To : Mr Mohd Nasir Bin Ismail

Head of Engineering Department,

APR-MRO Services (M) Sdn Bhd.

From : Mr Mohd Rafaee Bin Manja

License Aircraft Maintenance Engineer (A&C),

APR-MRO Services (M) Sdn Bhd.

Subject : Boeing 747-400 ( 9M-XYZ ) No. 2 Engine Removal and Installation

Date : 11/06/2010

Dist : QA Manager
Maintenance Planner Department
Human Resources Department
FOREWORD

Dear Sir,

According to the Pilot Report (PIREP) on June 01, 2010, no.2 engine was flame
out in-flight during decent at low altitude. An in-flight re-ignition was failed and
emergency landing declared. Aircraft has landed safely with the full alert from
Fire and Rescue Department (BOMBA) and Malaysia Airport Berhad (MAB).
Inspection carried out on the no.2 engine revealed damage of the compressor
fan blade and cowl due to bird strike as in figure 1(Appendix). Further
inspection using the Baroscopic test in the internal engine found the early stages
until the intermediate stages of compressor blade bend and damage more than
permissible limit. As refer from the Maintenance Manual, the engine has to be
removed and sent for overhaul.

A new

The purpose of this report was to provides an overview of the process and
present my evaluation.

Indicated Damage Possible Cause

1. Fan blade bend and damage.
2. Early stage – intermediate Bird strike at low altitude
compressor blade stages
bend or cracks.
SUMMARY

Dear Sir,

The engine removal and installation has been carried out by a group of
maintenance teams under my supervision. During the process, there are some
problems occurred that contribute to the delayed of works and consume time
more than it required to be done. Insufficient of man power required for the
works to be finish at the exact time. The team has to work extra time and this
lead to fatigue and loss of concentration. Refer figure 2 (Appendix)

In addition to this, some mechanics and technicians have lack of knowledge,

experience and exposure to this task that prevent them to works fast and
efficient.

In the concern of safety, one member of the team accidently injured his feet. It
happen after one engine hoist beam on the left hand side drop down and
smashed straight onto his foot. Luckily he was on his safety shoes. He wasn’t at
the right position when handling the task.

Common general and safety precaution has been observed before the process to
maintain the continuity of the works without any delayed. Here are some of the
precaution and procedures:-

• The weight, balance, and the airplane center of gravity (C.G.) have been
determined and make sure it remains within the safe limits.
• Ground the airplane to an approved grounding lug.
• Hydraulic system No. 2 has been depressurized as applicable for the
engine being removed
• Electrical power been removed before disconnect the fuel, the hydraulic
and the electrical lines.
• Aircraft battery was in ‘off’ position.

• Tools and bootstrap equipment used are serviceable.

• All attachable lines/hose (electrical, hydraulic and fuel) are disconnected

properly and blank as required.

During the operation, there are some hazard that might be affected the
personnel and aircraft. Some could lead to the injuries and maybe fatal injuries
to the personnel. I listed some hazardous things that happen during the process;

• Some crew of maintenance keep walking below the engine during process
of engine removal

• There are also, some of the crew that were not wearing proper protective
equipment (PPE)
 • The proper tools not used for the right work that could lead in damage the
tools or part.

DETAILS OF DISCUSSION

Dear Sir,

In this detail of discussion, I want to recommend some proposal to overcome the

problem facing during the process. From my point of observation, for the
insufficient man power, there should be an extra 2 man for the job that means all
6 men in the team. Estimate man-hours for the job should be 6 men multiply by
10 hours of job, was about 60 man-hours. This will make sure the work done in
the time given without any delayed. Refer Figure 2.

For the some mechanics and technician with lacks of experience and exposure,
there should be a course session held for the maintenance crew. The purpose
was to inform and educate the crew in basic area of removal/installation of the
engines. Such session would eliminate the problems involving the inexperienced
crews in our department. This will result in the fast and efficient work that affects
the good company reputation in engineering department.

I also recommend that, all the crews should be educating about the proper
safety attire and thus reducing such incident that might cause their life. A safety
classes or sessions conducted for all engineering personnel will straightly
focusing the important of safety in work environment. I volunteer myself as
instructor if the need is to be met.
APPENDIXES

Figure 1: Fan blade bent by the bird strike impact.

Figure 2

Establish Man-hours Job Done Effect

6 man x 10 hour = 60 4 man x 10 hour = 40 Lack of 2 man power

Man-hours Man-hours contributes to delay.