MR-06 · Maintenance Reliability & RCM Program

📊

Process Flow Diagram (BPMN)

📋

L4 Process Steps

Step	Step Name	Role / Swim Lane	System	Input	Output	KPI	Dec?	Exc?
Phase 1 1.1	Extract technical delay & cancellation events	Reliability Engineer	AMOS by Swiss AviationSoftware	Daily operations data feeds, PIREP submissions, MEL deferrals	Reliability event log with ATA chapter coding	Technical dispatch reliability ≥99.0% (IATA target)	N	N
1.2	Compile PIREP and cabin defect report data	Reliability Analyst	AMOS by Swiss AviationSoftware	Pilot reports (PIREPs), cabin defect logs, maintenance findings	Consolidated defect database partitioned by ATA chapter	Repeat defect rate <2% per ATA chapter per month	N	N
1.3	Calculate ATA chapter reliability metrics	Reliability Engineer	Tableau / Power BI	AMOS defect export, flight operations hours and cycles data	ATA chapter reliability scorecard (events per 1,000 flight hours)	Alert threshold: >3 events / 1,000 flight hours per ATA chapter triggers review	N	N
1.4	Assess alert threshold breach and escalate	Reliability Manager	AWS Redshift	ATA chapter reliability scorecard	Alert notification issued to MRB, or threshold cleared and monitoring continues	100% of threshold breaches assessed within 2 business days of month-end data close	Y	N
Phase 2 2.1	Initiate formal failure investigation record	Reliability Engineer	AMOS by Swiss AviationSoftware	Alert notification from MRB, repeat defect flag	Investigation record opened in AMOS with case owner assigned	100% of Level 1 alert items investigated within 5 business days of alert	N	N
2.2	Perform MSG-3 logic and FMEA assessment	Reliability Engineer	Boeing Toolbox / CAMP	Failure investigation record, OEM Maintenance Planning Document (MPD)	FMEA worksheet with failure mode, cause, and effect documented	FMEA completed for 100% of Level 1 alert items within investigation SLA	N	N
2.3	Classify failure consequence category	Reliability Engineer	Boeing Toolbox / CAMP	FMEA worksheet, MPD task data, airworthiness directive index	Failure consequence classification: Safety / Operational / Economic / Hidden	100% classification accuracy validated by MRB at monthly review	Y	Y
2.4	Identify and document corrective task recommendation	Reliability Manager	AMOS by Swiss AviationSoftware	Failure consequence classification, OEM service bulletin index	Task change recommendation record with justification and urgency rating	Recommendation issued within 10 business days of alert escalation	N	N
Phase 3 3.1	Evaluate existing MPD task applicability	Fleet Technical Manager	Boeing Toolbox / CAMP	Task change recommendation, current approved MPD tasks	Task gap analysis identifying intervals to extend, reduce, or replace	Task revision scope defined within 5 business days of recommendation receipt	N	N
3.2	Develop revised maintenance task intervals	Reliability Engineer	AMOS by Swiss AviationSoftware	Task gap analysis, reliability trend data, Weibull statistical model output	Draft task card revision with updated intervals (FH / FC / calendar)	Interval extension justified at ≥95% statistical confidence using Weibull analysis	N	N
3.3	Assess regulatory change approval requirement	Fleet Technical Manager	AMOS by Swiss AviationSoftware	Draft task card revision, FAR Part 121.370 compliance matrix	Regulatory assessment memo classifying change as self-approval or FSDO submission	100% of safety-consequence task changes submitted for FAA/EASA regulatory review	Y	N
3.4	Issue Engineering Order or Maintenance Program Amendment	MRO Engineering	AMOS by Swiss AviationSoftware	Approved task revision, regulatory assessment memo	Engineering Order (EO) or Maintenance Program Amendment (MPA) document	Engineering Order issued within 15 business days of task approval	N	N
Phase 4 4.1	Submit MPA to FAA FSDO or EASA for approval	Continuing Airworthiness Manager	AMOS by Swiss AviationSoftware	Maintenance Program Amendment with supporting FMEA and reliability data	Regulatory submission package with acknowledgement reference number	FAA approval turnaround ≤90 days for non-safety items per FAR 121.370	N	Y
4.2	Update approved task cards in AMOS	MRO Engineering	AMOS by Swiss AviationSoftware	Regulatory approval letter or self-approval sign-off, approved MPA	Updated task cards activated in AMOS with new intervals and applicability	100% task card accuracy post-update verified by QA within 48 hours of activation	N	N
4.3	Validate task card update accuracy via QA audit	Quality Assurance Inspector	AMOS by Swiss AviationSoftware	Updated AMOS task cards, approved MPA source document	QA sign-off record or discrepancy report requiring correction	Zero task card interval discrepancies at post-update audit; 100% of failed audits remediated within 5 days	Y	N
4.4	Train maintenance technicians on revised tasks	Training Manager	SAP SuccessFactors	Approved revised task cards, training needs analysis	Training completion records with competency sign-off per technician	100% technician training completion within 30 days of task implementation	N	N
Phase 5 5.1	Generate monthly reliability performance report	Reliability Manager	Tableau / Power BI	AMOS reliability data export, flight operations performance data	Monthly Reliability Report (MRR) with ATA trend charts and open action items	Report published within 5 business days of month-end data close	N	N
5.2	Present findings to Maintenance Review Board	Reliability Manager	Tableau / Power BI	Monthly Reliability Report, open investigation items	MRB minutes with closed actions and new action items assigned	100% of open MRB action items tracked to closure within agreed timescales; MRB held monthly	N	N
5.3	Assess corrective action effectiveness and close investigation	Reliability Manager	AMOS by Swiss AviationSoftware	MRB minutes, post-change reliability trend data (90-day lookback)	Investigation closure record or re-escalation trigger for repeat failure	Recurrence rate <5% within 90 days of corrective action implementation	Y	N

📋

Process Attributes

Identification

Process IDMR-06

L1 DomainMaintenance, Repair & Overhaul

L2 ProcessAirworthiness & Compliance

L3 NameMaintenance Reliability & RCM Program

L4 Steps19 across 5 phases

Decision Gates5 (all with iteration loops)

Exceptions2 documented

Swim Lanes (Roles)

Reliability Engineer

Reliability Analyst

Reliability Manager

Fleet Technical Manager

MRO Engineering

Continuing Airworthiness Manager

Quality Assurance Inspector

Training Manager

Systems & Tools

AMOS by Swiss AviationSoftwareTableau / Power BIAWS RedshiftBoeing Toolbox / CAMPSAP SuccessFactors

Key Performance Indicators

Extract technical delay & cancellation eventsTechnical dispatch reliability ≥99.0% (IATA target)

Compile PIREP and cabin defect report dataRepeat defect rate <2% per ATA chapter per month

Calculate ATA chapter reliability metricsAlert threshold: >3 events / 1,000 flight hours per ATA chapter triggers review

Assess alert threshold breach and escalate100% of threshold breaches assessed within 2 business days of month-end data close

Initiate formal failure investigation record100% of Level 1 alert items investigated within 5 business days of alert

Perform MSG-3 logic and FMEA assessmentFMEA completed for 100% of Level 1 alert items within investigation SLA

Classify failure consequence category100% classification accuracy validated by MRB at monthly review

Identify and document corrective task recommendationRecommendation issued within 10 business days of alert escalation

Airline-Specific Risks & Pain Points

AMOS data quality degrades at outstations using paper-based PIREP capture; electronic sync lags up to 24 hours, distorting daily reliability figures

Inconsistent ATA chapter coding across maintenance bases causes mis-classification; repeat defects counted under different chapters, masking true recurrence rates

Manual data extraction from AMOS via CSV export introduces processing lag of 2–3 days; no real-time API feed from AMOS to BI platform

Alert threshold logic embedded in legacy spreadsheets not integrated with AMOS or Redshift; threshold parameters updated manually and inconsistently across fleet types

Insufficient root cause data available when aircraft operated at remote outstations; maintenance findings not captured in AMOS before aircraft repositions

Boeing Toolbox concurrent-user licence constraints limit simultaneous FMEA sessions; engineers queue for access during peak investigation periods, extending cycle time

Inputs / Outputs

Primary InputDaily operations data feeds, PIREP submissions, MEL deferrals

Primary OutputInvestigation closure record or re-escalation trigger for repeat failure

←PreviousMR-05 · Airworthiness Directive (AD) Compliance NextMR-07 · Aircraft Technical Records Management→