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The reviewed documents provided the background for understanding the inner workings of the
units and interrelationships of the units, subsystems, and interfacing systems. Their removal,
installation, functional checks and inspections, and adjustment procedures were documented in
the Aircraft Maintenance Manuals (AMM). Unit operation, testing, repair, and cleaning
procedures were documented in Component Maintenance Manuals (CMM).
3.4 REVIEW OF INITIAL ASSESSMENT AT CERTIFICATION.
Failure modes and effects summaries (FMES), fault tree analyses (FTA), hazard assessments
(HA), and cascading analyses/system safety analyses (SSA) provided by Airbus were reviewed.
These provided insight into the designers’ logic for determining failure modes and effects.
Anticipated failure modes were identified in FMES and used as a benchmark for documentation
of repairs. Unanticipated failure modes or effects could generate service bulletins (SB), special
technical letters, and perhaps, Airworthiness Directives (AD). Those documents were obtained
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and reviewed. HAs, SSAs, and FTAs were associated with subsystem and system-level
assessments in which potential safety issues between units and interfacing systems were
addressed and probabilities were propagated. A dedicated common mode analysis was not
reported for the rudder mechanical control, presumably due to the newness of the assessment
tool at the time of the A320 design. Additionally, airlines and manufacturers had developed the
maintenance steering group (MSG)-3 logical decision processes to guide scheduled maintenance,
and these were also reviewed. Required, recommended, and improved or upgraded practices
were noted.
3.5 REVIEW OF IN-SERVICE DATA.
Two Microsoft® products were used to manage the file and data processes. Microsoft Visual
SourceSafe® (VSS) [4] was used to allow version/iteration control and documentation of the
processes. VSS backs up any file when changes are made and allows recovery of an old version
at any time. Files were shared and available to team members. Microsoft Access® [5] was used
to develop a repository database to allow data mining and coding, reviews, and queries. Data
received was stored in Access data tables. Queries then were written to retrieve data in the
format needed for risk analysis. Data sources are described in the following sections.
3.5.1 The A320 Aircraft Fleet Information.
Airbus provided the A320 aircraft-related information as well as records of installation of major
parts and serial numbers on each aircraft under investigation. Fleet information included aircraft
model, serial number, registration, air date/delivery date, ownership/operator, and cumulative
flight hours and cycles. On each aircraft, component information included part and serial
numbers. These data files, provided by Airbus, were processed and organized in the database
where availability of cumulative information was noteworthy. It provided a tracking history of
aircraft-specific age, calendar time, usage, flight hours, cycles, and change of ownership, which
were essential for the life cycle analysis. These records also formed the aircraft and component
populations of the study.
3.5.2 Repair Data From Original Equipment Manufacturers.
The other primary data owners were the OEMs. Airbus and Sandia National Laboratories
worked with the OEMs to retrieve the repair data residing with them and their authorized repair
shops. During repair, parts removed from service were routinely logged by aircraft model, air
carrier, removal date, and part service cycles and hours, and tested for performance and
functionality. Repair data obtained from the OEMs were linked in the database with the aircraft
on which the parts were installed. The data were also reviewed and coded with the diagnosed
reason for removal. Over time, the analysis tracked increasing trends in removal of parts, as well
as dominant removal events, signs of aging, and clustered removal patterns. Differences among
operators, manufacturers, and design upgrades were also noted.
The reasons for returned parts by operators and repair shop findings and diagnoses were
reviewed and categorized for use in the analysis. Emphasis was placed on part removals and
reasons for removal that occurred in sequence, in clusters, or in dominant manners. This
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extensive review provided an understanding of how the components failed as well as information
on prioritizing maintenance actions.
3.5.3 Airclaims Database/FAA National Aviation Safety Data Analysis Center.
Airclaims is an international aviation insurance underwriter whose database contains
comprehensive historical data on over 50,000 registered aircraft, including hours and cycles.
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