Publications: Aviation Week's AviationNow.com -
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Published on: 3/21/2001
Last Visited: 3/21/2001
Christophe Canard , manager of service programs for Dassault Falcon Jet Corp. , the New Jersey-based Falcon business jet marketing and support organization for North and South America and the Pacific Rim Asian countries for French OEM Dassault , said his company developed a special airframe inspection program for one of its largest customers , Columbus , Ohio-based Executive Jet Inc. ( EJI ) .Currently , EJI deploys its fleet of 10 Falcon 2000 twinjets -- slated to increase to 15 by year-end -- under NetJets , the world's largest fractional ownership program.The inspection plan , Canard said , received European JAA , and subsequent FAA , approval in the summer of 1998 , and went into effect the following January to coincide with first deliveries of the Falcon 2000 to EJI.
EJI had two goals in mind for the maintenance program we developed for them , said Canard.First of all , they wanted to minimize the number of times each aircraft would be out of service for scheduled maintenance.And , they wanted to schedule the maintenance events as far apart as possible so the aircraft would be in service more..
There are five basic types of inspections mandated by Dassault for its current-production Falcon Jet models -- the Falcon 50 EX , Falcon 2000 , Falcon 900C , and the Falcon 900EX -- all of which conform to a recognized airframe maintenance standard , known as ATA Chapter 5-10.The OEM recommended airframe inspections for the current production Falcons break down into five separate events -- Basic , A , A+ , B and C-level inspections , Canard said.For the NetJets program , the major change was with the Basic inspection , which takes about 15 man-hrs. , or about half a day.
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Dassault took all of the tasks covered by the Basic inspection , and incorporated them into the A , A+ and B inspections , Canard said.The OEM then took all of the tasks covered by those inspections , and divided them into four separate blocks to be carried out at 150-flight hr. intervals , or every 60 days , whichever comes first.The result was that the events that fell under the Basic inspection were carried out at intervals of 60 days , instead of their original 30-day schedule , creating the need for European Joint Airworthiness Authorities ( JAA ) approval of the EJI customized Falcon 2000 inspection program.
Approval was granted , Canard said , because there was a sufficient amount of maintenance data generated by the total Falcon 2000 fleet to justify the extended interval for the tasks that specifically fell under the Basic inspection.Along that line , he said , Falcon Jet guaranteed the cost of this program by structuring it on the basis of a flat fee per flight hr.The fee covers both scheduled and unscheduled events , including AOG situations.
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Along with the combination and redistribution of maintenance tasks , all of the individual tasks involved in the four inspections were grouped by access requirements , Canard said.
This takes into account the panels and other parts of the aircraft that have to be opened in order to carry out certain tasks , plus the specific ground support equipment and tooling required , he said.So , if there are three separate tasks , each requiring the removal of the same panel , using the same tools , then those three would be combined into a single inspection block to maximize the efficiency of the maintenance technician , and cut downtime..
Canard said that the program will make no alterations to the C inspection , a heavy airframe event.For current-production Falcons ( with the exception of the Falcon 50EX ) , the C check is carried out once every 3 , 750 cycles or every six years , whichever comes first.For the Falcon 50EX , the C check is done at six-year intervals , and is not tied to cycles.
Even though the program still is in its infancy , maintenance man-hrs. already have been reduced by 10 % to15 % over the standard OEM inspection regime , Canard said.As the program continues , downtime will drop 10 % more , according to company estimates.Currently , under NetJets , the Falcon 2000s are flown an average of 1 , 000 hrs. per year.As high usage of the fleet gives Falcon Jet more experience with the program , changes are likely to be made.
We might find that some inspections could be done at longer intervals , which would benefit everyone -- not just the high-time user , Canard said.But , I also want to stress that the program was developed for EJI because they bought the aircraft new.