined as those actions performed to detect the

degradation of the components. It involves routine scheduled activities intended to keep a

system performing at its best and has the goals of preventing the system’s breakdown and

extending its useful life.

Preventive maintenance has several advantages. By performing preventive maintenance the

full design life of the components may be realized.

Preventive maintenance (e.g., lubrication, filter changes, sealing pavement joints) will generally

help equipment run more efficiently. This results in reduced costs and improved user

satisfaction. Airlines can plan and assign staff appropriately by applying scheduled preventive

maintenance.

Importance of Preventive Maintenance

Safety Airlines maintenance directly contributes to keeping airports and their facilities safe for

users. Preventive maintenance helps ensure that those systems used by pilots are functioning

properly. Similarly, well-maintained fueling facilities and airport vehicles help improve safety

for their users.

Economics Preventive maintenance extends the life of facilities and avoids costly and early

replacement or rehabilitation. An aircraft or personal accident related to poor airport

maintenance is not only tragic but can be costly to the airlines owner. Increased energy usage

caused by poorly maintained electrical systems is also costly.

Reduction in Energy Usage Poorly maintained electrical and mechanical systems lead to

increased use of energy. Airfield lighting systems with aging cable and loss of energy drive

electrical bills up. This can be managed through an effective preventive maintenance program.

Similarly, poorly maintained HVAC units or weatherproofing in a general aviation terminal

building will increase energy costs.

System Longevity The life of many airport infrastructure systems can be extended with proper

preventive maintenance. Examples of PM are crack sealing, servicing HVAC equipment, regular

oil changes for airlines vehicles, checking and replacing airfield lighting, greasing door

components, and keeping drainage free so can drain properly.

Environmental Impacts Some airlines infrastructure can adversely affect the environment if not

well-maintained. Examples include drainage systems that start backing up and allow poor

quality runoff to environmentally sensitive areas. Fuel leakage from poorly maintained fueling

facilities will harm the environment.

In PIA the steps taken for preventive maintenance program are as follows, Replacing hose connection except hydraulic connections removing, checking, and

replacing magnetic chip detectors and replacing any cowling.

Removal of the prop is required to get the nose bowl off.

Replacing prefabricated fuel lines cleaning or replacing fuel and oil strainer or filters

replacing or cleaning spark plugs and setting gap.

Landing gear tires, servicing struts wheel bearings safety wire or cotter keys lubrication,

not requiring disassembly.

Replenishing hydraulic fluid Replacing side windows. Repairing upholstery replacing

safety belts replacing seats or seat parts.

Replacing & servicing batteries.

Trouble shooting and repairing broken circuits in landing light wiring.

Replacing bulbs, reflectors, & lenses or position or landing lights.

Simple fabric patches refinishing decorative coatings applying preservative or protective

materials.

Making simple repairs to fairings, nonstructural items.

Replacement or adjustment of nonstructural fasteners etc.

Tools and Equipment Hand tools, Mowers, Weed trimmers, Snow removal equipment, Maintenance vehicles,

Maintenance equipment storage, and Personal safety equipment for maintenance personnel.

Suggested steps that PIA should adopt for developing or improving an airline’s preventive

maintenance program are:

1. Understand and embrace important guiding principles.

2. Establish a baseline of information about the airline’s infrastructure and condition.

3. Identify the preventive maintenance needed for each system.

4. Prioritize maintenance based on airfield safety, economics, operations, contractual

requirements, and extension of the life of each facility.

5. Obtain resources (funding, staffing, equipment/tools, and outside contracts). Ensure that

staff is properly trained.

Name Ovais mahfooz

Roll No ME-082

Sec D

CONCLUSION Following are the things, with that, I would like to conclude my visit knowledge.

History In 1946, Quaid-e-Azam Muhammed Ali Jinnah realized the need for a flag carrier for the

prospective country and requested financial help from a wealthy businessman Mirza Ahmad

Ispahani and Adamjee Haji Dawood for this purpose. Around that time, a new airline 'Orient

Airways’ was registered in Calcutta on 23 October 1946.

On 7 June 1954, Orient Airways started its operations. On 11 March 1955, Orient Airways

merged with the government's proposed airline, becoming Pakistan International Airlines

Corporation.

Fleet PIA's fleets of modern aircraft are spacious, comfortable, and designed to get you to your

destination safely. PIA operates a range of advanced aircraft, ranging from the world's

preferred Boeing 777 airplane to the super-quiet Airbus A-310. A brief introduction of PIA fleet

is given below:

1. Boeing 777 The Boeing 777 family comprises of long-range, wide-body twin-engine airplanes. PIA was the

first airline in the world to operate all the three variants of the 777 family: 777-200LR, 777-

200ER and 777-300ER, all of them are well loved by PIA's seasoned travelers for their

spaciousness and comfort. PIA also holds the privilege of being the launch customer for 777-

200LR, one of PIA’s aircraft holds the record for the longest commercial jet flight in aviation

history. At present PIA is serving destinations in USA, Canada, UK and Europe through its 777

fleet.

2. Boeing 747 The Boeing 747, often referred to as “Jumbo Jet”, is amongst the world's most iconic and

recognizable jet airplanes. This 4 engine long haul wide-body airplane has a two-deck

configuration. PIA operates two variants of 747 family which includes 747-300 and 747-200

Combi. 747 Combi is so called as it has mixed pax and cargo configuration on the main deck. At

present due to its capacity, 747-300 fleet is mostly deployed to cater high density requirements

like carrying intending pilgrims to and from Saudi Arabia.

3. Airbus A310 The Airbus A310 is a medium to long range wide-body airplane providing a spacious interior to

its travelers. PIA has deployed the A310-300 fleet on Far East, Regional as well as Domestic

routes.

4. Boeing 737 The Boeing 737 is one of the world's favorite narrow-body short/medium haul jet airplane.

Amongst its many credits, it has the distinction of being the most ordered and produced com

Base Maintenance

PIA clientele comprises of large numbers of international operators and its experience of over

50 years enables to find the right solutions for all operational and maintenance needs. PIA’s

highly qualified engineering personnel offer comprehensive engineering services, backed up by

excellent equipment and systems. They have sufficient aircraft support dock installations in the

hangars, as well as trained manpower and tooling, to undertake simultaneous work on various

types of aircraft in PIA fleet, around the clock.

Name Asad Siddiqui

Roll No ME-082

Sec D

Why Preventive Maintenance? Preventive maintenance is predetermined work performed to a schedule with the aim of preventing the wear and tear or sudden failure of equipment components. Preventive maintenance helps to:

Protect assets and prolong the useful life of production equipment Improve system reliability Decrease cost of replacement Decreases system downtime Reduce injury

Mechanical, process or control equipment failure can have adverse results in both human and economic terms. In addition to down time and the costs involved to repair and/or replace equipment parts or components, there is the risk of injury to operators, and of acute exposures to chemical and/ or physical agents. Preventive maintenance, therefore, is a very important ongoing accident prevention activity, which you should integrate into your operations/ product manufacturing process.

What is involved? To be effective, your preventive maintenance function should incorporate the following elements: Planned replacements of components designed around the following:

Reliability of components (equipment failure is usually caused by its least reliable component

Maintaining equipment service records Scheduling replacement of components at the end of their useful service life Acquiring and maintaining inventories of:

least reliable components critical components components scheduled for replacements

Replacing service-prone equipment with more reliable performers By introducing the element of planning into your maintenance function, you are likely to reduce your repair and manpower requirements.

Exploratory maintenance to anticipate and prevent breakdowns. Diagnostic measures to analyze your plant requirements include:

- Operating and performing specifications of equipment - Past experience with components: - Inspection records - servicing records - Replacement frequency - inspected component failures

Regularly scheduled lubrication program:

identify lubrication points on equipment

color code in order to identify lubrication frequency

consult manufacturer and accepted industry best practices to establish schedule

check manufacturer’s information

Check accepted industry best practice

Identifying Maintenance Hazards The hazards associated with maintenance activities can be classified as follows: Safety Hazards Mechanical Electrical Many of these hazards are interrelated. Examine your process, the layout of your process area, and the process equipment used, to determine the exact nature of the hazards likely to be encountered during your maintenance activities. For example, maintenance work carried out in confined spaces carries a greater risk of critical injuries and acute exposures to chemical and physical agents. These risks are associated with equipment and materials in the space itself and from nearby operations. Fatalities are quite common.

Controlling Maintenance Hazards Ideally, the hazards likely to occur during maintenance activities should be addressed in the planning stage. Health Hazards Chemical Agents Physical Agents

Name Muhammad Adnan

Roll No ME-009

Sec D

Conclusion Our sole objective was to study preventive maintenance.

Preventative maintenance is maintenance that is regularly performed on a piece of equipment to lessen the likelihood of it failing. Preventative maintenance is performed while the equipment is still working, so that it does not break down unexpectedly. Preventative maintenance is planned so that any required resources are available.

The maintenance is scheduled based on a time or usage trigger. A typical example of an asset with a time based preventative maintenance schedule is an air-conditioner which is serviced every year, before summer. A typical example of an asset with a usage based preventative maintenance schedule is a motor-vehicle which might be scheduled for service every 10,000km. Preventative maintenance is more complex to coordinate than run-to-failure maintenance because the maintenance schedule must be planned. Preventative maintenance is less complex to coordinate than predictive maintenance because monitoring strategies do not have to be planned nor the results interpreted.

Advantages Planning is the biggest advantage of preventative maintenance over less complex

strategies. Unplanned, reactive maintenance has many overhead costs that can be avoided during the planning process.

Preventative maintenance does not require condition-based monitoring. This eliminates the need (and cost) to conduct and interpret condition monitoring data and act on the results of that interpretation. It also eliminates the need to own and use condition monitoring equipment.

Disadvantages Unlike reactive maintenance, preventative maintenance requires maintenance planning.

This requires an investment in time and resources that is not required with less complex maintenance strategies.

The frequency of preventative maintenance is most likely to be too high. This frequency can be lowered, without sacrificing reliability when condition monitoring and analysis is used.

Routine Maintenance: The routine maintenance tasks performed by an AMT in Pakistan International Airlines are:

Cleaning Aircraft and Components

Application of Corrosion Prevention Compound

Lubricating Parts

Draining and Troubleshooting Fuel Systems

Checking and Servicing Hydraulic and Pneumatic Systems

Replacing Components

Inspecting for General Wear and Tear

Maintenance engineers usually perform Replacing hose connection except hydraulic connections removing, checking, and replacing

magnetic chip detectors and replacing any cowling. Removal of the prop is required to get the

nose bowl off. Replacing prefabricated fuel lines cleaning or replacing fuel and oil strainer or

filters replacing or cleaning spark plugs and setting gap. Landing gear tires, servicing struts

wheel bearings safety wire or cotter keys lubrication, not requiring disassembly. Replenishing

hydraulic fluid Replacing side windows. Repairing upholstery replacing safety belts replacing

seats or seat parts. Replacing & servicing batteries. Trouble shooting and repairing broken

circuits in landing light wiring. Replacing bulbs, reflectors, & lenses or position or landing lights.

Simple fabric patches refinishing decorative coatings applying preservative or protective

materials. Making simple repairs to fairings, nonstructural items. Replacement or adjustment of

nonstructural fasteners etc.

Type of advancements that should be done Newer and updated applications can be used for maintenance data bases

Inviting foreign experts to help PIA keeping up with moderns standards

Encourage employees with workshops, safe environment and good financial structure.

Name Bilawal Mahar

Roll No ME-092

Sec D

Conclusions The maintenance in an airline industry is carried out for three principle reasons:

Operational: To keep the aircraft in a serviceable and reliable condition so as to generate revenue.

Value Retention: To maintain the current and future value of the aircraft.

Regulatory Requirements: Regulated by the aviation authorities of the jurisdiction in which the aircraft is registered. It establish standards for repair, periodic overhauls, and alteration by requiring that the owner or operator establish an airworthiness maintenance and inspection program to be carried out by certified individuals qualified to issue an airworthiness certificate.

Repair stations are certified under FAR Part 145 and Aircraft Maintenance Technicians (AMTs) are certified under FAR Part 65.FAR Part 43. Preventive Maintenance:

PIA is conducting it preventive maintenance program excellently and fulfilling the 10 elements required for an Air Carrier Maintenance Program. These 10 elements are:

Airworthiness Responsibility

Air Carrier Maintenance Manual

Air Carrier Maintenance Organization

Accomplishment and Approval Of Maintenance And Alterations

Maintenance Schedule

Required Inspection Items

Maintenance Recordkeeping System

Contract Maintenance

Personnel Training

Continuing Analysis and Surveillance System (CASS) The preventive maintenance program is to be based on the flight hours or flight cycles. Flight hours represent the amount of time aircraft has been operational whereas one flight cycle is completed when an aircraft takes off and then lands. Some of the components are maintained as per flight hours and some are on the basis of flight cycle, depending on the manufacturer that how it has defined the maximum useful life of the component. Aircrafts have to go through an extensive inspection process, also referred to as “checks.” In PIA the maintenance department has categorized the checking intervals with letters from A to D. A-check being a light routine inspection and a D-check being the most intensive long-term check. Inspection in PIA is based on the following two programs:

Ageing Aircraft Corrosion Prevention and Control Program (CPCP)

Supplemental Structural Inspection (SSI)