Chapter 8.1.1
Production and Maintenance of Maintenance Schedules
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Table of contents Paragraph |
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2 Policy on the production and maintenance of maintenance schedules
3.2 Schedule standardization measures
4.3 Reviews by civilian contractors
4.5 Schedule standardization measures for older aircraft
5 Aircrew Landaway Flight Servicing Schedules
6.1 Continuing Airworthiness Support Division 43(CASD)
6.2 Integrated Project Team (IPT)
6.3 4Material Integrity Group (MIG)3.. 6
6.4 4Repair & NDT Squadron3.. 6
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List of tables
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Table 1. Maintenance Schedules List.
This chapter details the specific policy and instructions, additional to those detailed in Chapter 8.1, concerning the production and maintenance responsibilities for maintenance schedules. It also provides guidance on the measures to be taken to achieve standardization of such schedules and details procedures for their production, initial issue, revision and amendment. These measures may be achieved either through a task on a Service organization or under a contract with an external organization.
Throughout this chapter the generic term 'schedule' is to be interpreted as meaning any aircraft, airborne equipment or air-launched guided weapons and their installed or associated equipment maintenance schedule derived and maintained in accordance with the requirements of this chapter.
This chapter applies to all aircraft and associated equipment maintenance schedule publications used in the Military Air Environment (MAE). It does not include Flight Test Schedules (Topic 5M), procedures for which are detailed in Chapter 8.1.2. The range of maintenance schedules that may be issued for an aircraft type is as follows:
Table 1. Maintenance Schedules List.
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Codification |
Title and content of Topic |
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4F |
Bay maintenance schedule1 |
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4M1 |
Receipt schedule1 |
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4T |
RN armament procedure sheets1 |
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5A1 |
Master maintenance schedule |
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5A2 |
Hazard and maintenance information |
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5A3 |
Maintenance and test procedures |
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5A4 |
Suggested maintenance plans |
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5A6 |
Weapon loading off-loading procedures |
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5B1 |
Flight servicing schedule |
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5B1A |
Continuous operation mandatory maintenance |
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5B1C |
Role equipment flight servicing schedule |
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5B2 |
Primary maintenance schedule |
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5B2 & C |
Primary and minor maintenance schedule |
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5B2A |
Flexible primary maintenance schedule |
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5C |
Basic or Minor maintenance schedule |
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5D |
Major maintenance schedule |
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5E |
Change of role procedures |
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5F |
Bay maintenance schedule |
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5G |
Non-destructive test schedule |
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5G1 |
Vibration analysis schedule |
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5G2 |
Electro-magnetic compatibility schedule |
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5J |
Special-to-type support equipment schedule |
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5K |
Schedule of component lives2 |
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5L |
Storage maintenance list |
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5N |
Preparation for storage schedule |
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5P |
Maintenance during storage schedule |
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5Q |
Recovery from storage schedule |
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5R |
Dismantling and re-erection schedule |
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5S |
Cross-servicing schedule |
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5T |
Operational turn round schedule |
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5U1 |
Operational readiness servicing schedule |
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5U2 |
Operational readiness servicing schedule (subject to special approval) |
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5U3 |
Operational readiness servicing schedule (when applied to unarmed aircraft) |
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5V |
Sampling requirements and procedures |
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5W |
Summary of component repair plans |
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5X |
Weapon preparation and de-preparation procedures |
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5(CTY) |
Contingency or Wartime maintenance schedule |
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5Y |
Aircrew landaway flight servicing schedules |
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5Z |
Anti-deterioration maintenance schedules3 |
Notes:
1 The Topic 4F, 4M1 and 4T may be maintained for legacy aircraft, but for new aircraft the Topic 5 series should be used instead.
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2 The information in the Topic 5K should also be replicated in the Topic 5A1.
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3 The Topic 5Z might include schedules for operations in:
3.1 Cold or hot weather.
3.2 Saline environments, including embarked operations.
3.3 High humidity climates.
3.4 Continuous high ultra violet light.
2 Policy on the production and maintenance of maintenance schedules
The preventive maintenance requirements identified in the Support Policy Statement (SPS) for an aircraft or equipment are to be implemented by the production, issue and use of maintenance schedules. A maintenance schedule is to be derived, using the methodology of Reliability-Centred Maintenance (RCM) analysis, to avoid or reduce the consequences of failure or degradation for every type and mark of aircraft or associated equipment that requires preventive maintenance. Once in being, a maintenance schedule is to be maintained throughout the life of the type and mark of aircraft or equipment to which it refers, using RCM.
A comprehensive range of schedules for aircraft and equipment introduced using Integrated Logistic Support (ILS) is to be written to the policy defined in this chapter and is to conform to the standards detailed in paragraph 3.2. Each schedule is to be published and be available for use by the Logistic Support Date (LSD) of the aircraft or equipment. Integrated Project Teams (IPTs) are to ensure that a task is placed on the Designer or another Subject Matter Expert (SME), such as a Schedule Maintenance Agency (SMA), at an early stage in the procurement cycle to meet the LSD. IPTs are to make similar provision, when appropriate, for the production of aircraft storage schedules.
Where aircraft Technical Information (TI) is provided as electronic TI (ETI), the layout of the schedule information should mirror, or improve on, the layout of the paper Topic 5; however, where an aircraft is provided with both ETI and paper TI, the layout of the ETI and paper versions of schedules must be the same within the limits of the display media used.
3.2 Schedule standardization measures
The requirements of AP 100C-20, DAP 100C-22 and AP 100K-20 are the preferred options when applied to schedules for aircraft, air-launched guided weapons and their installed equipment. IPTs are to seek advice from the relevant SME on which data is required to produce an RCM-based maintenance schedule before the appropriate contract is let. Notwithstanding, the following items are mandatory deliverables required from a contractor in order to produce an RCM-based maintenance schedule:
1 A Failure Modes Effects and Criticality Analysis for each new aircraft and equipment programme and a Failure Modes Effects Analysis for existing schedules under review; produced in accordance with 4Def Stan 00-45 Part 33.
2 The RCM analysis – IPTs are to agree with the SME the format of the RCM analysis deliverable.
3 The list of Structurally Significant Items, Functionally Significant Items, critical components (see Chapter 5.3.1) and associated inspection periodicities.
The preferred format for TI is detailed in Chapter 8.1. The requirements of this chapter are mandatory for the amendment and revision of maintenance schedules originally produced using RCM. Owing to the adoption of ILS and the possibility of schedule maintenance reviews being conducted under contract by an agency external to the MAE, it is important that there is compliance with the procedures detailed in this chapter. Much of the data required to apply the provisions of these APs satisfactorily to aircraft or equipment schedules can be obtained only from the aircraft/equipment manufacturer. IPTs are advised that a Part-RCM schedule review will look at systems only. Consequently, a Part-RCM revision is unlikely to produce the projected savings in maintenance, or corresponding reduction of tasks in the maintenance cycle, that may be achievable under a full RCM revision.
The IPT is to conduct the first review of a schedule no later than 5 years from the Introduction to Service Date.
The IPT is to set a frequency for subsequent schedule reviews as detailed in Chapter 8.1 and publish it in the relevant SPS. The periodicity is to be re-assessed as part of the SPS review process, taking account of the full range of airworthiness, performance and safety issues and the cost of conducting a review. Factors that may bear on this process are as follows:
1 Aircraft maturity and design stability.
2 Changes to life parameters of major structural systems.
3 Changes in aircraft role, fit or capability.
4 The cumulative effect of schedule amendments, which may have degraded the schedule's overall logic and coherence.
5 The potential for achieving significant savings in maintenance costs.
The IPT is to endorse changes to the schedule review frequency, including deferment to subsequent financial years, and is to engage the appropriate SME and Front Line Command (FLC) staffs in the schedule review process, so that those organizations can plan accordingly.
4.3 Reviews by civilian contractors
The IPT may decide to use a competent civilian contractor to carry out schedule reviews if the capacity of Service sources is exceeded, or it is judged that this offers the best value for money. The IPT may seek guidance from an SMA in selecting the civilian contractor to act as SME for a schedule. The IPT retains the responsibility, as TI sponsor, for ensuring that such schedules comply with all MOD standards and may use an SMA to ensure that the final deliverables of the contract include auditable RCM documents in a format compatible with current procedures.
Schedules are to be maintained by appropriate amendment action as detailed in Chapter 8.2, apart from revisions, which are carried out by system analysis. Personnel at all levels using, or otherwise associated with, schedules are to contribute to their correctness by reporting errors and anomalies as soon as they are apparent and by suggesting improvements whenever they are conceived. Amendments to a schedule are to be initiated as detailed in Chapter 8.2. Routine amendments are to be effected by reissue of the pages concerned and not by 4handwritten entries, which3, as detailed in Chapter 8.2, are only to be authorized when airworthiness is affected or the error could endanger personnel or equipment.
4.5 Schedule standardization measures for older aircraft
IPTs managing older aircraft types and associated equipment with maintenance schedules produced before the introduction of RCM, and for which the necessary manufacturer's data is not available, are to make every effort to obtain such data before the next schedule revision. Where the cost of obtaining such RCM data is judged prohibitive, or the data is otherwise unobtainable, IPT Leaders may seek a concession from this policy through 43Continuing Airworthiness Support Division Pol (CASD Pol), who will seek the endorsement of CASD 4Air Vehicle Integrity (CASD AVI).3
5 Aircrew Landaway Flight Servicing Schedules
The Topic 5Y (Aircrew Landaway Flight Servicing Schedule (ALFSS)) may be produced in response to an 4FLC3Staff requirement or a specific business need. The ALFSS details the technical requirements of the 4flight servicing3schedules to enable the aircrew, when away from their maintenance support, to carry out the required inspections and replenishments in a clear and logical manner that can be combined with the aircrew pre-flight checks. Where possible, the correct engineering support should be used. The ALFSS should not alter, or reduce, the 4flight servicing requirements3from the Topic 5B1 (Flight Servicing Schedule) simply because the servicing is to be carried out by aircrew.
The ALFSS should be developed and produced from the Topic 5B1 for that particular aircraft type and ideally be an extract of the Topic 5B1 for configuration control and amendment action. This is achieved in consultation, where necessary, with the Course Design Team for new aircraft or OC Aircraft Standards Team (eg STANEVAL) for in-service aircraft. Sponsorship of the ALFSS resides with the IPT. OC Handing Squadron (OC HS) will normally act as 4Publishing Organization (PO)3for the ALFSS and will format and publish it on behalf of the IPT.
5.3.1 Amendment to ALFSS
Amendments to ALFSS should be proposed using the processes detailed in Chapter 8.2.
5.3.2 Amendments to ALFSS as a result of changes in the Topic 5B1
The IPT is to ensure that any amendment to the Topic 5B1 is, when necessary, reflected in the ALFSS. Where possible, amendments to the Topic 5B1 and ALFSS should be issued concurrently. In order to control amendment action, the following procedure may be adopted:
1 On completion of the Topic 5B1 amendment process by the appropriate SME, a proof copy of the amendment, marked 'ADVANCE COPY – NOT SUBJECT TO AMENDMENT', should be passed for comment to addressees nominated by the aircraft IPT and to OC HS.
2 OC HS should produce a print-ready copy of the ALFSS amendment and forward 2 copies to the IPT for approval and one copy to the appropriate SME for comment. Once approved, the IPT should return the amendment to OC HS for production and incorporation in the ALFSS.
6.1 Continuing Airworthiness Support Division 43(CASD)
4CASD has the following responsibilities in the production and maintenance of maintenance schedules:
1 CASD Pol is to formulate and promulgate overall MAE policy for schedules.
2 CASD AVI RCM 1 is the MOD Schedule Maintenance Agency (SMA) for aircraft and associated equipment schedules and is located at Wyton for fixed-wing (FW) aircraft and at Middle Wallop for rotary-wing (RW) aircraft.
3 CASD AVI also maintain schedules, on behalf of IPTs, dealing with the various aspects of storage. Schedules are maintained at Wyton for FW aircraft and Middle Wallop for RW aircraft.3
6.1.1 Schedule Maintenance Agency (SMA) responsibilities
The SMA provides the Services’ in-house schedules specialists who provide advice and guidance to IPTs and other organizations on the production and maintenance of schedules. In addition they produce and review schedules at an IPT’s request and can assist in selecting a suitable alternative schedules SME. The SMA should be consulted to identify any other aircraft or aircraft-related equipment that may be affected by the introduction of a schedule.
6.2 Integrated Project Team (IPT)
As TI sponsor, an IPT is to exercise overall control of the content of all schedules throughout the life of a particular type of aircraft or equipment and ensure that it complies with MOD policy.
1 IPTs are to specify the requirements for4TI3, including schedules, at an early stage in the procurement of an aircraft or equipment project and are to appoint a suitable SME/SMA to produce the appropriate schedules.
2 For aircraft and associated equipment introduced under ILS, responsibility for the production of schedules rests with the Designer. In the event that the Designer is unable to produce the schedules, the IPT may transfer the task to an alternative SME.
3 When required, the IPT is responsible for producing, authorizing and maintaining an ALFSS, ensuring that any amendment of the FSS is reflected in the corresponding ALFSS in order to maintain the airworthiness of the aircraft.
6.3 4Material Integrity Group (MIG)3
4The MIG, within FLEET Forward Support (Air) based at Fleetlands, is the SME for RW Topics 5G (Schedules for Non-Destructive Testing) and provides NDT support for RW aircraft.3
4The Repair & NDT Squadron, 42 Expeditionary Air Wing (Repair & NDT Sqn 42 EAW) based at St Athan, is the SME for FW Topics 5G and provides NDT support for FW aircraft.3
This chapter refers to the following publications:
1 AP 100C-20 – RAF Engineering – Preparation and Amendment of Maintenance Schedules.
2 DAP 100C-22 – RAF Engineering – Procedures for the Development of Preventative Maintenance.
3 AP 100K-20 – Army Aircraft Engineering – Maintenance Schedules – Preparation and Amendment.
4 4Def Stan 00-45 – Guidance on the Application of Reliability Centred Maintenance3