Türk Hava Yolları Teknik A.Ş.

Maintenance Management Services

AD and SB Evaluation
The manufacturer’s publications and their revisions such as the Service Bulletins, Service Letters, etc., that recommend the inspections and modifications and the Airworthiness Authority’s Directives, which are issued to keep the aircrafts (or rotorcrafts), engines, propellers or components in Turkish Technic Capability List in airworthy condition, are supplied in digital or hard copy format. These documents are evaluated by the specialist engineers and necessary Engineering Orders and other internal publications are issued to ensure the incorporation on time. This evaluation is done in the aspects of,

1.Safety and Reliability :
A.If the failure and/or event has ever been experienced
B.The probability level of the failure and/or event
C.The p0ssible results of the failure and/or event
D.The effectiveness of the improvement on the flight safety, reliability, performance, passenger comfort, etc.

2.Cost :
A.Material cost
B.Labor cost
C.Elapsed time

In addition, all the other documentation and their revisions of the aircrafts, engines, propellers and components in Turkish Technic Capability List are supplied and the digital document management is done through the intranet.

 

Preparation/Update of Maintenance Program
Preparation/Update of Maintenance Program according to the Manufacturer Maintenance Planning Document (MPD).

Maintenance Programs are prepared for the customers aircraft that their maintenance responsibility have been taken considering the Manufacturer Maintenance Planning Document (MPD) as source. During preparation of Maintenance Programs, the documents such as MRBD, CMR, ALI,FAL and Safe Life Limits (LLP)   that are approved by CAA and issued by Aircraft Manufacturer are also used as source.
The periodic Job Cards that are prepared according to AD/CN, SB, SIL and airline’s experience in aircraft maintenance are also included in the Maintenance Program.

During developing Maintenance Program, maintenance check type and interval values are determined taking into account the reference intervals in MPD, operational requirement of airline and the utilization values of aircraft, and making maintenance optimization for minimize of maintenance cost.

AD and Mod Status that are required to get Turkish CAA approval for Maintenance Program are prepared and the engineering support is given to the operator during discussion with Turkish CAA.

 

Preparation/Update of Maintenance Job Packages and Job Cards
A) Preparation/Update of Maintenance Job Packages that will be applied to aircraft in the scheduled maintenance for all check types.
Maintenance Job Packages that will be applied to the customer aircraft are prepared according to the Maintenance Program approved by CAA.
The required information such as effectivity, threshold/packaging interval, material/tools, access panel/door, skill code, man-hour, zone for every task cards are entered in TAMES (Turkish Airlines Maintenance Information System) and maintenance job package lists are obtained for any aircraft and any maintenance check type.

Maintenance Job Packages are updated by reflecting any revision on Maintenance Program.

B)  Preparation/Update of Maintenance Job Cards required for the scheduled maintenance.
For the customer aircraft;
The Job Card that are based on MPD  (MPD Job Cards)
These Job Cards are prepared by using AMM and Task Cards in PDF or SGML format that are taken from aircraft manufacturer and Job Cards are printed automatically by using a work order number for any maintenance package.

The Job Card that are not based on MPD  (non-MPD Job Cards)
In order to make the reliability higher for the components, structure, electrical and electronic hardware of aircraft, to decrease the problems faced infrequently and to held the aircraft interior quality upper level,  various job cards that are not mentioned from aircraft manufacturer are issued. So the scheduled maintenances are made as more effective. By following by the engineering department any likely problems are checked and servicing costs are decreased. By using technical information collected by these job cards, preventive action can be done for any likely problems in the beginning.

The material and tools that are required for the prepared Job Cards are determined and are obtained before maintenance.

The references (MRBD, MPD, AMM, SB, SIL, Task Cards,...) of the Job Cards are followed and Job Cards and TAMES are revised continuously.

 

Power Plant Engineering Services

Evaluation of Engine /APU Performance Parameters:
In order to monitor the engine performance, basic flight parameters are recorded by ACMS (Aircraft Condition Monitoring System) during all flight phases. These parameters are transferred to the computers after each flight for the Airplanes equipped with ACARS systems or within certain periods via the portable cards. After processing transferred engine parameters by computers by means of sophisticated engine condition monitoring programs, engine performance trend reports are analyzed and evaluated by the qualified powerplant engineers by using their engine system knowledge, experiences and manufacturer’s recommendations. And based on this evaluation, engine performance losses, engine  potential failures and high-cost damages are identified beforehand and the necessary corrective actions are taken urgently. Thanks to this information; the flight safety, reliability and maintenance costs of engine and engine related systems which are one of the most critical systems for flight and the most expensive systems in terms of maintenance costs; are kept consistently under control. By means of taking the necessary corrective actions,  engine potential problems can be avoided before they actually appear.

Besides, in order to monitor the APU performances, the collected APU operating parameters are analyzed and evaluated by the qualified powerplant engineers by using their engine system knowledge, experiences and manufacturer’s recommendations.  According to such evaluation, APU performance losses, potential failures and high-cost damages are identified beforehand and the necessary corrective actions are taken urgently. Thanks to such evaluation; flight safety and reliability are maintained and APU maintenance costs are kept consistently under control.

Preparation of Workcope for Engines/APU’s
For each engine or APU removed from the aircraft on a scheduled or unscheduled basis, a detailed workscope which includes all necessary maintenance actions to be taken and also repairs & inspections to be performed during the shop visit is prepared for the relevant modules and components taking into account of  its maintenance history and configurations as to meet customer expectations.

The workscope is prepared by the qualified power plant engineers with high-level experience, taking into account of / aiming to maximization of the engine/APU’s flight life-span, improvement of the reliability and optimization of the maintenance cost. Necessary modifications are also performed on engines/APUs and their components in accordance with the shop visit workscopes prepared in line with the operational requirements of the customer, lease agreement conditions/requirements for the relevant aircraft / engine and customer expectations. Consequently, a higher engine/APU flight life-span and an improved reliability are maintained and also engine maintenance cost per flight hour is decreased.

Technical Management of Engines and APUs in the Customer Fleets
The technical management service for engines/APUs in customer fleets is provided by qualified engineers taking into account of criteria of the safety, the reliability, the performance and the cost for engine/APUs installed on customer airplanes.

A prompt and effective troubleshooting service with an active support and involvement of experienced engineers for technical problems faced during operations results in facilitating operators’ work in the airline business & sector where dispatch and total reliability concepts are important and where a knocking/high competition takes place.

In the event that repair & overhaul services to customer engines are provided by an MRO other than Turkish Technic, the necessary technical support and coordination services are still available to the customer by Turkish Technic. Consequently, an effective shop visit term and optimization of the cost are maintained.

Besides, if the maintenance agreement is on the power by the hour basis, all of the necessary repair, maintenance, overhaul and modifications are performed in the scope of the agreement with no additional charge to the customer. Thereby, all necessary technical support is provided to maximize on-wing retention of the engine together with reliable and trouble-free operation. Therefore, customer’s engine/APU maintenance costs are kept under control and maintenance costs’ prediction is achieved.

Selection of Engines / APUs
One of the most expensive and difficult decisions taken during new aircraft selection is to determine the suitable engine/APU type for a selected aircraft type. Turkish Technic Powerplant Engineering Department  provides technical consultation services for the selection of the most suitable engine/APU type according to the customer’s operation, fleet structure and financial resources. In the making of such selection, the customer shall have a substantial advantage to work with Turkish Technic having the flight operation experience in a large fleet scale and keeping in-house repair and overhaul capability for different kind of engines / APUs.

Delivery and Re-delivery of the Engines /APUs In Accordance With Lease Agreements
One of the other services which Turkish Technic offers  to the customers is the technical support and consultation in delivery and re-delivery processes of engines/APUs according to the aircraft lease agreements. Turkish Technic performs physical inspections  and documentation review of the engines which the customer is planning to take by lease in order to make sure that the engine meets delivery or return conditions. By doing this,  on-time delivery of the engine in the best conditions and on-time re-delivery of the engine with the lowest costs after expiry of lease term is achieved.

Reliability Management
1.Reliability Analysis
2.Maintenance Program Effectiveness Analysis
3.Flight Data Processing and Reporting
4.Reliability Training
5.Consultancy Services

Reliability Analysis
Reliability Analysis provides the continuous improvement of maintenance program by increasing the safety and reliability of aircraft, system and components with the economic maintenance principle of “The Right Maintenance at the Right Time”.
•Dispatch/Operational Reliability Analysis
•Fleet, Aircraft, System, Subsystem Reliability Analysis
•Component Reliability Analysis
•No-Fault Found Analysis, NFF
•Root Cause Analysis
•Preventive and Corrective Action Recommendations
•Reporting

Dispatch/ Operational Reliability Analysis – Maintaining a good Dispatch and Operational Reliability level that reflects the performance of depart on-time and arrive at their destination without any technical problem which is one of the basic customer satisfactions. In addition to providing reliable and safety flights, the reliability analysis helps to keep air turn back/diversions, aircraft substitutions and cancellations events at the minimum level with the high aircraft availability and minimum operational cost.

Taking into consideration all above, it is clear that the achievement of high Dispatch and Operational reliability is one of the most important objectives for most airlines. With the reliability analysis aimed at achieving the goal, in addition to taking the required actions for improving aircraft, system and component reliability, it is determined the other corrective actions based on the defined probable root causes.

Fleet, Aircraft, System, subsystem Reliability Analysis – Defining  the fleet, aircraft, system, subsystem and/or components that genuinely need improving by comparing critical technical incidents ( IFSD etc.), ground and air interruptions (delays, cancellations, air turn back, aircraft substitution etc.), repetitive defects, pilot/maintenance/cabin reports belongs to customers’ fleet  with Turkish Technic Inc. Customers’ fleet and World averages.

Component Reliability Analysis – The critical and rogue components are determined by using the new and effective methods (Weibull, Laplace trend test etc.) in addition to the traditional reliability analysis like component MTBUR, MTBF trend analysis.

Spare level estimation is done according to TAT and Component reliability analysis results.

The reliability analysis is performed to reduce the In flight shutdowns and unscheduled removals of engine and APU which are the main aircraft cost driver components that have many sub-assies.

No-Fault Found Analysis, NFF – As a result of reliability analysis, with regard to the high NFF rate, the worst components are determined. With the experience of Turkish Technic Inc. system engineers, component shop repairmen and troubleshooters, the number of No-Fault-Found units can be reduced.

Root Cause Analysis – Possible Root causes that requires corrective actions are determined by reviewing the criteria like operator, station, fleet, aircraft, shop actions, maintenance program and airline applications for fleet, aircraft, system, subsystem and/or components that need amendment.

Preventive and Corrective Action Suggestions – Based on the probable root causes, the required corrective and preventive actions (SB, modification, control, etc.) are determined by experienced Turkish Technic engineers.

Reporting – Customized Reliability Report is prepared according to the customer request and Civil Aviation requirements.

Maintenance Program Effectiveness Analysis
Reliability Management provides the evaluation of approved maintenance program effectiveness by means of Reliability Program. Following the reliability and maintenance performance parameters such as critical technical incidents (IFSD, etc.), ground and air interruptions (delay, cancellation, air turn back, aircraft substitution, etc.), repetitive defect rates, component MTBUR, MTTUR, MTBR, MTBF values, non-routines, Pilot/Maintenance reports, SB/Modification status etc. and determining deficiencies, maintenance program is optimized with the cooperation of Turkish Technic Inc. Maintenance Optimization Working Group.

Processing and Reporting Flight Data
For different types of aircrafts, data which are recorded to flight data recorder during flight can be processed, listed and reported for analyzing (FDM, ECM, etc.).

Reliability Training
“Aircraft Maintenance and Reliability” – This training contains aviation rules about reliability, maintenance reliability, Reliability Program development, data collection and reporting, Reliability calculation and analysis methods, maintenance optimization, MSG-2 and MSG-3 methods, and etc.

“Reliability Data Analysis Methods” – This training contains, probability and statistic concepts used for reliability analysis, data types, fundamentals of reliability data collection and analysis, distributions used for data modeling (Weibull, Normal, etc.), analytical technicals used for solving and analyzing reliability problems.

Consultancy Services
Supporting Services at Preparing Reliability Control Program and Getting Approval from Authority

By experienced Turkish Technic Inc’s Reliability engineers and specialists, Reliability Control Program can be prepared and procedures for approval can be determined for customers.

Improving Data Collection System
Every day, large amount of data are collected for tracking aircraft reliability strictly. For the current data collection system, more and effective data are needed with the increased data sources and developed feed-backs. Our aim is to give consultancy service to our customers at increasing data reliability and data sources based on ATA SPEC2000 Chapter 11 and 13 which is formed by the leadership of Boeing and Airbus and cooperation of some of world wide operators, maintenance and repair companies and vendors. Turkish Airlines is one of the core operators which have started to apply this standardization.

Evaluation of the Structural Damages
The structural damages occurred on Aircraft/Engine/Components which are covered in standard maintenance documents are being evaluated by experienced engineers. The damage is being evaluated and reported to the manufacturer with or without a repair proposal, and an approved repair procedure is requested. The accomplishment of the repair is being observed, and problems encountered are resolved by engineers. Upon accomplishing the repair, the manufacturer is being advised and approval form is being requested from the civil aviation authority which the manufacturer is affiliated with.