An overview of trends in aircraft maintenance program development:

Past, present, and future

A. Ahmadi, P. Sderholm, & U. Kumar
Lule University of Technology, Lule, Sweden

ABSTRACT: The purpose of this paper is to describe the trends in aircraft maintenance program development during the last 50 years, including the reasons for the aircraft industry to change its view of maintenance. The major milestones and fundamental reasons for such development are also discussed and illustrated
in relation to a flow diagram, which shows the logical and chronological order of the trends. Finally, the paper describes some possibilities and challenges as regards applying Information & Communication Technology (ICT) within the emerging approach of e-Maintenance in order to enhance the surveillance of aircraft
maintenance program performance.
1 INTRODUCTION
Before 1950, technical items were mostly simple,
which made them reliable and easy to maintain. The
maintenance concept were mostly based on the belief that failures were mostly caused by wear and
tear and the common maintenance strategy was Corrective Maintenance. By the late 1950s, the second
generation of maintenance started, with the introduction of more complex items, mostly due to lack of
labor and high performance requirements. With increasing complexity and criticality of items, the importance of a preventive maintenance program for
failure management increased. However, one of todays major challenges remains how to determine
the success of such maintenance programs.
The first part of this paper provides some background to the airlines problems during the 1960s,
with a short discussion on efforts leading to the publication of the first systematic review of aircraft systems, known as the MSG-1 and the MSG-2 methodologies. Next, the efforts of United Airlines, which
led to the Reliability-Centered Maintenance (RCM)
methodology are described, outlining how the preventive maintenance concept was influenced by system level thinking. The effect of RCM on the MSG
methodology, which resulted in the publication of
MSG-3, will also be described. All these developments and trends are discussed with the help of a
flow diagram, which illustrates the developments in
a logical and chronological order.
Finally, the possibilities and challenges related to
e-Maintenance for the surveillance of an aircraft

maintenance programs performance is discussed as

a future development.
2 EARLY MAINTENANCE STRATEGIES AND
RELATED PROBLEMS
Prior to World War II, maintenance was a skill
learned through experience and rarely based on scientific theories. The maintenance requirements were
determined by a few experienced technicians with
assistance from the Original Equipment Manufacturer (OEM). The items were quite simple, which
made them reliable and easy to maintain. In those
days, the common maintenance strategy was Corrective Maintenance, based on the belief that the failures were mostly caused by wear and tear. Hence,
the maintenance was applied in order to restore the
functional capability of failed items. This was a reactive approach to maintenance since the action was
done after the failure had occurred. This period of
maintenance is known as Pre World War II. (Moubray, 1997)
By the late 1950s, or Post World War II, the second generation of maintenance started to evolve. Industry became more competitive and a lack of manpower, improved design standards, and new
performance requirements led to increasingly complex and mechanized items. Therefore, the maintenance of items required more downtime and resources. Hence, maintenance costs were high and
availability became another problem. These changes,
together with penalties associated with loss of production, forced industry to consider how to prevent

the item from failing by applying Preventive Maintenance instead of relying on Corrective Maintenance.
In an effort to reduce the number of failures, industry concluded that, based on the accepted wear
and tear model of failure, every item had a fixed
age at which either complete overhaul or discard
was necessary to ensure safety and operating reliability.
Based on these concepts, there was a widespread
belief that all failures could be prevented by agebased overhaul. As a result, Time-Based Maintenance became the norm for Preventive Maintenance.
This kind of approach motivated the indiscriminate
use of overhaul or preventive replacement for all
items included in a Preventive Maintenance program. (Tsang, 1995)
Consequently, the failure rate increased rapidly
and maintenance costs grew accordingly. This
prompted the airline industry to look for new preventive maintenance concepts. In addition, the Federal Aviation Administration (FAA) in the US was
concerned that the reliability of some engines had
not been improved by changing either the type or the
frequency of overhaul. The available data indicated
that although the frequency of some failures had
been reduced, many more had remained unchanged
or actually increased. These findings could not be
explained by using the accepted model of failure.
During this time, a new approach to maintenance
evolved within the aircraft industry. Based on analysis of failure data, it was found that the probability
of failure did not increase with operating age and the
traditional time-based policies were found to be ineffective for controlling the failure rate of many
items. (processonline, 2007)
During 1960, FAA was surprised that,
notwithstanding many previous efforts, it was not
possible for airlines to control the failure rate of a
certain type of engine, by changing the scheduled
overhaul policy. Moreover, due to congested continuous maintenance activities, fleet availability
dropped significantly, causing operation and maintenance costs to increase rapidly without equivalent
improvements in reliability. The reasons for the
problems mentioned above can be summarized in
the following nine areas:

4.

5.

6.

7.
1. Risk analysis was not considered in maintenance
analysis. The objective of the maintenance activities was mostly to retain the technical characteristics of the items, rather than reduce or mitigate the consequences of item failures.
2. The objectives of preventive maintenance were
not recognized. Consequently, the applicability
and effectiveness criteria for maintenance tasks
were not defined either.
3. The operating context was not considered in
maintenance analysis. Therefore, one mainte-

nance program was applied to all aircraft fleets

regardless of operating profile, weather, operator, etc. This approach was insufficient, since the
operating context affects the failure characteristics and changes the failure rate. Hence, the
maintenance task and its interval applicable to
one operating context may not be applicable to
another.
Maintenance was applied to control the degradation of functional performance and reliability of
all items. It was believed that there was always
an appropriate maintenance task to retain the inherent reliability or to restore the functional performance of the items. However, it is now
known that, due to the nature of some failures, it
might be impossible to retain or restore the item
performance to the designated level. Hence,
some of the maintenance tasks were inappropriate and contributed to anomalous maintenance
effort and downtime without giving any benefits.
It should be noted that inherent reliability is a
function of design and cannot be improved without redesign or modification.
It was incorrectly assumed that all items had
age-related failure characteristics and would
benefit from age-based maintenance measures.
Therefore, specific actions, mostly overhaul
measures, were planned for every item. However, according to the reliability investigations
conducted by United Airlines, no more than 11%
of the items would benefit from a limited operating age or scheduled overhaul. Thus, for the remaining 89% of the items, these were inappropriate maintenance measures, which contributed
to unnecessary maintenance efforts and nonbeneficial downtime.
Prescribing hard-time actions for non-age-related
failures had an adverse effect on the availability
and reliability of the items, because it contradicted the actual failure characteristic and degradation processes. Therefore, serviceable items
were unnecessarily removed from service and
sent to shops for overhaul or other maintenance
measures. This intrusive maintenance practice
had a negative impact on manpower resources,
spare parts, down time, total costs, and availability performance.
Since there is seldom any strong relationship between the items operating time and failure probability, many failure modes did not benefit from
age-based shop visits. These failures were one of
the main sources of unscheduled corrective
maintenance, sudden aircraft unavailability, and
disturbed operation. Even though many failure
modes are not age-related, it is most often possible to identify and recognize the conditions that
indicate an imminent functional failure. Hence, it
is possible to apply On-Condition measures, i.e.
scheduled inspections designed to detect a poten-

tial failure condition, in order to initiate preventive maintenance actions and thereby avoid the
functional failure or its consequences. (Moubray,
1997)
8. All the items of systems were considered for
maintenance regardless of the importance of
their functions for system availability. Hence,
limited maintenance budgets were not distributed in accordance with the importance of the
items function for availability performance of
the system.
9. Previous experience in the development of
scheduled maintenance instructions had revealed
that a program of effective maintenance measures could be developed through the use of logical analysis and decision-making processes.
Hence, there was a need for a structured decision
process to assess the maintenance requirements
of the systems, and to develop an applicable and
effective maintenance program.
In order to respond to the above-mentioned challenges and to find a proper solution, FAA formed a
task force, including representatives from both FAA
and American Airlines. The purpose was to evaluate
the effectiveness of traditional time-based maintenance, investigate the capabilities of scheduled
maintenance, and find the possible relationship between scheduled maintenance and reliability. These
analyses gave rise to the following surprising discoveries (Kennedy, 2005; Equipment Links, 2007;
processonline, 2007):
x
x
x
x
x

Scheduled overhauls had little or no effect on the

overall reliability of a complex item unless it had
a dominant failure mode.
There were many items for which there was no
effective form of scheduled maintenance.
Many types of failures could not be prevented or
effectively reduced by right-age overhauls, no
matter how intensively they were performed.
Cost reductions in maintenance could be
achieved with no decrease in reliability.
The intrusive nature of the overhauls was itself a
major cause of unreliability.

The outcomes of the efforts mentioned above led

to the first formal FAA - Airlines Reliability Program being issued in November 1961. The program
was developed to improve the control of reliability
through an analysis of the factors that affect reliability and to provide a set of actions to improve low reliability levels when necessary. As the propulsion
system had been the area of greatest concern, and
since power plant data was readily available for
study, programs were developed for the propulsion
system first. The introduction to that program stated
that (Nowlan & Heap, 1978):

in the past, a great deal of emphasis has been

placed on the control of overhaul periods to provide
a satisfactory level of reliability. After careful study,
the Committee is convinced that: reliability and
overhaul time control are not necessarily directly associated topics; therefore, these subjects are dealt
with separately.
3 THE FIRST STRUCTURED MAINTENANCE
PROGRAM PROCEDURES: MSG-1 & MSG-2
United Airlines started a research program in 1965,
to substantiate the outcomes of the FAA task force
and to provide a generally applicable systematic review of the aircraft design. Hence, in the absence of
operational experience, the best maintenance process
should still be utilized through a structured logical
decision tree. In June of 1967, T.D. Matteson and
F.S. Nowlan presented a paper on the use of this
methodology at an aircraft design and operations
meeting of the American Institute of Aeronautics
and Astronautics (AIAA). As a result, rudimentary
decision logic was created and over the next few
years, it was developed with the cooperation of airlines, manufacturers, and FAA. The methodology
was used to develop the Boeing-747 initial maintenance program document. This document was published on 10 July 1968 by ATA under the title Boeing-747 Maintenance Steering Group (MSG)
Handbook: Maintenance Evaluation and Program
Development (MSG-1) (Nowlan & Heap, 1978).
This was the first attempt at applying reliabilitycentered maintenance concepts when developing an
aircraft maintenance program.
MSG-1 was a bottom-up approach to the Boeing-747 systems, in which components were the
highest level to be considered. Hence, MSG-1 focused on a component such as the Fuel Control Unit
(FCU) in a system and analyzed which part of that
component might fail. Then, it was determined what
kind of maintenance action was required to prevent
the failure. Through MSG-1, the potential maintenance measures for each maintenance strategy were
selected and evaluated from criteria based on operating safety or essential hidden function protection.
The remaining potential maintenance tasks were
evaluated to determine if they were economically
viable.
MSG-1 introduced three broad processes to classify the scheduled maintenance requirements, i.e.
Hard Time (HT), On-Condition (OC), and Condition
Monitoring (CM). OC requires an item to be periodically checked, or tested, against an appropriate
physical standard to determine whether the item can
continue in service or not (Nakata, 1984).
The efficacy of the systematic MSG-1 methodology applied to Boeing-747 was considered to justify
a generic solution, which could be applied to other

new aircraft. This resulted in the publication of a

second document by ATA in 1970 as MSG-2: Airline manufacturer maintenance program planning
document. This document was used to develop the
maintenance programs for aircraft such as the L1011 and DC-10. (Smith & Hinchcliffe, 2004)
The objective of the two MSG methodologies was
to develop scheduled maintenance programs that assured maximum safety and reliability of the item, at
the lowest possible cost. MSG-1 and MSG-2 both
followed the same process, but MSG-2 was a generic document, and non-aircraft type-related (Nowlan & Heap, 1978) .
Subsequently, in 1972, United Airlines used the
idea of MSG-2 under the US Department of Defense
(DOD) contract to develop the P-3A and S-3A maintenance programs, and the F-4J program in 1974.
(Smith & Hinchcliffe, 2004)
An enhanced document was also prepared in
Europe, called EMSG-2. It was used to develop
maintenance program requirements for such aircraft
as the Airbus A-300 and Concorde.
MSG-2 and EMSG-2 continued to use a bottomup approach to aircraft systems and were maintenance process oriented, whereby the integrity of
components in sub-systems was considered before
those of the overall system
The most important advantage of MSG-1 and
MSG-2 was the application of On-Condition (OC)
maintenance, which made them unique. The introduction of OC began an era of new thinking. It was
permissable to let an aircraft pass an immediate
maintenance check with known deterioration, degradation or wear, and postpone the required maintenance action until the next earliest opportunity, as
long as the appropriate physical standard and prescribed limitations were met. This approach helped
the operators to have fleets that were more available
and made planning more flexible. Moreover, since
the cost of correcting potential failures is often far
less than the cost of correcting functional failures,
OC maintenance reduced the maintenance costs.
Furthermore, OC maintenance strongly reduced the
number of irrelevant scheduled overhauls, which
was the main source of infant mortality and unreliability. In addition, by avoiding premature removals
of items that were still in a satisfactory condition,
required spare part volumes were reduced.
Depending on the operating context of the asset,
warning of incipient failure enables the users of an
item to reduce or avoid consequences in a number of
ways (Moubray, 1997):
1. Down time: corrective action can be planned at a
time that does not disrupt operations.
2. Maintenance costs: the user may be able to take
actions to eliminate the secondary damage,
which would be caused by unanticipated fail-

ures. This would reduce the downtime and the

maintenance costs associated with the failure.
3. Safety: warning of failure provides time to either
shut down an item before the situation becomes
dangerous, or to move people out of harms way.
Today, OC tasks are well known because the inspected items are allowed to be left in service on
condition that they continue to meet specified performance standards (Moubray, 1997), until a potential failure is detected. For example, as many as 400
items that might have required scheduled overhaul
prior to MSG-1/MSG-2/EMSG-2 were reduced to
about 10 afterwards (ATE&M, 2001) .
In 1975, NAVAIR rewrote the MSG-2 procedures, to apply an analytical maintenance program
to naval aircraft and engine programs, which resulted in NAVAIR Systems Command (NAVAIR
00-25-400). This was applied to in-service naval
aircraft and the manual was utilized to revise the
preventive maintenance requirements for most of the
Navys in-service aircraft. (MIL-STD-2173)
The MSG-2 methodology revolutionized Navy
procedures for developing preventive maintenance
programs; but there were still aspects to consider for
further development of both MSG-2 and NAVAIR
00-25- 400 documents. For example, they did not
cover the procedures for developing inspections intervals and for refining the initial analysis. (MILSTD-2173)
Moreover, the effectiveness criteria for different
maintenance strategies and failure consequences
were not considered and there was still a problem of
balancing the requirements of cost and dependability. In addition, there was still pressure to decrease
maintenance costs. In fact, the incentives to reduce
the cost were changed from technical and engineering issues during design to economical issues and
cost-effective maintenance during operation. As a
result, the industry was expected to construct a
framework that incorporated cost-effective maintenance strategies.
4 INTRODUCTION OF RELIABILITYCENTERED MAINTENANCE
The US Department of Defense (DOD) sponsored
United Airlines to write a comprehensive report, entitled Reliability-Centered Maintenance (RCM)
(MIL-STD-2173). Stanley Nowlan and Howard
Heap of United Airlines wrote this report in 1978 as
the initial RCM Bible (DOD report AD-A0665791).
The report gave a detailed rationale and analytical
logic, which required a fundamental shift in the current methodology for maintenance program development (i.e. MSG-2).
RCM is a methodology that supports a wellstructured, logical decision process used to identify

the policies needed to manage failure modes that

could cause the functional failure of any physical
item in a given operating context. These policies
will reduce the risk of function loss and are: Preventive Maintenance, Predictive Maintenance, or Redesign. Hence, RCM can be considered as an overall
risk management program, to effectively manage the
risk of function losses through effective maintenance.
As one of the major elements in risk management
is reliability, the RCM methodology is used to develop and optimize the preventive maintenance and
inspection requirements of an item in its operating
context to achieve its inherent reliability, where inherent reliability can be achieved by using an effective maintenance program.
Any RCM methodology shall ensure that all the
following seven questions are answered satisfactory
in the order given below (Rausand, 1998):
1. What are the functions and associated performance standards of the item in its present operating context (function)?
2. In what ways does it fail to fulfill its functions
(functional failures)?
3. What are the causes of each functional failure
(failure modes)?
4. What happens when each functional failure occurs (failure effects)?
5. In what way does each failure matter (failure
consequences)?
6. What can be done to prevent each failure (proactive tasks and task intervals)?
7. What should be done if a suitable preventive task
cannot be found (default actions)?

Failure Consequences
Approach

First Generation
Pre World War II

x
x
x
x
x

System level instead of component level.

Top-down instead of bottom-up approach.
Function preservation instead of failure prevention.
Task-oriented instead of maintenance process
oriented.
Consequence-driven, where the consequences of
failures are far more important than their technical characteristics.

In an RCM process, the consequences of every

failure have to be analyzed. It should clearly separate hidden failures from evident failure modes, and
distinguish events that have safety, environmental,
operational and or economic consequences.
By using an approach based on system level and
function preservation, RCM treats components differently in terms of relative importance according to
the correlation between the equipment and system
function. Huge benefits can be derived by implementing RCM. These achievements include higher
safety and operating performance, better understanding of the failure modes, and reduction of operation
and maintenance costs (Tsang, 1995). Figure 1 illustrates how the maintenance concept has changed in a

Second Generation
Post World War II

Third Generation
After Mid 1970s
RCM
Methodology
MSG-3
Methodology

MSG-1& MSG-2
Methodology
Using Condition Based
Maintenance

Failure Mode
Approach
Technical Characteristic
Approach

System Safety and Risk Analysis approach

In order to answer the questions above, RCM uses

a structured decision diagram, and encompasses the
well-known Failure Mode & Effects Analysis
(FMEA) methodology to identify functions, func-

tional failures, and failure modes of an item. Furthermore, FMEA classifies the severity of each failure effect according to severity classification criteria
established by each program. Hence, the quality of
the RCM analysis strongly depends on the quality of
the FMEA execution.
The RCM logic requires an age exploration program for all maintenance tasks where reliable historical information is not available. It also requires
an independent auditing of all performed analyses,
see Nowlan & Heap (1978) and Moubray (1997). In
contrast to earlier methodologies supporting maintenance program development (e.g. MSG-1 and MSG2), the RCM methodology was based on:

Time Based Maintenance

Reactive Maintenance

Failure Rectification

Failure Prevention

Funtion Preservation

Failure management strategy

Figure 1: Changes and milestones in maintenance methodology development with regard to risk and failure management.

logical and chronological order.

Since Nowlan and Heaps report, RCM has been
widely used by different industries, such as the nuclear and power generation industries, offshore oil
and gas industries, and has been refined, developed,
and customized to their specific requirements.

Methodology

MSG-1
(1968)

Characteristics
x
x
x
x
x

5 PUBLICATION OF MSG-3
A decade after MSG-2 was published and subsequent to Nowlan and Heaps report, US Association
of Air Transport (ATA) formed another task force to
review MSG-2 experience in 1979. In this review, it
became obvious that there were some areas for improvement (Overman et al., 2003; ATA, 2005):
x
x
x

MSG-2
(1970)

MSG-3

The rigor of the decision logic.

The clarity of the distinction between economics
and safety.
The adequacy of treatment of hidden functional
failures.

The high fuel price increased the total operating

cost of aircraft, and the pressure to decrease maintenance costs was still present. In addition, the development of new-generation aircraft, new regulations
and new damage tolerance rules for structures,
which had a heavy influence on maintenance program development including the new premises of
Nowlan and Heaps RCM methodology, provided in
the basis for the development of a new, improved
Airline/Manufacturer Maintenance Program Planning Document MSG-3, published by ATA in
1980. (Transport Canada, 2003; ATA, 2005)
This methodology was a combined effort by the
manufacturers, regulatory authorities, operators, and
ATA. The MSG-3 methodology implicitly incorporated the principles of RCM to justify task development, but stopped short of fully implementing reliability-centered maintenance criteria to audit and
substantiate the initial tasks being defined (Transport
Canada, 2003).
Since Nowlan and Heaps report served as the basis for MSG-3, it made major departures from MSG2. Hence, MSG-3 involves a top-down, systemlevel, and consequence-driven approach, to classify
failure effects in one of the failure consequences
categories, see Figure 2. Since its original publication, MSG-3 has been revised five times. Revision 1
was issued in 1988 and revision 2 in 1993. MSG32001 and MSG-3.2002 were issued in 2001 and
2002 respectively and the latest revision was made
in 2005. (ATA, 2005)

(1980)

Bottom-up approach
Component level
Maintenance process oriented
Aircraft type-related (Boeing-747)
Using On-Condition and ConditionBased Maintenance

x Same as MSG-1
x Generic document, non-aircraft typerelated
x
x
x
x
x
x
x
x

Generic document
Top-down approach
System level
Maintenance task oriented
Emphasis on structural inspection programs
More rigorous decision logic diagram
Distinction between safety and economy
Hidden functional failure treatment

Figure 2: Summary of some of the major conceptual differences and improvements between MSG-3 and previous versions of the methodology.

6 FURTHER DEVELOPMENTS OF
RELIABILITY-CENTERED MAINTENANCE
One of the most valuable efforts to develop RCM
methodologies was performed by the US Department of Defense (DOD), and was initiated by the
AD-A066579 report published in 1978. This report
was based on the principles of MSG-logic and was
the foundation of the most modern RCM methodologies. Based on that report, DOD issued several
documents related to RCM analysis; most notably,
Military Handbook (MIL-HDBK) 266, RCM Requirements for Naval Air-craft, Weapons Systems
and Support Equipment in 1981, which superseded
NAVAIR 00-25-400 for all applications of RCMdecision logic. It also applied the principles of RCM
(as covered by the DOD report and MSG-3) to Naval aircraft, weapons systems and support equipment. (Leverette et al., 2005)
In 1985, as another effort, US Air Force (USAF)
issued MIL-STD-1843: RCM Requirements for
Aircraft, Engines and Equipment. This standard
was similar to MSG-3, which was cancelled without
replacement in 1995. In 1986, DOD issued MILSTD-2173, RCM Requirements for Naval Aircraft,
Weapons Systems and Support Equipment (MILSTD-2173; Leverette et al., 2005).
In the early 1990s the DOD decided that new acquisitions should rely, as much as possible, on commercial or performance standards, instead of using Military Standards. As a result, a group called

Reliability, Maintainability and Supportability

(RMS) Partnership, began coordinating the efforts
of various other organizations involved in developing related standards. Since no equivalent commercial standard existed at that time, the RMS Partnership requested the Society of Automotive Engineers
(SAE) to lead the development of an RCM standard
(Leverette et al., 2005).
The SAE RCM subcommittee initially consisted
of representatives from the US Navy and some DOD
contractors. As the group was supposed to find out
more about the lessons learned through commercial
industry efforts, John Moubray and some of his colleagues became involved in late 1997. With new
participation and a clearer direction, the group was
able to complete the SAE JA1011 standard in 1999.
7 AIRCRAFT MAINTENANCE PROGRAM
SURVEILLANCE
The main objective of an aircraft maintenance program is to ensure that the aircraft meets and continues to meet the designed function to serve dependable and airworthy services. Hence, it is important
for operators to determine any deviation from this
objective and to assess the success of the program
after bringing the aircraft into operation.
Today, it is known that an aircrafts reliability and
safety will be strongly affected by its operating context, e.g. operator organization, humidity, temperature, utilization load, and so on. Hence, the original
assumption of effectiveness criteria made during the
design of the initial aircraft maintenance program
will probably change and the surveillance of the aircraft maintenance program will be important. In order to manage this surveillance, the operators normally follow a defined surveillance program, which
has been approved by the authorities.
In an ideal world, an applicable and effective
maintenance program would ensure that there were
no failure events between scheduled aircraft maintenance tasks. However, due to differences between
design assumptions and actual operational conditions, each maintenance program must be adjusted to
achieve this ideal situation. (Moubray, 1997)
According to official FAA research Continuing
Analysis and Surveillance System (CASS) , an effective continuous airworthiness maintenance program should identify elements that are detrimental to
the overall effectiveness of the air carriers maintenance program, and correct any deficiencies before
they become systematic problems. Therefore, the
operators should develop indicators to determine
possible deviations from defined objectives and to
measure the effectiveness of an aircraft maintenance
program. These objectives might be based on risks
related to health, business, safety, environment,
property, and on-time services.

According to MIL-STD-2173, effectiveness is a

measure of the result of the task objectives, which is
dependent on the failure consequences. Therefore,
the effectiveness of applicable tasks in preventing
the failure consequences must be determined.
Hence, for each failure consequence, it is possible to
develop indicators according the effectiveness criteria as follows:
x
x

Safety: the task must reduce the risk of failure to

assure safe operation.
Operation: the task must reduce the risk of failure to an acceptable level from an operational
point of view, or remove the operational consequences.
Economics: the task must be cost-effective.

In order to measure the performance of an aircraft

maintenance program, actual operational and support data are necessary. This data can be obtained
from sources such as aircraft inspections, pilot reports, air safety reports, scheduled maintenance findings, reliability programs, unscheduled maintenance
actions, deferred maintenance actions, teardown reports, recorded flight data, and so on.
However, gathering data and converting it to information is very time-consuming. In addition, the
effectiveness of these analyses will decrease with
time. To mange these difficulties, e-Maintenance is
one promising approach.
8 E-MAINTENANCE AND MAINTENANCE
PROGRAM SURVEILLANCE
Information resources are critical to maintenance
and maintenance support, for example to support
surveillance of an aircraft maintenance programs
performance. Hence, technological opportunities to
improve the surveillance, such as innovative design
features in the aircraft or its support system utilizing
new technology applications can help to improve the
maintenance program. The inclusion of developing
technologies can also avoid early obsolescence and
extend the useful life of the aircraft at the same time
as availability performance and Life Cycle Costs
(LCC) are improved. One example of new technology is Information & Communication Technology
(ICT), which to an increasing degree is included in
both the aircraft and its support system and that also
integrates the two. The application of ICT within
maintenance and maintenance support enables the
emerging approach of e-Maintenance. (IEC 603003-14; Candell et al., 2007)
e-Maintenance is the application of ICT for remote maintenance (i.e. maintenance of an item performed without the maintenance personnel having
physical access to the item) and for representing the
physical world in an digital model aimed at supply-

ing tailored information such as decision support regarding appropriate maintenance activities for all
stakeholders independent of time, geographical location, or organizational affinity. Hence, the eMaintenance approach is not limited to the management of condition monitoring data, explicit technologies, or any specific support service solution.
(Candell et al., 2007)
One important source of information that supports
maintenance program surveillance is the maintenance database, which should be structured so that it
facilitates the seamless transfer of data to other databases (e.g. the maintenance work order system) and
analysis tools (e.g. RCM software) used by stakeholders involved in maintenance program development. However, it is also important that the maintenance database is kept under configuration control to
ensure that it reflects the latest design standard of
the aircraft and its indenture levels, to provide an
audit trail and to ensure the integrity and consistent
use of support data. The database should also be
kept up-to-date to reflect changes in customers use
and requirements and thereby provide the guidance
necessary for future maintenance program development. In this context, e-Maintenance facilitates the
use of one single maintenance database that is
shared by all involved stakeholders, which in turn
decreases the risk of redundant, contradictory, and
obsolete data (IEC 60300-3-14; Sderholm, 2007).
Another important source of information for
maintenance program surveillance is the maintenance work order system, which is used to initiate,
control and document specific maintenance tasks. As
stated in the maintenance program, a maintenance
task is either triggered by a predetermined time
measure (e.g. calendar time, number of flights, or
flight hours) or the items actual condition. The
work order is used to identify and plan required resources and to schedule execution of the work. Finally, it is used to record results, observations, and
resources actually used, which all provide the basis
for assessment and improvement of the aircraft
maintenance
program.
An
appropriate
eMaintenance solution should enable easy access to
the maintenance work order system and also integration with other maintenance systems. (IEC 60300-314; Candell et al., 2007)
Another important part of an e-Maintenance solution, which also is valuable for maintenance program surveillance, is Built-in-Test (BIT) systems included in the aircraft. Using BIT systems it is
possible to analyze the failures at the exact point in
time when they occur at a specific indenture level of
the aircraft during operation. Operational data that
should be monitored and recorded include data on
bus inputs, strain gauge and other dynamic data,
propulsion parameters, BIT failure data, and environmental data. Continuous monitoring of the aircrafts condition helps to identify the nature of in-

termittent faults and the stresses imposed on an item

during operation. Hence, it is possible to obtain an
enhanced understanding of failures, failure modes,
failure mechanism, and failure effects. However, in
addition to digitally monitored parameters, relevant
operator and maintainer observations, which cannot
be digitally recorded, such as decisions based upon
various circumstances, should also be recorded. All
this data can act as input to the surveillance of the
maintenance programs performance and update the
engineering judgments made during initial aircraft
maintenance program development. (Sderholm,
2007)
As described above, one important aspect of eMaintenance is the combination of maintenance and
ICT. Hence, it is necessary to have expertise in both
areas in order to achieve a good e-Maintenance solution that satisfies the requirements for aircraft maintenance program surveillance. Thereby, maintenance
and maintenance support may be seen as the problem domain to which selected and adapted ICT is
used as a solution. (Candell et al., 2007)
Some of the obstacles related to e-Maintenance,
which have to be overcome in order to achieve effective and efficient maintenance program surveillance, are (Karim & Sderholm, 2007):
x

Heterogeneous organizations: there are different

structures in the organizations involved in providing and receiving maintenance and maintenance support.
Heterogeneous ICT-environments: there are differences in technology in systems that are normally used for different purposes, but are needed
to exchange information in order to support
maintenance program surveillance.
Information integration strategy: it is necessary
to have a strategy to integrate a number of different types of hardware and software in a seamless manner. The content type has an impact on
the overall ICT strategy.
Documentation and archiving strategies: it is essential to provide and manage documentation of
different types. The context requires different
types of strategies for storage, distribution,
safety, security, accessibility, availability, reliability, archiving, and destruction.

One example of a civil aircraft with on-board

technologies that support an e-Maintenance solution
for aircraft maintenance program surveillance is the
Boeing-787, which will be certified during 2008.
The aircrafts on-board technologies will also be integrated with off-board technologies within the support system. Another similar example is the intelligent software Airman, which is provided by Airbus.
This software can connect the different sources of
maintenance information in a seamless manner and
also provide tailored information to different stake-

holders. In military aviation, the Joint Strike Fighter

(JSF) program is one example where on-board and
off-board technologies are integrated in order to
achieve an autonomic logistics system. Another
military example is the Maintenance Work Station
(MWS) efforts connected to the Swedish combat
aircraft JAS 39 Gripen. These aircraft systems are
examples where e-Maintenance will be very beneficial to aircraft maintenance program surveillance.
The reason is that e-Maintenance enables measures
supporting surveillance of aircraft maintenance program effectiveness to be more or less automatically
collected, analyzed into indicators, and distributed to
concerned stakeholders independent of the maintenance echelon.
9 CONCLUSIONS
This paper describes the trends in aircraft maintenance program development during the last 50 years,
including milestones such as different versions of
MSG and RCM.
Examples of fundamental changes described are:
from failure correction to failure prevention; from
time-based to condition-based maintenance, from
bottom-up to top-down analysis; from component
level to system level analysis; from technical characteristics to failure consequences; and from item rectification to function preservation.
Furthermore, the paper describes some of the reasons for these changes, e.g.: item complexity, system
dependence, competition, and failure consequences,
but also increasingly stringent requirements related
to: dependability, costs, airworthiness, sustainability, and safety.
The paper ends with a description of challenges
and possibilities related to e-Maintenance, which is
believed to promote effective and efficient surveillance of an aircraft maintenance program in a near
future.
10 ACKNOWLEDGEMENTS
The authors would like to thank Mr. Dave Nakata
and Mr. Christian Delmas for their useful comments
on drafts of this paper:
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