MR-12 · Avionics & Systems Modification

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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	Receive and log AD/SB notice into tracking system	Continuing Airworthiness Manager	CAMP Systems	FAA AD Federal Register notice or OEM Service Bulletin release	Applicability assessment report with fleet impact analysis	AD applicability assessment completed within 3 business days of issuance; 100% of ADs logged	N	N
1.2	Assess compliance deadline and work priority flag	Continuing Airworthiness Manager	CAMP Systems	Applicability assessment report, AD/SB compliance timeframe, flight-hours and cycles data	Compliance deadline schedule, priority classification (EAD / mandatory / optional)	100% of mandatory ADs scheduled before compliance deadline; 0% AD overrun rate	N	Y
1.3	Determine mandatory vs. optional modification track	Director of Maintenance / CAMO	CAMP Systems	AD/SB classification, compliance deadline, cost-benefit analysis for optional SBs	Work authorization decision: mandatory track (expedite) or optional track (standard planning)	Mandatory ADs never exceed compliance deadline — 0% regulatory non-compliance rate	Y	N
Phase 2 2.1	Develop Engineering Order from OEM technical data	Avionics Engineer	Boeing TechConnect	Approved SB/AD task data, AMM chapter reference, IPC part numbers	Engineering Order (EO) with task card, materials list, and tooling requirements	EO development cycle 5 business days for standard modifications; 2 days for emergency ADs	N	N
2.2	Classify modification as major or minor alteration	Avionics Engineer / DER	FAA FSIMS (Flight Standards Information Management System)	Engineering Order draft, modification scope and system criticality assessment	Major/minor alteration determination per FAR Part 43 Appendix A; DER involvement decision	Major/minor determination documented within 1 business day of EO draft completion; 0% misclassification findings on FAA audits	Y	N
2.3	Submit Engineering Order to CAMO for formal approval	Quality Assurance Engineer	AMOS by Swiss AviationSoftware	Completed EO with DER determination, SB copy, applicability data, materials list	CAMO-approved EO, released work order number in AMOS	CAMO EO approval turnaround 2 business days for standard modifications; same-day for EADs	N	N
Phase 3 3.1	Raise parts requisition for avionics LRUs and consumables	Materials Planner	AMOS by Swiss AviationSoftware	Approved EO materials list, IPC part numbers, supplier approved vendor list (AVL)	Purchase order or stores issue request for LRUs, connectors, wire, and consumables	Parts availability confirmed 72 hours before scheduled modification slot; on-time parts availability rate 95%	N	N
3.2	Verify parts serviceability, traceability, and shelf-life	Stores Controller / Materials Planner	AMOS by Swiss AviationSoftware	Parts received from stores or supplier, FAA Form 8130-3 / EASA Form 1 certificates	Go/No-Go decision for scheduled modification slot; quarantine order if parts rejected	Parts shortage-driven deferral rate 5% of avionics work orders; counterfeit parts detection — 0 unapproved parts reaching aircraft	Y	Y
3.3	Reserve hangar bay, tooling, and technician staffing	Production Planner	AMOS by Swiss AviationSoftware	Approved EO, parts availability confirmation, aircraft schedule and induction date	Confirmed maintenance event: hangar bay, specialized avionics tooling, staffing plan, and ground support equipment reservation	Avionics modification slot utilization 85%; aircraft out-of-service time within 10% of planned duration	N	N
Phase 4 4.1	Remove existing avionics LRU and prepare installation zone	Licensed Avionics Technician (A&P/IA)	Trax	Approved EO task card, aircraft inducted into maintenance bay, tooling issued	Removed LRU tagged with part number, serial number, and removal date; cleared and inspected installation area	LRU removal and serviceable tagging completed per AMM procedure; 0 FOD events per modification event	N	N
4.2	Install avionics modification per EO and AMM procedure	Licensed Avionics Technician (A&P/IA)	Trax	Approved EO, new LRU with FAA Form 8130-3, wiring diagram, torque specifications	Installed avionics component with completed installation task card; connector and harness photographs	Installation rework rate 2% of avionics work orders; first-time quality rate 98%	N	Y
4.3	Inspect wiring integrity, bonding, and HIRF protection	Quality Assurance Inspector	Trax	Completed wiring installation, bonding resistance test results, HIRF test equipment readings	Wiring inspection pass/fail determination; rework order issued if failed	Wiring inspection pass rate 96% first pass; rework cycle 4 hours; 0 HIRF non-conformances at release	Y	Y
Phase 5 5.1	Load approved avionics software and update configuration data	Licensed Avionics Technician (A&P/IA)	Honeywell GoDirect	Approved software part number, Loadable Software Aircraft Part (LSAP) list, aircraft data loader	Confirmed software load complete; post-load configuration report with part number and version verification	Software load completion without error within 2 hours; LSAP compatibility verified against aircraft CDS 100%	N	Y
5.2	Execute functional ground test per approved test procedure	Avionics Test Technician	BITE (aircraft-native Built-In Test Equipment) / Trax	Completed modification, aircraft on ground power unit, approved test procedure and acceptance criteria	Functional test report with pass/fail for each test parameter; BITE fault code log	Avionics ground test pass rate 94% first run; 0 open safety-of-flight defects at release	N	N
5.3	Evaluate test results against acceptance criteria	QA Inspector / Avionics Lead	Trax	Functional test report, BITE fault codes, acceptance criteria from EO and AMM	Airworthiness determination: proceed to release or raise defect work order for rework	Discrepancy rate at final test 4%; 0 open safety-of-flight items at time of release	Y	Y
Phase 6 6.1	Complete maintenance release and regulatory documentation	Authorized Release Certifier (ARC) / IA Inspector	Trax	Completed task cards, functional test report, DER approval (if major alteration), FAA Form 8130-3	Signed maintenance release; FAA Form 337 filed for major alterations; updated aircraft log entry	Maintenance release documentation completeness 100% before aircraft release; FAA Form 337 filed within 30 days of major alteration completion	N	Y
6.2	Update aircraft configuration records and return to service	Continuing Airworthiness Manager	CAMP Systems	Signed maintenance release, EO closure, modification documentation package	Updated aircraft status in CAMP (mod state, AFMS revision, AD compliance record); aircraft released to operations	Configuration record update completed within 24 hours of maintenance release; CAMP mod state accuracy 99.5%	N	N

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Process Attributes

Identification

Process IDMR-12

L1 DomainMaintenance, Repair & Overhaul

L2 ProcessAirworthiness & Compliance

L3 NameAvionics & Systems Modification

L4 Steps17 across 6 phases

Decision Gates5 (all with iteration loops)

Exceptions7 documented

Swim Lanes (Roles)

Continuing Airworthiness Manager

Director of Maintenance / CAMO

Avionics Engineer

Avionics Engineer / DER

Quality Assurance Engineer

Materials Planner

Stores Controller / Materials Planner

Production Planner

Licensed Avionics Technician (A&P/IA)

Quality Assurance Inspector

Avionics Test Technician

QA Inspector / Avionics Lead

Authorized Release Certifier (ARC) / IA Inspector

Systems & Tools

CAMP SystemsBoeing TechConnectFAA FSIMS (Flight Standards Information Management System)AMOS by Swiss AviationSoftwareTraxHoneywell GoDirectBITE (aircraft-native Built-In Test Equipment) / Trax

Key Performance Indicators

Receive and log AD/SB notice into tracking systemAD applicability assessment completed within 3 business days of issuance; 100% of ADs logged

Assess compliance deadline and work priority flag100% of mandatory ADs scheduled before compliance deadline; 0% AD overrun rate

Determine mandatory vs. optional modification trackMandatory ADs never exceed compliance deadline — 0% regulatory non-compliance rate

Develop Engineering Order from OEM technical dataEO development cycle 5 business days for standard modifications; 2 days for emergency ADs

Classify modification as major or minor alterationMajor/minor determination documented within 1 business day of EO draft completion; 0% misclassification findings on FAA audits

Submit Engineering Order to CAMO for formal approvalCAMO EO approval turnaround 2 business days for standard modifications; same-day for EADs

Raise parts requisition for avionics LRUs and consumablesParts availability confirmed 72 hours before scheduled modification slot; on-time parts availability rate 95%

Verify parts serviceability, traceability, and shelf-lifeParts shortage-driven deferral rate 5% of avionics work orders; counterfeit parts detection — 0 unapproved parts reaching aircraft

Airline-Specific Risks & Pain Points

AD applicability across mixed fleet configurations (different mod states, AFMS revisions) requires manual cross-check in CAMP — no automated fleet-wide applicability filter exists, creating missed-applicability risk on large fleets

Short-fuse Emergency ADs (EADs) compress planning windows to less than 48 hours, forcing AOG-level priority and displacing planned line maintenance events across multiple stations

Optional SBs reclassified as mandatory mid-stream (e.g., OEM safety recommendation upgrade) force reprioritization and resource reallocation from already-scheduled maintenance events

Boeing TechConnect access latency and AMM revision currency issues cause engineers to reference outdated task data — no automated revision alert in AMOS when OEM documentation is superseded post-EO creation

Major vs. minor alteration boundary under FAR Part 43 Appendix A is subjective for novel avionics integrations — misclassification exposes the airline to FAA enforcement action and certificate action during oversight audits

AMOS approval workflow does not enforce mandatory attachment validation (SB copy, applicability data), allowing incomplete EOs to route to the shop floor and cause mid-task holds for missing documentation

Inputs / Outputs

Primary InputFAA AD Federal Register notice or OEM Service Bulletin release

Primary OutputUpdated aircraft status in CAMP (mod state, AFMS revision, AD compliance record); aircraft released to operations

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