Initial Exercises—Manage Maintenance Program
Initial Exercises
Purpose: The purpose of these initial exercises is that
the instructor will use them for demonstrating how to do maintenance planning
according to a few commonly used principles in IFS/Vehicle Information
Management (IFS/VIM). The exercises cover the following sub-processes:
IMPORTANT |
These initial exercises are intended for instructor use.
If you
are a student, it is extremely important that you set up and work
with your own assigned student number to maintain your data integrity.
|
Purpose: The purpose of this
exercise is to define the maintenance codes that are to be used for the part
revision. Instructions defined for the part revision can be connected to the
maintenance code defined here.
Windows:
Maintenance Codes per Serial Part Revision
Steps: To complete this exercise, perform the following
steps.
- Open the Maintenance Code per
Serial Part Revision window.
- Create 2 new records (F5) and enter the following information:
Part Number |
Revision |
Maint Code |
X747-900 |
T |
XA |
X747-900 |
T |
XD |
- Save the information (F12).
Purpose: The purpose of this
exercise is to define the general data for a maintenance program to be used for
our Aircraft X747-900, Revision T.
Windows:
Define Maintenance Program
Steps: To complete this exercise, perform the following
steps.
- Open the
Define Maintenance Program window.
- Create new record (F5) and enter Maintenance Program
T100, Description 'Maintenance for X747-900' and Revision T.
-
Save the information (F12).
-
Click the
Assign Parts tab and enter
Part Number X747-900
- Save the information
(F12).
- Click the
Assign Part Revisions
tab and delete all the revisions except T.
- Save the information (F12).
- Click the
Maintenance Groups tab and enter Part Number X747-900 and Maint
Group T.
- Save the information (F12).
-
Click the
Access tab and enter your
access group T.
- Save the information (F12).
-
Populate (F2) the window and verify that you have
access to the maintenance program.
Purpose: The purpose of this exercise is to show attendees
how to create an instruction for the refill of hydraulic oil on the A/C and link
this instruction to the A-check that is carried out every 100 FHR or 7 days. There is a need for
max. 4 liter of Hydraulic Oil, but experience shows that only 1 liter is used.
The refill takes place on the left wing. No tools or facility is required. First
we register an instruction, then we specify the maintenance plan.
Windows:
Instruction
Maintenance Plan
Steps:
To complete this exercise, perform the following
steps.
- Open the
Instruction
window.
- Create new record (F5) and specify Part Number X747-900, Revision
T, Operation
Number 29113 and Description to Refill of Hydraulic Oil.
- Specify Type XCHK, Location XLWU
and Strategy XINT.
- Specify Function breakdown on Product Number 7X7
and Model Number X747-900.
- Specify Function Number 2900, Sub Function 2910 and Bottom
Function 2912.
- Specify Affected Part Number X747-900 and Affected Part Rev
T.
- Specify Competence XMECH, No. Of Persons 1 and Hour Cons. 0.5.
- Specify a simple Work Description on how to do the refill.
- Save the information (F12).
-
Click the
Material List tab and create a new record (F5).
- Specify Sub Part Number X32HDF7005, Revision * and enter a predefined Manufacturer
and Manu Part No Specify Quantity 4 liters with a Probability
of 25% (normally only 1 liter is needed)
- Save the information (F12).
- Click the Connect Task Codes tab and then click the
Maintenance Code
sub tab.
- Create a new record and connect this instruction
to Maint Code XA.
- Save the information (F12).
- Right Click on the
Instruction
window header and then click
Maintenance Plan.
- Make sure you find your maintenance program T100.
-
Click the
Intervals tab.
- Create new record (F5) and specify Maint Code XA (A-check).
- Specify Maint Interval 100 FHR and Calendar Interval 7 days. Select the
Recurring Calculation
check box and specify the same intervals here.
- Set Days Forewarning to 2 days and Duration Workshop to 0.5hrs.
- Set Calculation Rule
to Inspection
and Cycle to No Cycle.
- Save the information (F12).
- Select the record just entered, right-click and select
Instructions per Maint. Code to verify that the instruction and the maintenance
code are linked together.
Purpose: The purpose of this exercise is to show attendees
how
to create an instruction for an engine boroscope check. This check should be included in the
D-check on the 747-900 aircraft. A maintenance facility and a boroscope are needed to
do the check that takes 6 hours to complete for 2 mechanical operators. No
material is needed. D-check is executed every 3000 FHR or 2 years. An interval tolerance of +/-150
FHR is acceptable.
Windows:
Instruction
Maintenance Plan
Steps: To complete this exercise, perform the following
steps.
- Open the
Instruction window.
- Create new record (F5) and specify Part Number X747-900, Revision T, Operation Number 72100
and Description to Engine Boroscope Check.
- Specify Type XHVY as this is a Heavy Maintenance check.
- Specify Location XENG.
- Specify Strategy XINT (This is an interval check)
- Specify Product Number 7X7 and Model Number X747-900.
- Specify Function Number 7200, Sub Function 7250 and Bottom Level 7251.
- Specify Affected Part Number X72ENG7010, Affected Part Revision *. (GE engine, CF600).
- Specify Competence XMECH, No Of Persons 2 and Hour Cons. 6.0 hrs.
- Enter a simple Work Description on how to do the boroscope check
and what to look for.
- Save the information (F12).
- Click the
Tools and Facilities tab.
- Create new record (F5) and specify Tool/Facility Type HGR, Tool/Facility
ID XHGR1, Quantity to 1
and Planned Hour Consumption to 3.
- Save the information (F12).
- Click the
Criticality tab and create
a new record (F5).
-
Specify Criticality Code
Safety
and Criticality Level Important.
- Save the information (F12).
- Click the
Connect Task Codes tab and then click the
Maintenance Code
sub tab.
- Create a new record and set this check to be included in Maint Code XD (D-check).
- Save the information (F12).
- Right Click on the
Instruction
window header and click
Maintenance Plan.
-
Make sure you find your maintenance program T100.
-
Click the
Intervals
tab. Here you will specify
interval for this D-check.
- Create new record (F5) and specify Maint Code XD, Maint Interval to 3000
FHR and Calendar Interval to 24 Months.
- Select the Recurring check box and enter the same Recurring Interval
and Recurring Cal. Interval.
- Select the Use Tolerance check box and specify Lower/Upper Tolerance
5%
(which means 150 FHR).
- Set Days Forewarning to 14 days, Duration Workshop to 6 hrs.
- Set Calculation Rule
to Inspection
and Cycle to No Cycle.
- Save the information (F12).
Purpose: The purpose of this exercise is to show attendees
how to create a routine for condition based maintenance of the Nose Landing
Gear (NLG).
With the load of an empty Aircraft, the relative position of the NLG hydraulic cylinders indicates the
remaining volume of hydraulic fluid. Relative position is measured on a 0-10
scale. When serviced (refilled), the standard oil level is at 10. Level below 6 should give
a Warning, and level below 4 indicates Danger. A drop of more than 2 units
between 2 consecutive measurements should also trig a maintenance task. The
condition check should be performed every 4 weeks.
Windows:
Condition Monitoring Program
Steps: To complete this exercise, perform the following
steps.
- Open the
Condition Monitoring Program window.
- Query (F3) for the Part Number X747-900 and Revision T.
- Click the
Condition Limit tab and create a new record (F5).
-
Specify the following:
Condition Category - LDG
Condition Code - LDIND
Condition Code Description - Load Indicator
Standard Value - 10
Condition UoM - * (no unit)
Warning Limit Min. - 66
Warning Limit Max. - 10
Danger Limit Min. - 4
Danger Limit Max. - 10
Change Limit - 2
Measure Frequency - 4 weeks -
Save the information (F12).
-
Click the
Instructions tab and select
the Condition Category
and Condition Code as specified above.
- Click the
Operations
sub tab.
- Create new record (F5) and specify Operation Number 32102, Operation
Description Check Oil Level,
Type XPRV and Location XNLG.
- Specify Competence XMECH, No. Of Persons 2 and Hour
Consumption 1.5.
- Double-click on the Work Description field and enter a brief guide in the
text editor window.
- Specify Affected Part Number X32NLG7001 (Landing Gear) and Rev T.
- Specify Product Number 7X7, Model Number X747-900
and Function Number 3200.
-
Save the information (F12).
- Click the
Material
Usage sub tab.
- Create new record (F5) and specify Operation Number 32102, Sub Part
Number X32HDF7005, Rev * (Hydraulic Oil).
- Specify Manufacturer Number V53655, Manufacturer Part Number S22890, Quantity
1.5 liter and Probability to 80%.
- Save the information (F12).
- No tools or facilities are needed for this operation.
Purpose: Based on requirement from the engineering
department, the purpose of this exercise is to
define a
modification of landing wheels by changing from rim revision "*" to
revision "1" on your serial TX10000 of the X747-900 fleet. Modification is mandatory
and should be executed together with next A-check, within 300 FHR from now, but
not later than 2 months from now. Pre-check is not necessary. You require 1 week task forewarning,
and the modification takes one day in workshop. After modification,
the wheel rims should be checked every week for a period of 12 weeks. This post check takes
0.5 hours and
should have a 1 day forewarning. To do the modification you need a skilled
mechanics for 3 hours and a 200 tons jack.
Windows:
Define Modification
Steps: To complete this exercise, perform the following
steps.
- Open the
Define Modification window.
- Create new record (F5) and specify your Mod Code XNEWRIM, a Description
and an initial revision.
- Specify Category Mandatory, Assignment
Type to By Revision All Serials, Workshop Code to LAX-L and Mod Type to XENG
and
a Level Code.
- Enter Days Forewarning, Duration Workshop and Rescission Date to Sysdate+2 months according to the given information.
- Select the Allow Quick Reporting check box.
- Save the information (F12).
- Click the
Assign Parts tab and specify Part
Number X747-900. Remember to specify Next
Interval Maintenance XA (A-check).
- Save the information (F12).
- Click the
Assign Part Revisions tab, specify Part
Number X747-900 and Revision T and save the changes (F12).
- Click the
Define Post Maint tab and select the Enable Post Maintenance Check
check box.
Specify Days Forewarning to 1, Cal. Interval to 1 week and
Cal. Limit (days) to 84 days.
- Save the information (F12).
- Set Hour Estimate per Serial to 0.5 hrs (tab
Definition).
- Save the information (F12).
- Right click on the
Define Modification window header and
then click Modification Details.
- Click the
Instructions tab and chose
Mod Execution Type Terminating Action for your Part/Revision X747-900/T.
- Click the
Operation
sub tab and
enter new Operation Number
32900
and specify a proper Operation Description for the operation. Enter Type XMOD. Competence XMECH, No
Of Persons 1 and Hour Consumption 3. Enter a brief Work
Description. Use Affected Part Number X32WHE7002/T.
- Specify Product Number 7X7, Model Number X747-90T and Function
3200/3220/3224.
- Save the information (F12).
- Click the
Material Usage sub
tab. On your Operation
Number, create new record (F5) and specify Sub Part Number
X32RIM7002, Revision to 1, Quantity to 2
and Probability to 100%.
- Save the information (F12).
- Click the
Tools and Facilities
sub tab and define the requirement of a
jack for 3 hrs.
- Save the information (F12).
- Activate the modification by navigating to the
Define
Modification
window (right click on the window header and then click
Define Modification).
- Execute menu selection Status and then Set Active.