Introduction to aviation maintenance
By Morris Silverman
ATP. G-VI/V/IV, Challenger 601/604, Falcon 2000EX EAsy
Since the dawn of aviation, the existence of a maintenance-designated person or entity has always been crucial. Over time, it became an inseparable element of developing new ideas, plans, and manuals which have gone hand-in-hand with the work of innovators within the aviation community.
Pioneers
Charles E Taylor was a mechanic, machinist, and inventor. Thanks to his ingenuity, the Wright brothers had their very first aircraft engine. Without his contributions, development of a viable self-propelled aircraft might have taken longer. His input to aviation was pivotal, and is reflected in the naming of FAA’s Charles Taylor Master Mechanic Award and the Department of Aviation Maintenance Science at Embry-Riddle Aeronautical University.
Next came Charles Lindbergh and his famous solo Atlantic crossing in the Spirit of St Louis. The aircraft was built by Ryan Airlines based on a Ryan M-2 design. It underwent significant modifications in just 60 days, thanks to the ingenuity and expertise of engineers and maintenance personnel. With the most modern instruments available at the time, Lindbergh took off from Roosevelt Field, Long Island NY. The rest, as they say, is history.
In large part, thanks to the cooperation of designers, engineers, pilots, air traffic controllers, and maintenance personnel, the airline industry evolved from a potentially perilous endeavor into one that was safe and reliable. Despite occasional headline-making failures, the dedication of maintenance professionals who ensure the safety of daily flights across the globe cannot be praised enough. Their efforts mean that millions of passengers board aircraft every day with confidence that their destination will be reached safely.
Ever-growing complexity
By the 1930s, aircraft were becoming more complex, with innovations designed to extend range and improve passenger comfort, such as larger fuel loads and pressurized cabins. Mechanics became essential to ensure these increasingly complex aircraft remained airworthy.
Back then, the Aeronautics Branch of the Department of Commerce was responsible for overseeing aviation. This was before it evolved into the Civil Aeronautics Authority and, ultimately, the FAA. The agency was responsible for overseeing safety standards, licensing, and regulations, and played a significant role during this era of standardization.
Looking back at aviation’s history, it’s impressive to see how aircraft maintenance has evolved. Today’s maintenance practices resemble those in the medical field, with specialists applying the latest technologies to ensure the best outcome possible. The focus now is on predictive maintenance and scheduled events, which has led air travel to become the safest form of transportation today.
3D printing, AI, robotics, and blockchain technology
Leading aircraft manufacturers, such as Airbus, Boeing, Bombardier, Dassault, Embraer, and Gulfstream, have been at the forefront of integrating cutting-edge digital technologies into aircraft maintenance.
For example, 3D printing has alleviated issues that have plagued the industry, like part shortages. Artificial intelligence (AI) is now playing a major role in problem-solving by analyzing vast amounts of data, resulting in more precise predictive maintenance schedules, reduced downtime, and fewer unnecessary repairs.
AI also helps in the creation of 3D aircraft models that can be projected via specialized goggles to assist engineers in ensuring proper ergonomics and component positioning. Lastly, robotics have become exceptional tools for accessing hard-to-reach areas in aircraft, creating perfect welds, carrying out paint jobs, and conducting tests that require precision beyond human capabilities.
Another significant advance is the use of blockchain technology. After incidents where counterfeit or unapproved parts caused accidents or fatalities, it became essential to ensure that only certified parts are used in repairs, manufacture, and service. Blockchain technology promises to reduce the use of counterfeit parts, preventing a potential catastrophe. For example, in 2021 FAA fined Boeing for installing unapproved parts on more than 700 of its 737 airliners.
Shifting from reactive to preventative maintenance
Modern aircraft are equipped with a wide array of onboard computers connected to communication servers, enabling manufacturers to know immediately of any irregularities in an aircraft’s performance. This has paved the way for predictive maintenance, which identifies potential failures well before they happen, reducing downtime and ensuring maintenance schedules are more streamlined, which in turn makes life easier and safer for flight crews.
A shift in maintenance philosophy is occurring – it’s moving from a reactive approach, where technicians address problems reported by flight crews, to a more proactive, preventative mindset. Using advanced software, like CAMP, CAMS, and CMMS, maintenance teams can schedule repairs before issues arise, thus avoiding the headaches caused by sudden aircraft breakdowns.
Modern challenges
One of the greatest challenges modern maintenance departments face is the shortage of qualified technicians. As experienced workers retire, the next generation of technicians may not yet have the hands-on experience to diagnose and address complex maintenance issues.
The growing demand for air travel also puts additional pressure on maintenance teams, sometimes leading to delays in aircraft delivery, which can frustrate customers and operators.
We’ve all experienced supply chain disruptions – whether it’s missing items on grocery store shelves or sudden price hikes – and the aviation industry has not been immune to this. While some manufacturers report that delivery schedules are returning to normal, the disruption has created challenges for maintenance and operations.
Aircraft are becoming increasingly sophisticated, requiring highly skilled technicians who understand the complexities of modern systems. A small mistake in maintenance procedures can result in significant damage to delicate electronic systems. As the demand for air travel continues to rise, maintaining an adequately trained workforce becomes even more critical.
A common complaint among aircraft owners and operators is the perceived high cost of maintenance. The price of spare parts has increased, aircraft systems are more advanced, and the tools required to repair these systems are specialized and expensive. Combined with ever-changing regulations that demand in-depth understanding from maintenance professionals, these factors contribute to the rising costs of maintenance.
Personal reflections
All of my life as a business aircraft pilot, I’ve been fortunate to have a dedicated mechanic who traveled with us to remote destinations. This offered me and my passengers the reassurance that we were in good hands should anything go wrong. Our departures were always smooth, as the aircraft was always ready, the APU was running, and all checks had been performed. This peace of mind is what makes professional maintenance invaluable.
Whether working with independent contractors, in-house teams, MROs, or full-fledged manufacturers, I have always respected maintenance professionals. They are essential to the safe and efficient operation of aviation, using the latest tools and technology to ensure that aircraft are always ready for flight.
With continued advancements in technology, such as AI, robotics, and blockchain, the future of aircraft maintenance is looking brighter than ever. Thanks to the tireless efforts of maintenance professionals, air travel remains a safe, efficient, and reliable mode of transportation.
Morris Silverman’s aviation career started at age 18 with a small airline in Acapulco, Mexico. He moved to the US to pursue his comm/multi/inst ratings with FAA. On returning to Mexico, he served as pilot for a district attorney and the owner of Pepsi-Cola. He moved back to the US to earn his ATP license and flew Challenger 601 and 604, Falcon 2000EX, and Gulfstream VI, V, and IV bizjets.