Heavy Check Reliability Maximizes the Task Card Deck Efficiency

RepairMaps allows users to enter a man hour-value for each individual Tracked Item.


This value is intended to reflect the amount of time expended in accomplishing the activity detailed in the Tracked Item.  It is important to know this value especially in the context of another attribute: Gen-By.


When taken together, Man-Hours and Gen-By form the basis for a reliability program specific to the heavy maintenance structural task cards.

The ability to adjust the intervals and/or method employed for each task card is intrinsic to almost all Continuous Airworthiness Maintenance Programs.  The key to exercising this ability with the happy concurrence of one’s regulatory body is to have hard data with which to prove the case that a card should be adjusted in scale or frequency to maximise efficiency.  Also, it is worthwhile to know when one should perform a task card more often or in a more rigorous manner.

Most traditional reliability programs count event totals per ATA.  This works well for traditional reliability programs.  We do not, however, feel this is the best method for maximising the efficiency of the heavy maintenance or structural inspection program.  It is our view that tracking man-hours and Gen-by is much more effective.  For example, if I am simply counting findings I may have 15 broken clamps discovered while executing a certain structural task card.  Rectifying these minor items will require minimal man hours.  If we are counting events, the number of events per task card execution will be skewed artificially high.  If, instead, we consider only man hours, the impact from executing the task card will correctly be judged to be low.  Conversely, we might find one single structural defect that requires hundreds of man-hours to rectify.  Here again, a simple item count will skew the results artificially low but again, the man-hour value will present a clearer picture of the condition of the inspected structure.

RepairMaps tracks all man hour values for Tracked Items as they relate to the generating task card, (or AD, SB etc), over time for the fleet and for each individual aircraft.  This gives you a powerful tool to analyse how well your heavy check deck is performing.  Let’s say that we have performed a certain task card 10 times and with each successive inspection, we find a trend of decreasing man-hours required for remediation work.  This gives us the ability to either extend the interval of this task card or perform the inspection in a less rigorous manner such as removing lavs and galleys less often.  On the other hand, if we see an upward trend in findings as expressed in man-hours, this task should be considered for an interval decrease or perhaps a more intensive inspection or preventive procedure application.  These types of data are perfect for informing an effective Continuous Analysis and Surveillance Program.

By collecting appropriate and accurate data we can maximize the efficiency of the structural program by focussing our attention more intently on areas where problems actually exist and less so in areas where we rarely find anything of any substance.