Maintenance Management of Aircraft

Yang dibahas dalam Menejemen Pemeliharaan adalah :

a. Effect Mentenance in aviation & Aircraft Technology
b. Basic Maintenance Concept
c. Maintenance Program Requirement
d. MSG atau RCM Methodologi
e. Reliability Equations & Probability Concept
f. Reliability Concept in Maintenance
g. Decompotition Part in Whole System of Aircraft
h. Distribution Used in Reliability
i. Classification of Failure or Failure Distribution Type
j. Failure Mode of Parts and System
k. Failure Analysis of Parts and System
l. Alert Level Calculation
m. Logistic Management in Maintenance
n. Maintenance Control by Reliability Methods
 LITERATURE
• A.K. Bameji Dkk, Mauntenance an Spare Parts Management
• Balbir S. Dhillon and Hans Reiche, Reliability and Mainatainability
management, Van Nostrand Reinhold Co. Inc.,1985
• Benyamin S. Blankard, & Fabricky, Logistics Engineering and
Management, 3rd Edition, Prentice Hall Int’l. 1992
• Benyamin S. Blankard, Dinesh Verma & Elmer L Peterson,
Maintainability (A Key To Effective Serviceability and Maintenance
Management), John Wiley & Son, 1985
• Benyamin S. Blankard, edited by Seiichi Nakajima, TPM Development
Program
• (Implementing Total Productive Maintenance), Productivity Press Inc.,
Cambridge Massachusetts 1989.
• Crosby, Philip B., Quality is Free, New York, McGraw-Hill Book
Company, 1979.
• Crosby, Philip B., Quality Without Tears, New York, McGraw-Hill Book
Company, 1979.
• David J. Smith, Reliability and Maintainability in Prespective (Pratical,
Contractual,
• Comercial and Software Aspects), 2nd Edition 1985, Macmillan
Pubisher LTD., London.
• Deming, W. Edward, Quality, Productivity and Competitive Position,
Cambrigde Mass : Massachusetts Institut of Technology, 1982.
•
LITERATURE
Gitlow, H.S., and S.J Gitlow, The Deming Guiade to Quality and
Competitive Position.,
• Englewood Cliffs, N.J.: Prentice Hall, Inc., 1987.
• Henley, Ernest J., and Hiromitsu Kumamoto, Reliability Engineering
and Risk Assessment.,
• Englewood Cliffs, N.J.: Prentice Hall, Inc., 1981.
• IB. Gertbach 1982, Models of Preventive Maintenance.
• Ishikawa, K., What Is Total Quality Control ?, Englewood Cliffs, N.J.:
Prentice Hall, Inc., 1985.
• M. Agus Mustofa, Manajemen Logistik, Akademi TNI AU, Edisi Kesatu
tahun 1995, berdasarkan Sekep Gubernur AAU, Nomor
Skep/19/VIII/1995 tanggal 1 Agustus 1995.
• M. Agus Mustofa, Diktat Kuliah Manajemen Perawatan, Edisi Kesatu
UII 1996.
• M. Agus Mustofa, Diktat Kuliah Manajemen Perawatan, Edisi Kedua UII
1997.
• Seiki Nakajima, 1981 Introduction to Total Productive Maintenance.
• Taguchi, Genichi, Introduction to Quality Engineering., Tokyo ; Asian
Productivity Organization
• William, JS., Maintainability & Reliability In Perspective.
• Winchell, William, TQM : Getting Started and Achieving Results with
Total Quality
• Management., Deaborn, Mich : Society of Manufacturing Engineers,
1992.
 EFFECT MAINTENANCE
IN AVIATION AND
AIRCRAFT TECHNOLOGY
DEFINITION OF MAINTENANCE
DEFINITION OF MAINTENANCE :

ALL ACTIFITIES SUBJECTED TO TECHNICAL SYSTEMS TO

BE KEPT IN THE CONDITION (PREVENTIVE) OR TO
BROUGHT IN THE CONDITION (CORRECTIVE) WHICH IS
REQUIRED TO FULFILL SPECIFIED FUNCTIONS

(Maintenance Engineering)

PERAWATAN DIDEFINISIKAN SEBAGAI SEMUA AKTIFITAS

DITUJUKAN KEPADA SISTEM TEKNIK UNTUK MENJAGA
KONDISINYA (PREVENTIF) ATAU MENGEMBALIKAN
KONDISINYA (KOREKTIF) YANG DIPERLUKAN UNTUK
MEMENUHI FUNGSI-FUNGSI TERTENTU.
 Definisi dari “Maintenance”
• Pemeliharaan merupakan salah satu
fungsi kegiatan logistik dalam rangka
mengoptimalkan kesiapan Peralatan
Industri untuk menghindari atau mencegah
terjadinya kerusakan yang bersifat sangat
merugikan/fatal dalam melakukan
pengamatan (surveillance) terhadap
kondisi items atau sistem dari
mesin/peralatan
 Munculnya ide pemeliharaan
• Jadual pemeliharaan yang diikuti dari vendor
sering terlalu over protective atau sering terjadi
kegagalan komponen jauh sebelum jadual
pemeliharaan terlaksana
• Penekanan ongkos pemeliharaan dan
optimalisasi operasional komponen
• Tidak adanya petunjuk baku tentang sistem
pemeliharaan
• Munculnya departemen Reliability Center
Maintenance yang mampu menggoyah QA
• QA adalah faktor subyektifitas orang yang
bertugas
 Aspek yang berhubungan dengan
manajemen pemeliharaan

• Mempertinggi performansi dan

mempertinggi reliability

• Penekanan ongkos pemeliharaan yang

menyangkut Man Hours Cost dan
component cost

• Pengoptimalan kemampuan personel

 Fungsi Pemeliharaan. Fungsi pemeliharaan
harus dapat memenuhi tuntutan sebagai berikut

• Kelaikan, mempengaruhi spesifikasi standar yang

ditentukan, untuk menjamin keselamatan (safety)

• Kemampuan Operasional, memenuhi ketentuan dan

tuntutan standar kemampuan/kinerja yang ditetapkan bagi
mesin/peralatan untuk melaksanakan misi.

• Kesiapan Operasional, memenuhi ketentuan jumlah

mesin /peralatan yang ditetapkan untuk melaksanakan misi.

• Kehandalan (reliability) Optimal, memenuhi ketentuan

standar kemampuan untuk melaksanakan misi dalam jangka
waktu dan kondisi/lingkungan operasi tertentu, tanpa
kerusakan.
 Falsafah Pemeliharaan

• a. Reliability. Reliability pemeliharaan

adalah suatu mesin atau peralatan
melaksanakan misi tertentu dalam kondisi
tertentu dan untuk jangka waktu tertentu
dengan tidak terjadi kerusakan.

• b. Economic penggunaan sumber

daya sehemat dan seefisien mungkin.
 Tujuan pemeliharaan
• Memperpanjang useful life
• Menjamin ketersediaan optimum
• Menjamin kesiapan operasional
• Menjamin keselamatan orang yang
menggunakan
Tujuan manajemen pemeliharaan
Menemukan interval inspeksi efektif yang
dapat mencegah timbulnya akumulasi
kegagalan komponen yang dipelihara
(dilihat dari data/sejarah pemeliharaan)
 EFFECTS ON MAINTENANCE
DEVELOPMENTS IN AVIATION : EFFECTS ON MAINTENANCE

• AIR TRANSPORT MARKET (DEMAND)

• AIR TRANSPORT CAPACITY (SUPPLY)
• ASPECTS OF BUSINESS ECONOMICS
• SAFETY IN AVIATION

DEVELOPMENTS IN TECHNOLOGIES : EFFECTS ON MAINTENANCE

• AIRFRAME
• AVIONICS
• PROPULSION
 EFFECT MAINTENANCE IN
AIRFRAME (STRUCTURE)
INCREASE REQUIREMENTS/PERFORMANCE
• TRANSPORT CAPACITY
• SPEED
• TAKE OFF WEIGHT
• WINGLOAD
DEVELOPMENT OF CONSTRUCTION AND DESIGN CONCEPTS
AVIATION SAFETY
HASIL INVESTIGASI KECELAKAAN
CONCORD 25 JULI 2000 PARIS (FI)
• 4.5 Kg sobekan kulit masuk ke port tangki BB
• Enine fire, engine 1 & 2 lost power(debris)
• Pilot cut off engine 2 after fire warning or
engine mati dengan sendirinya

Cause Possibilities :
• Poor Desain (jk pengelupasan ban hal yang
normal)
• Pre Flight Check (Scope Inspection/Skills)
• Post accident/incident (perbaikan desain
wajib, Airworthiness Directives/ADNotes)
 Effect avionics in maintenance
• Kenaikan speed dan penurunan flightime
• More and detailed inf : safety, traffic,
economics, noise constrains
• Kenaikan jumlah instrumen, indicator dan
controls
• Pengurangan cockpit crew
• Peningkatan wordload
 Perkembangan karakteristik elektronik
• 1940 electron tubes
• 1960 transistor
• 1970 I.C’s
• 1980 chips
Miniaturization and integration
• Kenaikan kapasitas dan memory
• Peningkatan reliability
• Penurunan power consumption and
volume
• Penurunan harga
 MAINTENANCE PHILOSOPHY
DEFINITION OF MAINTENANCE
ALL ACTIVITIES SUBJECTED TO TECHNICAL SYSTEMS TO BE KEPT IN
THE CONDITION (PREVENTIVE) OR TO BE BROUGHT IN THE
CONDITION (CORRECTIVE) WHICH IS REQUIRED TO FULFILL
SPECIFIED FUNCTIONS

MAINTENANCE AND NON-MAINTENANCE ACTIVITIES

NON-MAINTENANCE ACTIVITIES :
OPERASIONAL ACTIVITIES
MODIFICATION (OPERASIONAL, TECHNICAL)
MODIFICATION COST
ACTIVATED (INCREASING REPLACEMENT VALUE)
 MAINTENANCE PHILOSOPHY
DEFINITION OF MAINTENANCE
ALL ACTIVITIES SUBJECTED TO TECHNICAL SYSTEMS TO BE KEPT IN
THE CONDITION (PREVENTIVE) OR TO BE BROUGHT IN THE
CONDITION (CORRECTIVE) WHICH IS REQUIRED TO FULFILL
SPECIFIED FUNCTIONS

BASIC MAINTENANCE POLICIES

MAINTENANCE

PREVENTIVE
MAINTENANCE

PERIODIC CONDITION BASED CORRECTIVE

MAINTENANCE MAINTENANCE MAINTENANCE

“HARD TIME” “ON-CONDITION” “CONDITION MONITORING”

PREVENT ANTICIPATE REMEDY
 MAINTENANCE CONTROL
TUJUAN MAINTENANCE CONTROL :
• MENJAGA KELAIKAN TERBANG (AIRWORTHINESS) PESAWAT
• MENJAGA KETEPATAN JADWAL PENERBANGAN (ON TIME PERFORMANCE)
• MEMINIMUMKAN BIAYA PERAWATAN

PROSES KONTROL MAINTENANCE DIMULAI SEJAK PESAWAT DLM TAHAP

DESAIN, TAHAP PENGEMBANGAN DAN SERTIFIKASI PESAWAT BARU, DAN
BERLANJUT TERUS SAMPAI SAAT PESAWAT DIOPERASIKAN

OPERATOR KOMUNIKASI DINAS KELAIKAN UDARA

INTENSIF (REGULATOR)
(AIRLINES)

PABRIK PEMBUAT A/C

(MANUFACTURER)
 Cost development
• DOC (Direct Operation Cost) per seat :
•Larger aircraft
•Increase in speed
•Fuel consumption
• DOC breakdown :
•Boeing 747 cost in 1986 (was designed before oilcrises  jarak
jauh) : 44% Fuel, 24% Depr/Rent, 17 % Crew and 15% Total maint
•Boeing 767 cost in 1986 (was designed when oilprices were at a
peak  jarak menengah) : 33% Fuel, 27% depr./rent, 23% crew
dan 17% total maint
•Trends in unit operating cost :

DOC (%) 1978 1983 1988

Flight Oper.’s 30,3 25,9 32,9
Maintenance 22,2 17,8 22,8
Depreciation 14,3 12,8 15,5
Fuel and oil 33,2 43,5 28,8
 Depreciation (berhub. dgn. umur pesawat dan
harga pesawat)
• Extension depreciation period :
•1935 3-5 years 3000 FH
•1992 20-25 years 100000 FH
• Investment per seat :
•1935 30000 USD
•1985 220000 USD
• Result :
•Same ratio depreciation/DOC
•Decrease in DOC/seat
• Ageing aircraft : (1992 average age of Airliner 12 years)
•Corrotion control program
•Extended heavy maintenance visit
•Modification kits
•Re-engine program
 Cost of maintenance
• 50% decrease in cost of maintenance per
average seat mile

• Maintenance Pools : terjadi penurunan

dari HMV, engine, LD & APU serta
component
 Fuel Cost
• Use of energy by other means of
transfortasion :
Aircraft (%) Car (%) Train (%) TGV (%)

Avg speed 500 (100) 95 (19) 100 (20) 210 (42)

KJ/seat. km 1500 (100) 600 (40) 135 (9) 185 (12)

KJ/pax.km 2150 (100) 1800 (84) 350 (16) 265 (12)

 Market Development
• 1978 Deregulation in the USA :
Competition/ticket price, Hun &
Spoke’System & merging /bankruptcy of
airlines
• Today Europe : price and capacity
agreements & rates twice as high as in US
• 1993 deregulation in Uerope : new
routesystem. Limited number of carriers
and (hub-) airports and competition /
prices
Development of Hub and Spoke
System
• All traffic is directed via the hub
• Traffic flows are concentrated larger
aircraft with lower DOC per seat kilometer
• Higher aircraft utilization
• Interdependent connections
• Overnights at outstations
• Shorter Turnaround time (Dispatch
reliability & Delay recovery)
 Airframe (Structure)
• Increased requirements / Performance
•Transportcapacity
•Speed
•Take of weight
•Wingload
Development of construction and design concepts
1930 Wooden frame and linen
teel tube and linen
1930-1950 Lightmetal (DC-3 ± 11000 ex)
Wing repture (fatique)
Safe life limit / HT (Hard Time)
1956 FAR 25 & Fail safe (multiple load path & inspection / on condition)
1974 JAR & Bounded construction (Fokker Bond Tester)
1978 Further development fail safe
Calculation insp. Interval on basis of residual life after detected crack
 Airframe (Structure)
• 1978 DAMAGE Tolerance Concept (fracture mechanics)
• Slow crackgrowth
• Residual Strength
• Inspection interval
• 1980 Composites
• Today ± 5 % sec parts
• Future : primary parts (tail, vertical stabilizers)
• Detection of interval damage

1985Ageing Aircraft
Accidents
Combination fatigue and corrosion
Discrepancy old aircraft (fail safe) and modern philosophies (damage
tolerance)
extra inspections
Modification programs
•
AVIONICS
Increased requirements
•Increased speed and decreased flighttime
•More and detailed information : safety, traffic, economics & noise
constraints
•Increase in number of : instruments, indicators and controls
•Reduction cockpit crew
•Result : increased workload

• Development and characteristic of electronics

•1940 electron tubes
•1960 transistors
•1970 I.C.’s
•1980 chips

• Miniturization and integration :

• increase calculating capacity and memory
•Increase reliability
•Decrease power consumption and volume
•Decrease of expenses
 Development avionics
• FMS Flight Management System : flight planning,
navigation, performance calculation, fuel management &
flight execution
• TCS Thrust Control System
• FCS Flight Control System
• AFCAS Automatics Flight Control Augmentation
System : flight characteristics & stability
• EFIS Electronics Flight Instrument System : CRT
(cathode ray tube) or MFDS (multi function display system)
• FWCS Flight warning computer system : workload
depending
• FADECFull authority digital engine control : full
automatics engine control
• Exchange of digital data (databus)
• Interchangebility of components
 Development of maintenance
• Maintenance characteristics
•No effect on airworthiness
•Effect on flight operations
•Ensure mechanical integrity
•Function performance (fuel consumption)
•Expensive maintenance (spare parts)
•On condition (limited HT-items)

• Modularization : interchangeability , turnaround stock/ spare modules &

diagnostics

• Boroscope : on aircraft inspection

• AID system

• Oil analysis

• Performance and health monitoring : gaspath analysis