BACHELOR THESIS IN AERONAUTICAL ENGINEERING 15 CREDITS, BASIC LEVEL 300

School of Innovation, Design and Engineering

Establishment of a Technical Procedure

Manual at West Air Sweden AB

Photo: Charles Polidano – Touch The Skies, Airliners.net

Author: Dellshad Kassal

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ABSTRACT

This thesis describes the establishment and development of a Technical Procedure Manual

for the cargo airline West Air Sweden AB. The purpose with a TPM is to ease the workload for

the maintenance organization and to minimize the occurrence of human errors in the

maintenance organization system software. Until today West Air Sweden has had an absence

of documented procedures of the administrative chores within Part-M and Technical

Records. West Air Sweden desires a manual consisting of clear directives and working

procedures in the maintenance computer system. The computer system is new to West Air

Sweden, since the maintenance organization took a large step forward by switching

maintenance system software from the; Integrated Aviation Software (IAS) to; Rusada

Envision (RAL). This conversion of maintenance system software has increased the necessity

of a TPM within the West Air Sweden maintenance organization. It was necessary to gain

self-experience within the system in order to chart out the structure and foundation of a TPM

suitable to West Air Sweden. Interviews and meetings with other modules within the

company such as Stores, Logistics, Engineering, IT, Economy and Flight Operations was held

to predict and complete the outlook of a reasonable TPM. The predicted outline of the TPM

was fulfilled and the result was satisfactory in accordance with the requirements of West Air

Sweden. The significant outcome of the TPM is the structure; which is a valuable key along

with explanatory and pedagogical wording. It was major beneficial to obtain insight and

experience within the organization. The development of the TPM has been a long-term

process and has been revised several times. Small and major adjustments have been

performed during the development and accomplishment of the TPM. The aim is to constantly

revise the manual in order to keep the TPM as effective as possible. Employees of West Air

Sweden Tech Records are currently working in the system with guidelines from the TPM. A

hard copy is available at every desk of the Part-M office and is also electronically accessible

on the company’s intranet. The work was performed at West Air Sweden’s head office in

Gothenburg. The TPM is considered as a confidential document and therefore it will not be

published.

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SAMMANFATTNING

Denna avhandling beskriver etableringen och utvecklingen av en teknisk procedur manual

för flygbolaget West Air Sweden AB. Syftet med en TPM är att minska arbetsbördan för

underhålls organisationen samt minimera förekomsten av mänskliga fel i

underhållsorganisationens systemprogramvaran. West Air Sweden har haft en avsaknad av

dokumenterade rutiner för de administrativa sysslorna inom Part-M och Technical Records.

West Air Sweden är i behov av en handbok beståendes av tydliga direktiv, procedurer och

arbetssätt i förhållande till underhållssystemet. Datorsystemet är nytt för West Air Sweden

då underhållsorganisationen tog ett stort steg framåt genom att uppgradera sin mjukvara

från Integrated Aviation Software (IAS) till, Rusada Envision (RAL). Detta stora steg framåt

för underhållsystemet har ökat behovet av en TPM inom West Air Swedens

underhållsorganisation. Det var nödvändigt att skaffa egen erfarenhet i systemet för att

kartlägga strukturen och grunden för en TPM lämplig för West Air Sweden. Intervjuer,

möten, mail - och muntliga korrespondenser med andra avdelningar inom företaget som

Stores, Logistik, Teknik, IT, Ekonomi och Flight Operations ökade min klarhet berörande

struktur och innehåll av en praktisk TPM. De mål som sattes uppnåddes med goda resultat

och var tillfredsställande i enlighet med West Air Swedens behov. Det betydande resultatet

av TPM är strukturen, det är en värdefull egenskap kombinerat med förklarande och

pedagogiska formuleringar. Personalen på West Air Sweden Tech Records arbetar för

närvarande i systemet med riktlinjer från TPM. En papperskopia finns på varje skrivbord på

Part-M kontoret och är även tillgänglig i elektronisk form på företagets intranät. Arbetet

utfördes på West Air Swedens huvudkontor i Göteborg. Den Tekniska Procedur Manual

betraktas som ett konfidentiellt dokument och kommer därför inta att publiceras.

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Date: 04 April 2013

Carried out at: West Air Sweden AB

Advisor at MDH: Tommy Nygren

Advisor at West Air Sweden: Leif Åström

Examinator: Mirko Senkovski Karlsson

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PREFACE

This thesis was compiled to consummate the last segment of the Bachelor degree in

Aeronautical Engineering at Mälardalens University in Västerås.

The work was performed upon the request of West Air Sweden AB’s head office in

Gothenburg. There was an absence of an official TPM within the maintenance organization at

West Air Sweden AB. This proposal was brought forward by me to consolidate the existing

CAME with clear directives and procedures. This handbook will be used be the Part M

organization at WAS.

I was a student of the Flight Engineering Program at Mälardalens University in Västerås.

My alignments during the education were involved in flight mechanics, avionics maintenance

technology, aircraft structures and power plant technology. My aim was to perform a thesis at

a company to practice my skills in the real world and to understand the organization of an

airline.

Gothenburg, April 2013

Dellshad Kassal

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ABBREVIATIONS

TPM Technical Procedure Manual

BAE British Aerospace

ATP Advance Turbo Prop

CRJ Canadian Regional Jet

ATR Avions de Transport Regional

NCAA National Civil Aviation Authority

CAME Continuing Airworthiness Management Exposition

WAS West Air Sweden AB

MEL Minimum Equipment List

HIL Hold Item List

AMP Aircraft Maintenance Program

MOE Maintenance Organization Exposition

EM Engineering Manager

MSC Maintenance System Coordinator

TC Task Card

SB Service Bulletin

NRC Non Routine Cards

MPD Maintenance Planning Document

MRB Maintenance Review Board

AD Airworthiness Directive

AMM Aircraft Maintenance Manual

CAME Continuing Airworthiness Management Exposition

CAMO Continuing Airworthiness Management Organization

CMM Component Maintenance Manual

CRS Certificate of Release to Service

EASA European Aviation Safety Agency

MDH Mälardalens Högskola

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CONTENTS

Chapter 1 INTRODUCTION

1

1.1 Background ..........................................................................................................1

1.2 Objective ..............................................................................................................1

1.3 Problem formulation .......................................................................................... 2

1.4 Limitations .......................................................................................................... 2

Chapter 2 METHOD(S) 3

2.1 General ................................................................................................................ 3

2.2 Experience .......................................................................................................... 3

2.3 TPM Framework ................................................................................................. 3

2.4 Aircraft Technical Log ......................................................................................... 4

2.5 Work Order ......................................................................................................... 4

2.6 Serialized Components ....................................................................................... 4

Chapter 3 RESULTS 5

3.1 Picture; Scheme from the TPM ........................................................................... 6

3.2 Picture; Workflow from the TPM ....................................................................... 7

Chapter 4 DISCUSSION 9

Chapter 5 CONCLUSIONS 10

Chapter 6 RECOMMENDATIONS 11

Chapter 7 ACKNOWLEDGEMENTS 12

Chapter 8 REFERENCES 13

Chapter 9 APPENDIX: TECHNICAL PROCEDURE MANUAL 14

1

Chapter 1

INTRODUCTION

1.1 Background

West Air Sweden AB is a carrier where efficiency and cost reduction are important

aspects of the market. To maintain these aspects it is very important to have clear directives

of the procedures within an organization. It is a great advantage to have a handbook/manual

which describes the practices within the department.

The intention of having a TPM is to ease the workload of the Part-M department. The manual

shall assist the user while performing procedures in the maintenance system software. With a

functional and user friendly manual the Part-M department will be able to minimize their

workload and focus on assignments that are not maintenance system software associated. It

will also help to introduce the system software to new users during an educational period.

The TPM will be a handbook that will be frequently used by the Part-M management.

WAS is a cargo airline with the headquarters based in Gothenburg, Sweden. It operates

scheduled and ad hoc freight charter services for FedEx, DHL, TNT and UPS. It is also

contracted to operate mail flight on behalf of the Swedish and Norwegian post office. The

cargo airline was established in 1955 as LBF-Eda Varken operating air taxi flights. The name

was changed to Abal Air in 1982 and to West Air Sweden in 1992, in conjunction with the new

airline Time Air Sweden. It then converted to cargo airline in May 1997. During 2006 West

Air gained a contract with the Norwegian Postal service. In October 2008 it was announced

that the airline would merge with the British cargo airline; Atlantic Airline to form the new

airline West Atlantic. WAS has a fleet that consists of BAe ATP-F, Bombardier CRJ-200 PF,

ATR72, Boeing 737-300 and Lockheed Electra L188.

1.2 Objective

The main objective of this development is to minimize the occurrence of human factor

errors. This manual will become as important as any other aircraft manual. Corrupt inputs in

the maintenance system carried out by a user could danger the airworthiness of an aircraft

and also affect the maintenance cost.

That is why it is beneficial to create a manual that can be used frequently by personnel within

the technical department.The manual should also aid new employees during their

educational period. The TPM will be defined as a supplement to the CAME.

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1.3 Problem formulation

The development and outline of the TPM was resolved by troubleshooting with following

questions;

What structure must the manual have?

What should be the content of this manual?

How to minimize human errors with help of the usage of this manual.

How elaborate should the manual become?

To avoid excessive information.

What resources are available?

What is the timeframe?

Will this manual become a useful complementary to the CAME?

1.4 Limitations

The major challenge was to establish completely new procedures since the company

upgraded the maintenance system software. It was necessary to look over the old procedures

and try to gain knowledge from those procedures.

Since my recent occupation was a student at the university It was challenging to get an

sound knowledge and understanding of the different segment in an airline company in such a

short period of time. I had to understand the environment in the old computer system which

user license was soon to expire and try to reform procedures and implement them into the

new system.

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Chapter 2

METHOD(S)

It was primarily agreed between me and Leif Åström to create a TPM with a 10 weeks’

timeframe. After realizing that it was necessary for me to understand and to work in this

environment for a period of time, it was decided to offer me a permanent employment. The

TPM has been developed adjacent to my everyday routines at work.

Brief introduction of the different segments and structure is necessary to narrow down the

content of the manual and summarize the different segments in the manual.

2.1 General

The technical department is controlled by several mandatory manuals and documents. The

most important manual that controls and summarizes the work at a technical department is

the CAME. The CAME is a mandatory and an obligation for each airline to possess one. The

CAME is monitored and authorized by the NCAA. All major and minor changes or

amendments shall and must be reported to the NCAA. This is a very time consuming process.

A TPM in this aspect is not a mandatory manual and it can therefore be updated and revised

without the confirmation and authorization by the NCAA. This manual will also improve the

understanding and communication between different segments within in the airline

company.

2.2 Experience

Self-experience and interviews with colleagues in the UK and in Sweden have been beneficial

tools in order to chart out the procedures at Part-M Technical Records. A Group of Key Users

was appointed in order to discuss new procedures, obstacles, system bugs etc. I was fortunate

to be appointed as one of the members of this group. The continuous gatherings with this

group gave me a clearer view of the daily issues that the other departments suffered in the

system. It simplified how to approach the issues that appeared during the development of the

TPM.

2.3 TPM Framework

To narrow the information it is was preferred to focus on the basic and most frequent

processes in the maintenance system software within the Technical Records module. The

procedures in the TPM are provided with basic introduction, explanation, examples and

flowcharts. Hyperlinks are embedded into the electronic manual in order to easily navigate

between the different sections.

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2.4 Aircraft Technical Log

All aircraft has an individual log book. The logbook is embedded with information such as;

aircraft type, registration, date, place & time for take-off/landings, total aircraft

time/landings, details of malfunctions, quantity of fuel/oil, modifications, reparations and

maintenance performed since the aircraft was new. It’s an aircraft document which is kept on

board, that permits to record the defects and malfunctions during an aircraft operation and

for recording detail of all maintenance carried out on the aircraft between scheduled

maintenance events. In addition, it is used for recording flight safety and maintenance

information that the crew needs to acknowledge. The WAS Flight Log system is a combined

flight/technical log. The flight log presents itself under the form of a counterfoil book,

numbered, and composed of pages with different colours. Each aircraft has its own Flight Log

book with numbered pages. All flight log sequences are to be implemented in to the

maintenance system software and the hardcopies stored/archived in a fire safe compartment.

2.5 Work Order

The maintenance system software collects checks, inspections and component changes in to a

due list which can be generated by a user in the maintenance system software. The

due/forecast list has information of estimated and actual – due date/time. It also provides

information if the work is planned and the work order sequence, base etc. The Planning

Manager compiles and gathers tasks related to each inspection and checks in a work order.

The work order is sent out to the line or base station where the aircraft is located; an engineer

will then perform the forecasted maintenance tasks and send the completed work documents

to the Part-M Technical Records. TR will then control and check signatures, stamps date and

time of the performed tasks. If an ordered task hasn’t been performed in time and has been

deferred in accordance with different category and time frame available in the MEL, it will be

transferred to a new work order and will be performed later on. The work orders will be

updated in RAL and hard copies stored in the archive compartment.

2.6 Serialized Components

Component changes occur frequently during line or base maintenance. Only components that

have a serial number are tracked and updated in the Technical Records segment of RAL.

Tools, equipment non serialized components are also registered in RAL but it isn’t relevant

information to TR. Some components have one, two or more maintenance requirements

tasks with various time limits. It is vital to set these values in RAL correctly in comparison to

the certification documents of the unit. The certification document of the unit is embedded

with information such as; time since new, time since overhaul, modifications etc. TR surveys

and controls the information and makes sure that the component that has been installed on

the aircraft is qualified to service and sets the tracking values in RAL.

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Chapter 3

RESULTS

The result became a manual with instructions which guides the user from the initial step to

the final step. The manual currently consist of 10 chapters; each with various subchapters. It

is intended to keep the manual live and up to date. Revisions could extend, change or delete

the contents. The manual instructs the user with explanatory wording and illustrations from

the system to ease the workflow. Each chapter starts with an introduction to prepare the user

upon further instructions.

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3.1 Picture; Scheme from the TPM

7

3.2 Picture; Workflow from the TPM

8

Chapter 1 is an introduction chapter which introduces the user all the different segments

within the technical records part of the maintenance system software. Chapter 2 provides the

user information and procedures of various setups that needs to be properly prepared before

starting to work in the system. It is not necessary to perform the setup instructions since the

system already has been setup. Still it is beneficial for the user to understand how the system

has been setup in order to solve issues that are system related. The actual procedures of the

TPM will start at Chapter 3 and end at Chapter 10. The TPM is a confidential document

which cannot be published upon the request of West Air Sweden.

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Chapter 4

DISCUSSION

Several obstacles, issues, questions aroused during the progress of the development of the

manual. All were often solved with the consultation of West Air Sweden’s advisor; Leif

Åström.

West Air Sweden had no previous experience of a student’s presence in the company.

This was a new experience for both me and Leif Åström. It was difficult trying to dispose the

outline of the TPM since the system was new to all of the personnel in the organization. I was

immediately engaged to understand the system and to load the system with necessary

information. Bridge checking and parallel update of the maintenance program between the

old and new system was performed on a daily basis until the company went “live” and turned

off the old system. The new system had to be updated as accurate as possible to avoid issues

with false or corrupt data which could have severed consequences to the maintenance

program. The majority of the time was to work in the system and participate in several

projects that were related to the system. I did my best to keep myself close to the project

manager; Leif Åström. Leif did always make sure that I was briefed with appropriate

information and never did he leave any questions unanswered. His knowledge and

experience was a major contribution to this development of a TPM.

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Chapter 5

CONCLUSIONS

The purpose of this project thesis has been fulfilled. The manual is live and is disposed by

users within the Part M organization. The company will have major benefits with a procedure

manual. It is comforting to have a manual when introducing the system to a new user or

solving question or issues during a process in the system.

The outline of the TPM was satisfactory and can easily merge with other manuals within

the company. The issues and questions that aroused during the progress, was solved

methodically and the solutions have birth to additional question. This was only profitable as

new and untried segments in system were explored. This was the thread throughout the

progress. Questions gave birth to other questions and the solutions provided us with ideas

and new procedures were created.

It was fortunate to gain this experience; to perform a thesis project at a company and to

be given the possibility of contributing and applying my knowledge’s from the university.

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Chapter 6

RECOMMENDATIONS

The manuals outline is created with the intentions to simplify the revision process. The

continued use of hyperlinks is recommended to have a convenient manual. Flowcharts and

examples are two very essential keys to help the user understanding the different steps. The

aim is keep the manual pedagogical and user friendly

With consideration that WAS had an absence of documented procedures within the Part

M organization it is recommended to keep and even supplement this manual with other

sections. This manual could be the foundation of future documented procedures within the

Part M organization.

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Chapter 7

ACKNOWLEDGEMENTS

Thank you

This thesis has been an exciting and an educational experience. I would like to give my

appreciations to EM; Leif Åström, MSC; Aleksandra Rashid and Tommy Nygren for their

major commitment, support and assist.

Gothenburg, April 2013

Dellshad Kassal

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Chapter 8

REFERENCES

Literatures

1. Kinnison, Harry A: Aviation maintenance management, McGraw Hill, New York,

2004, ISBN 0-07-142251-X.

2. Nygren, Tommy: Flygplansdrift och underhåll I MG1250, MDH, Västerås 2006

3. Nygren, Tommy: Flygplansdrift och underhåll II MFL016, MDH, Västerås 2007

4. Drews, Robert: CAME West Air Sweden, Göteborg 2012

5. Drews, Robert: AMP CRJ200 West Air Sweden, Göteborg 2011

6. Drews, Robert: AMP ATP West Air Sweden, Göteborg 2011

7. Ström, Torbjörn: MOE West Air Sweden, Göteborg 2010

Consultations

1. Åström Leif, Engineering Manager, West Air Sweden, Göteborg 2012

2. Rashid Aleksandra, Maintenance System Coordinator ,West Air Sweden,

Göteborg 2012

Internet

1. http://www.transportstyrelsen.se/, 2011

2. https://www.easa.europa.eu/, 2003-2013

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Chapter 9

APPENDIX: TECHNICAL PROCEDURE MANUAL

CONFEDENTIAL