777-200LR Flight Test Journal: Archives
18 November 2005
For the life of your airplane
Kurt Wipior, business and process analysis manager, Maintenance Engineering, Commercial Aviation Services CAS
Barbara Ecola, non-recurring, new airplane program manager, Maintenance Engineering, CAS
Neil Goedhard, CAS representative on the 777-200LR Program Leadership Team, Maintenance Engineering, CAS
Boeing's relationship with its customers doesn't stop with the delivery of an airplane. In fact, you might say that's where it begins. Just like when we buy a car, we depend on the owner's manual -- and often the dealership -- to help keep our vehicle in top shape. So it is with a commercial jetliner, only on a much bigger scale because of the integration and complexity of the aircraft. Boeing provides technical documentation in a suite of manuals to help customers keep their airplanes operating safely and efficiently.
Maintenance Engineering in Customer Aviation Services (CAS) develops and produces maintenance and repair data to support the lifecycle of Boeing aircraft. It's a lot of information. The documents include:
- Aircraft Maintenance Manual
- Fault Isolation Manual
- Structural Repair Manual
- Component Maintenance Manual
- Illustrated Parts Catalog, and
- Wiring Diagram Manual
We also develop Ground Support Equipment tooling and scheduled maintenance programs. All of these manuals work together to provide the maintenance and repair data the operators need and are customized to the aircraft, operator, or model level.
These documents are included in what the industry calls Instructions for Continued Airworthiness (ICAs). ICAs are a required part of the certification program. As part of the BCA Delegated Compliance Organization effort, Boeing and the FAA have further clarified the definition of ICAs and Boeing's responsibility for showing compliance.
The Aircraft Maintenance Manual (AMM) is widely used in the Boeing Flight Test program and by the airline and its operators to perform line maintenance. The manual has two parts: book one and book two. Each book is broken down into chapters that represent the major mechanical and avionics and electrical systems on the aircraft. For example, chapter nine is towing and taxing, chapter 24 is electrical power, and the engines are covered in chapters 70-80.
Book one is the system description section and contains description and operation information for each major aircraft system. It is mainly used as a training aid for airline mechanics and planners. Book two is maintenance practices and contains all the procedures that a mechanic can perform in the line-maintenance environment. If an issue comes up on an airplane, the Fault Isolation Manual is used to troubleshoot and isolate the problem. The mechanics then replace and test components using the AMM. They look for parts in the Illustrated Parts Catalog and the wiring information they need in the Wiring Diagram Manual or System Schematics Manual.
Boeing provides critical, technical documentation in a suite of manuals to help customers keep their airplanes operating safely and efficiently.
Components are taken to the bench to be overhauled using the Component Maintenance Manual. If the airplane has sustained structural damage, the Structural Repair Manual contains allowable damage limits and procedures to fix the structure. You can see how these documents fit together to provide the maintenance and repair information the customer needs. Many of the documents undergo a verification and validation process to ensure they are complete, accurate and efficient.
In the spirit of working together on the 777 program a few years ago, we forged a great relationship between Maintenance Engineering and Flight Test. For new airplane programs, Maintenance Engineering provides its documents to support the aircraft's first flight, and the Flight Test personnel use the manuals as the customer would. Most of the manuals are published one to three times per year to incorporate data for new airplanes, engineering changes and customer requests. There also is a temporary revision process to issue safety data immediately. The manual revisions continue even after the airplane is out of production to keep including safety information.
As you can see, it's a long-term commitment. Maintenance Engineering and Commercial Aviation Services as a whole are in business to support Boeing's customers and keep their aircraft flying safely and economically throughout the aircraft's life. So from our vantage point, the 777-200LR program is just beginning its journey.