Establishing Modification Control Data

Establishing Modification Control Data

In our previous blog, we discussed the setup of maintenance program data. In this post of the aircraft phase-in series, we shift our focus to the setup and initialization of modification control for M&E/MRO systems.

Aircraft modification management stands as a essential aspect of aircraft maintenance and operations. M&E/MRO systems provide a comprehensive solution for monitoring and managing alterations to an aircraft's configuration or maintenance status. The modification control module within MRO systems streamlines the management of modification requests, ensuring strict adherence to regulatory requirements and safety standards. This system diligently maintains all essential documentation and updates the aircraft's maintenance status and configuration records following the completion of modifications. In essence, MRO systems offer an efficient and effective approach to managing aircraft modifications while guaranteeing regulatory compliance—provided that data is managed meticulously.

Preparation Tasks

To establish modification control alongside within a Maintenance, Repair, and Overhaul (MRO) system, the initial step necessitates the acquisition of comprehensive and precise data pertaining to the aircraft or equipment, the modifications undertaken, and the individuals responsible for executing these modifications. Equally crucial is the presence of clear, comprehensive, and up-to-date documentation and procedures for executing modifications.

Several preparatory tasks are required for the effective configuration of modification control in an M&E/MRO system, commencing with the digital acquisition of the following:

  1. Regulatory Documents and Publications: These specify the regulations with which the aircraft operator must comply, in addition to documentation concerning aircraft and component modifications and configuration changes, accompanied by unambiguous work instructions for repetitive tasks.
  2. Historical Accomplishment Records: Status and/or next due records from the OEM, previous operators, or regulatory authorities are essential.

Required Data Sets for Modification Control Setup

While there are similarities between setting up modification control and establishing maintenance program tasks, notable differences exist. Commonalities include configuring the effectiveness/applicability of modifications/documents and specifying maintenance time requirements, which we won't revisit here. Refer to our previous article, "Aircraft Phase-In Series: How To Set Up Maintenance Program Data?" for a more in-depth discussion.

To configure a modification control module in an MRO/M&E system, the following data is typically imperative:

  1. Aircraft/Equipment Information: Make, model, and serial number details that the MRO system will track.
  2. Modification Details: Specifics concerning the type of modification, the part/component undergoing modification, and the modification date.
  3. Personnel Information: Pertinent qualifications, certifications, and training records of the individuals responsible for executing the modifications.
  4. Procedures and Instructions: Comprehensive guidelines for executing modifications, encompassing requisite approvals and certifications.
  5. Maintenance Schedules and Inspection Intervals: These are essential to ensure that modifications are seamlessly integrated into the maintenance plan for equipment or aircraft.

Additionally, one aspect demands special attention—the relationships between documents and modifications, often referred to as the sign-off tree or reference/relationship structure. This particular aspect can complicate the implementation of modification control due to the intricate network of relationships, regulations, and procedures associated with the sign-off process. The diverse array of modification types, each with its unique requirements, further compounds the complexity of this structure.

Managing and tracking the progress of multiple modifications concurrently, alongside the meticulous documentation and storage of these modifications, further complicates the implementation of the sign-off structure.

To alleviate this process, especially when aircraft phase-ins are recurrent, data validation and implementation tools can prove invaluable.

Similarly to maintenance tasks outlined in the MPD, dynamic datasets are required for initializing documents and modifications to establish the correct status. These datasets encompass:

  • Mod/Document Next Due Information (Date, Hours, Cycles): These figures, in conjunction with up-to-date aircraft utilization data, are sufficient for initializing documents to determine maintenance forecast values.
  • Modification Last Performed/History or Status (Date, Hours, Cycles): This stores the document's status, which can include categories such as Ex-Factory, Closed, Open/Repetitive, and Superseded. This information aids in historical analysis and next due calculations based on time requirements stipulated in the maintenance program.

The Process Step By Step

Once document/mod definitions have been established within the system, the integration of dynamic aircraft data, LD/ND, and document/mod status ensues. The process mirrors the checks employed during the MPD data phase:

  1. Document Verification: Verify if the document exists in the system, and if not, assess the need for its creation.
  2. Placement of LD/ND & Status: Determine whether LD/ND and status should reside within the document itself or on a lower-level document within the structure.
  3. Applicability Assessment: Confirm if the document in question is applicable for accommodating LD/ND and status.
  4. Dimension Compatibility: Evaluate if the dimensions provided in the source data align with the setup in the OEM system, and rectify discrepancies as needed.

Depending on the availability of LD/ND & status data from the source, the maintenance event can be initiated within the system. Ideally, when past data is present, the system should ascertain the next due based on the maintenance time requirements. In certain cases, the provided next due values can be utilized.

This data processing can be largely automated with the implementation of appropriate tools and infrastructure.

How to Avoid Common Pitfalls

Common pitfalls when establishing a modification control module in an MRO/M&E system include:

  1. Insufficient Data Collection: Incomplete or inaccurate data collection regarding the aircraft/equipment, performed modifications, and personnel responsible can lead to errors and data inconsistencies. Collect comprehensive data to eliminate gaps.
  2. Data Entry Errors: Errors in the data entry process can result in inaccuracies in recorded modification information. Standardize the data entry process to minimize errors.
  3. Lack of Data Validation: Absence of a robust data validation system can lead to errors and inconsistencies in recorded modification data. Implement a comprehensive data validation process to ensure a successful phase-in.
  4. Data Incompatibility: Incompatibility between source data for modifications and the OEM system can result in inconsistencies and errors. Address this issue by deploying advanced data processing tools.
  5. Complex Sign-off Structures: Setting up overly complex or impractical document sign-off structures, or lacking appropriate sign-off structures, can introduce inconsistencies within the system. Streamline the sign-off process for efficiency and consistency.

What is next in the Aircraft Phase-In Series

In the next article, we will talk about changes and documents and what you need to think about for a smooth process.

  1. Aircraft setup ✓
  2. Part number setup ✓
  3. Installed components✓
  4. Maintenance program✓
  5. Changes & Documents
  6. Extras

How EXSYN Can Help

EXSYN's team of aircraft data and aviation experts utilises a proven framework and methodology that has been applied to millions of terabytes of master data and includes:

  • NEXUS solution to sreduce project costs and duration.
  • EXSYN's data storage system 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.

For more information or to discuss your airline’s individual situation, click here or send an email to hello@exsyn.com to book a meeting today with one of our aircraft data specialists.

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