Aircraft Phase in series: How to set up modification control data?
In the previous blog, we discussed the setup of maintenance program data. In this aircraft phase in the blog, we will discuss modification control setup and initialization of maintenance events in an M&E/MRO system.
Aircraft modification management is an essential aspect of aircraft maintenance and operations. M&E/MRO provides a comprehensive solution for tracking and managing changes made to an aircraft's configuration or maintenance status. The modification control module in MRO systems allows for the efficient management of modification requests, ensuring compliance with regulatory requirements and safety standards. The system keeps track of all necessary documentation and updates the aircraft's maintenance status and configuration records after the modification is completed. In summary, MRO systems provide an efficient and effective way to manage aircraft modifications and ensure compliance with regulatory requirements. Provided that data is managed in the right way.
Preparation tasks
To properly set up modification control in a Maintenance, Repair, and Overhaul (MRO) system, it is important to start with obtaining complete and accurate data on the aircraft or equipment, the modifications performed, and the personnel performing the modifications. It is also important to have clear, complete, and up-to-date documentation and procedures for performing modifications.
There are a couple of preparation tasks required to properly set up modification control in an M&E/MRO system. This starts with (digitally) obtaining the following items:
The documents and publications specify regulations that the aircraft operator has to comply with. As well as documentation on aircraft and component modifications and configuration changes with clear work instructions to be performed in case of repetitive items.
If this is already set up in the systems it will be a matter of (digitally) verifying that it was set up correctly and that it is complete and able to accommodate future aircraft inductions.
Historical accomplishment records status and/or next due records from OEM, previous operator, or authority.
What data sets are required for modification control setup?
Similar the maintenance program tasks setup, there are some similarities. There are however some big differences as well. The similarities are the setup of effectivity/applicability of the modifications/documents and the maintenance time requirements if present. We will therefore not elaborate on these topics again. For that refer to: “Aircraft Phase-In Series: How To Set Up Maintenance Program Data? — EXSYN”
To set up a modification control module in an MRO/M&E system, the following data is typically needed:
Information on the specific aircraft or equipment that the MRO system will track, including make, model, and serial number.
Details on the specific modifications that will be tracked, such as the type of modification, the part or component that is being modified, and the date of the modification.
Information on the person who will be responsible for performing the modifications, including their qualifications, certifications, and training records.
Procedures and instructions for performing the modifications, including any required approvals or certifications.
Maintenance schedules and inspection intervals for the equipment or aircraft, to ensure that modifications are tracked and incorporated into the maintenance plan.
In addition to the above-mentioned items, there is one topic that requires special attention. These are the relationships between documents/modifications. Also more commonly referred to as the sign-off tree or reference/relationship structure. This particular topic makes the implementation of modification control cumbersome. The sign-off process may involve a complex network of relationships, regulations, and procedures that must be followed to ensure the safety and compliance of the modifications. The large number of different types of modifications, each with its own unique requirements, can also add to the complexity of the sign-off structure.
Furthermore, the need to manage and track the progress of multiple modifications simultaneously, and the importance of ensuring that modifications are properly documented and stored, can add to the complexity of the implementation of the sign-off structure.
Data validation and implementation tools can help ease this process, especially when an aircraft phase-in is a recurring theme within the company.
Similar to maintenance tasks from the MPD the dynamic datasets are also required in order to initialize the documents and modifications to set the correct status. These consist of the following:
Mod/Document next due information (Date, hours, cycles)
Having the above figures in conjunction with up-to-date aircraft utilization figures will be sufficient to initialize the documents in order to derive the to-go values on the maintenance forecast.
Modification last performed/history or status (Date, hours cycles)
To store the status of the document, statuses can for example be:
§ Ex-Factory
§ Closed
§ Open/Repetitive
§ Superseded
o Used for historical purposes and to calculate the next due based on the time requirement that is set up in the maintenance program.
The process step by step
After the creation of the document/mod definitions in the system, we can go ahead and phase in the dynamic aircraft data. The LD/ND and document/mod status. Similar checks for the MPD data phase are followed being:
Check document existence in the system, if not asses and create it, if required.
Can the LD/ND & status be accommodated on the document itself or should it be placed on a lower document in the structure?
s the document in question applicable to accommodate the LD/ND & status?
Are the dimensions provided in the source data compatible with the setup in the OEM system? If not assess discrepancies and adjust accordingly.
Depending on the source data availability of LD/ND & status the maintenance event can be initialized in the system. Preferably based on the last done when present, the system will determine the next due based on the system maintenance time requirements. Alternatively, the next due values as provided can be used in certain cases.
This data process can largely be automated by having the right tools and infrastructure in place.
How to avoid common pitfalls
Common pitfalls when setting up a modification control module in an MRO/M&E system include:
Insufficient data collection: If the data collected on the aircraft or equipment, the modifications performed, and the personnel performing the modifications is incomplete or inaccurate, it can lead to errors and inconsistencies in the data recorded for the modifications. Collect a full set of data to avoid gaps in the system.
Data entry errors: If there are errors in the data entry process, it can lead to inaccuracies in the information recorded for the modifications. Standardize the data entry process as much as possible.
Lack of data validation: If there is no robust system in place to validate and verify the data recorded for modifications, it can lead to errors and inconsistencies in the data. Ensure to have a data validation process is in place to complete the phase-in process successfully.
Data incompatibility: If the source data recorded for the modifications is not compatible with the OEM system it can lead to data inconsistencies and errors. A lack of advanced data tools is usually the cause of this pitfall. Ensure data processing tools are in place to overcome this issue.
Setting up a document sign-off structure that is too complex or unpractical. Or having a lack of sign-off structures which causes inconsistencies throughout the system.
What is next?
In the next blog of the aircraft phase-in series, we will address smaller additional topics related to aircraft phase-in and all related topics that need to be considered for a successful aircraft phase into a new system.
Aircraft phase in series:
✓ Modifications & Documents
Extras
How EXSYN can help
EXSYN's team of aircraft data and aviation experts utilize a proven framework and methodology that has been applied to millions of terabytes of master data and includes:
EXSYN’s NEXUS solution to reduce project costs and duration
EXSYN’s data warehouse to accelerate your phase-ins
Set up the best strategy for your situation based on years of experience with any aircraft type
Migration of both structured and unstructured data
ISO 27001 data security certified migration approach