MR-11 · Structural Repair & NDT Management

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Process Flow Diagram (BPMN)

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L4 Process Steps

Step	Step Name	Role / Swim Lane	System	Input	Output	KPI	Dec?	Exc?
Phase 1 1.1	Initiate structural damage finding report	Aircraft Structures Inspector	AMOS by Swiss AviationSoftware	Visual inspection finding, C-check opening discrepancy, or SRM-triggered inspection requirement	Damage Finding Report (DFR) with location, area, and initial severity classification	DFR opened within 2 hours of discovery; 100% of findings logged before repair initiation	N	N
1.2	Define NDT method and inspection scope	NDT Level III Engineer	Boeing Toolbox / CAMP	Damage Finding Report, Aircraft Structural Repair Manual (SRM) Chapter 51, airframe area access card	NDT Work Instruction specifying method (UT, ET, RT, PT, MT), zone boundary, and acceptance criteria	NDT scope defined within 4 hours of DFR; SRM chapter referenced on 100% of instructions	N	N
1.3	Evaluate damage against SRM allowable limits	Structures Engineer	AMOS by Swiss AviationSoftware	NDT Work Instruction, SRM allowable damage limits, measured damage dimensions	Disposition decision: within limits (proceed to NDT), beyond limits (escalate to engineering)	Disposition decision issued within 8 hours of DFR for non-AOG; 100% of beyond-limit findings escalated same shift	Y	N
Phase 2 2.1	Submit damage for engineering disposition review	Structures Engineer	AMOS by Swiss AviationSoftware	Beyond-limits damage finding, DFR with measurements, photographs, and SRM chapter reference	Engineering Disposition Request (EDR) submitted to Structures Engineering queue	EDR submitted within 2 hours of beyond-limits determination; completeness score ≥95% (all required fields populated)	N	N
2.2	Evaluate repair options against approved engineering data	Structures Engineering DER	Boeing Toolbox / CAMP	Engineering Disposition Request, SRM Chapter 51/53/57, applicable Airworthiness Directives (ADs), fleet history for recurring damage patterns	Repair scheme selection: SRM standard repair, SRM alternative repair, or DER-designed repair	Engineering disposition issued within 24 hours for non-AOG; 100% of dispositions reference specific SRM paragraph or approved data source	N	Y
2.3	Determine if OEM or DER engineering order is required	Structures Engineering DER	AMOS by Swiss AviationSoftware	Repair scheme assessment, FAA DER authority scope, airline DER/ODA delegation matrix	Decision: issue in-house Structural Repair Order (SRO) or submit to Boeing/OEM for Engineering Order (EO)	OEM referral decision made within 4 hours of disposition review; 0 instances of in-house repair where OEM EO was required by AD or AWL	Y	N
2.4	Issue Structural Repair Order and material requirements	Structures Engineering DER	AMOS by Swiss AviationSoftware	Approved repair scheme (SRM, in-house EO, or OEM EO), DFR, parts availability from stores	Structural Repair Order (SRO) with step-by-step instructions, material list (alloys, fasteners, sealants), tooling requirements, and inspector hold points	SRO issued within 2 hours of disposition approval; material list completeness ≥98% (no unplanned AOG parts requests during repair)	N	N
Phase 3 3.1	Assign certified NDT Level II/III inspector to task	NDT Supervisor	AMOS by Swiss AviationSoftware	NDT Work Instruction, inspector qualification matrix (NAS410 / EN4179 certifications), shift roster	Inspector assignment confirmed; qualification verified against required NDT method and aircraft type	Inspector assigned within 1 hour of work instruction release; 100% of assignments verified against NAS410 certification currency	N	Y
3.2	Execute NDT inspection per approved work instruction	NDT Level II Inspector	Olympus OmniScan (UT/PAUT) integrated with AMOS by Swiss AviationSoftware	NDT Work Instruction, calibration standards, aircraft access (panels removed, surface prepared), ambient condition log (temperature, humidity)	Raw NDT data file, calibration record, inspection coverage map, preliminary indication report	Coverage rate ≥100% of defined zone (no uninspected area); calibration performed every 4 hours or per shift change; scan data archived within 30 minutes of inspection completion	N	N
3.3	Assess NDT findings against work instruction acceptance criteria	NDT Level III Engineer	AMOS by Swiss AviationSoftware	NDT indication report, acceptance criteria from SRM or EO, prior repair history at location	Accept / reject determination; if additional damage found beyond initial scope, updated DFR issued	Level III review completed within 4 hours of inspection; 0 indications accepted beyond SRM limits without engineering sign-off	Y	Y
3.4	Archive NDT findings and close NDT work card	NDT Level II Inspector	AMOS by Swiss AviationSoftware	Accepted NDT indication report, calibration records, coverage maps, inspector sign-off	Closed NDT work card with digital signature; scan data archived to aircraft records in AMOS	Work card closed within 2 hours of Level III acceptance; 100% of scan data files attached to aircraft serial number record	N	N
Phase 4 4.1	Procure certified repair materials and special fasteners	Stores / Material Planning Analyst	SAP S/4HANA Finance (FI/CO) integrated with AMOS by Swiss AviationSoftware	Structural Repair Order material list, stores inventory status, certified material certifications (Mill Certs, C of C)	Issued materials kitted and delivered to work stand; material traceability records (batch numbers, C of C) linked to SRO in AMOS	Material kitting completed within 4 hours of SRO release for planned repairs; 100% of issued materials have traceable Certificate of Conformance	N	Y
4.2	Execute structural repair per approved Structural Repair Order	Airframe Structures Mechanic (A&P)	AMOS by Swiss AviationSoftware	Structural Repair Order, approved engineering data (SRM/EO), issued materials, calibrated tooling (torque wrenches, drill jigs)	Completed repair with installed doublers/patches/fasteners per SRO specifications	Repair step completion sign-off within SRO-defined sequence; 0 out-of-sequence step completions; fastener installation torque within ±10% of SRM specification	N	N
4.3	Verify repair dimensions and load path restoration	Structures Inspector (Inspection Hold Point)	AMOS by Swiss AviationSoftware	Completed repair assembly, SRO dimensional tolerances, engineering drawing, calibrated measurement tools	Dimensional check record; pass/fail determination; rework instruction issued if out of tolerance	100% of SRO-defined hold points signed before next step begins; dimensional non-conformance rate <2% of structural repair work orders	Y	Y
4.4	Apply corrosion inhibitor and sealant compound	Airframe Structures Mechanic (A&P)	AMOS by Swiss AviationSoftware	Approved repair with completed dimensional check, SRM-specified sealant (PR-1422, EC-776), surface preparation requirements	Sealed repair with corrosion protection applied; sealant cure time logged; area prepared for final NDT verification	Sealant applied within 30 minutes of surface preparation (ASTM D1002 open-time limit); cure time logged per batch number; 100% coverage of faying surfaces per SRM specification	N	N
Phase 5 5.1	Perform post-repair NDT verification scan	NDT Level II Inspector	Olympus OmniScan (UT/PAUT) integrated with AMOS by Swiss AviationSoftware	Completed sealed repair, post-repair NDT Work Instruction, original pre-repair baseline scan data for comparison	Post-repair NDT report confirming no sub-surface anomalies, fastener hole integrity, and bondline continuity	Post-repair scan coverage ≥100% of repair footprint + 25mm margin; indication-free result confirmed on 100% of primary structural repairs before inspector sign-off	N	N
5.2	Quality inspector independent review and dual sign-off	Quality Assurance Inspector (Independent)	AMOS by Swiss AviationSoftware	Completed SRO work card, NDT pre- and post-repair reports, material traceability records, dimensional check records, engineering EO or SRM reference	Quality release stamp on SRO; airworthiness release authorisation issued or corrective action required	Independent QA review completed within 4 hours of last work card sign-off; QA deficiency rate <1% of released structural repair work orders	N	Y
5.3	Verify documentation completeness and regulatory compliance	Quality Assurance Supervisor	AMOS by Swiss AviationSoftware	Closed SRO with all work cards, NDT reports, material certs, dimensional records, engineer EO sign-off, QA release stamp	Documentation compliance check result; return to service approval issued or documentation deficiency log created for correction	Documentation review completed within 2 hours of QA release; 0 aircraft released to service with open documentation deficiencies	Y	Y
5.4	Update airworthiness records and issue RTS authorisation	Quality Assurance Supervisor / DMIR	AMOS by Swiss AviationSoftware	Approved documentation package, recurring inspection task creation confirmation (if AWL-driven), aircraft maintenance record	Aircraft maintenance record updated; Structural Repair Register entry created; FAA Form 337 (if DER repair) filed; Return to Service (RTS) authorisation signed	RTS issued within 1 hour of documentation approval; 100% of DER repairs accompanied by filed FAA Form 337 within 8 hours of RTS; AWL recurring tasks created and confirmed in AMOS for 100% of limit-item repairs	N	N

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Process Attributes

Identification

Process IDMR-11

L1 DomainMaintenance, Repair & Overhaul

L2 ProcessHeavy Maintenance

L3 NameStructural Repair & NDT Management

L4 Steps19 across 5 phases

Decision Gates5 (all with iteration loops)

Exceptions7 documented

Swim Lanes (Roles)

Aircraft Structures Inspector

NDT Level III Engineer

Structures Engineer

Structures Engineering DER

NDT Supervisor

NDT Level II Inspector

Stores / Material Planning Analyst

Airframe Structures Mechanic (A&P)

Structures Inspector (Inspection Hold Point)

Quality Assurance Inspector (Independent)

Quality Assurance Supervisor

Quality Assurance Supervisor / DMIR

Systems & Tools

AMOS by Swiss AviationSoftwareBoeing Toolbox / CAMPOlympus OmniScan (UT/PAUT) integrated with AMOS by Swiss AviationSoftwareSAP S/4HANA Finance (FI/CO) integrated with AMOS by Swiss AviationSoftware

Key Performance Indicators

Initiate structural damage finding reportDFR opened within 2 hours of discovery; 100% of findings logged before repair initiation

Define NDT method and inspection scopeNDT scope defined within 4 hours of DFR; SRM chapter referenced on 100% of instructions

Evaluate damage against SRM allowable limitsDisposition decision issued within 8 hours of DFR for non-AOG; 100% of beyond-limit findings escalated same shift

Submit damage for engineering disposition reviewEDR submitted within 2 hours of beyond-limits determination; completeness score ≥95% (all required fields populated)

Evaluate repair options against approved engineering dataEngineering disposition issued within 24 hours for non-AOG; 100% of dispositions reference specific SRM paragraph or approved data source

Determine if OEM or DER engineering order is requiredOEM referral decision made within 4 hours of disposition review; 0 instances of in-house repair where OEM EO was required by AD or AWL

Issue Structural Repair Order and material requirementsSRO issued within 2 hours of disposition approval; material list completeness ≥98% (no unplanned AOG parts requests during repair)

Assign certified NDT Level II/III inspector to taskInspector assigned within 1 hour of work instruction release; 100% of assignments verified against NAS410 certification currency

Airline-Specific Risks & Pain Points

Manual damage measurement and paper sketches introduce transcription errors when uploaded to AMOS; no integrated photo capture workflow forces separate file attachment steps

Boeing Toolbox revision currency lag — SRM updates from Boeing Service Bulletins (SBs) can trail physical publication by 30–60 days, risking use of superseded acceptance limits

Ambiguous SRM allowable tables for compound damage (multiple adjacent findings) require engineering judgement; misclassification risk if junior structures engineers make disposition calls without Level III review

AMOS EDR workflow does not integrate directly with OEM damage disposition portals (Boeing SRM Online); engineers must duplicate data entry across two systems, increasing cycle time and error risk

Recurring structural damage at frame stations may indicate systemic fatigue or corrosion issues not captured in individual DFRs; lack of fleet-level damage trending in Boeing Toolbox means repeat repairs go undetected without manual cross-referencing

Airlines with limited ODA (Organization Designation Authorization) scope must route repairs to Boeing, incurring 5–15 business day lead times that drive AOG extensions; DER authority matrix not always current in AMOS, causing avoidable OEM referrals

Inputs / Outputs

Primary InputVisual inspection finding, C-check opening discrepancy, or SRM-triggered inspection requirement

Primary OutputAircraft maintenance record updated; Structural Repair Register entry created; FAA Form 337 (if DER repair) filed; Return to Service (RTS) authorisation signed

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