Maintenance Check Interval Escalation

In addition to, and often times, as part of the work we do for our clients, we develop processes based on insights that occur as our thinking is focused on certain types of challenges.

While the tools we design are based on the specific parameters of a challenge we have been tasked with solving, frequently they will serve as the basis for a solution that can have wider industry application.

The issue of Maintenance Check Interval Escalation is a good example.


The Genesis Of The Insight

Airlines are initially constrained by the maintenance check intervals established by the OEM through the MSG-3 process.

While it’s true that most OEM's work to escalate these certified intervals, this activity can often be delayed by other priorities. As a result, airlines in most countries may seek local approval for escalated check intervals, based on a statistical analysis.

This task, however, can be labour-intensive, complex and, of course, costly.

Key Insight

Since we are always looking for methodologies and processes that would streamline this various aspects of our business and consequently offer better value to our clients, we started to think long and hard about developing adaptable maintenance record analytical tools that would provide the statistical data and reports required to support and justify any airline's request for check interval escalation.

The following is an outline of how this process would and can work for virtually any airline.


1. Quantitative Data Analysis

  1. Fleet maintenance records are collected for a period of time, covering a number of checks.
  2. These records are cleansed and filtered to correct coding errors and remove routine tasks.
  3. The clean data is processed for ATAs, type/category of discrepancy, inspection findings and corrective actions taken.
  4. The data is then sorted and categorized by processed items as in B) for check type (A, 2A, 4A, 5A etc.).
  5. Issues and actions for each ATA are analyzed in detail to identify if major issues are critical in nature and whether they would prevent escalation to the airline's desired level.
  6. Inspection findings are then sorted by check type and by ATA chapter. These findings form the basis of the statistical and quantitative analysis needed to justify the request for check interval escalation.
  7. Based on the extensive quantitative analysis, the check interval escalation report is then prepared and submitted

2. Check Interval Qualitative Analysis

For the escalation process using statistical approach, the following techniques can be applied for its fitment on the data provided:

  • Exponential Distribution
  • Poisson Distribution
  • Lognormal Distribution
  • Gumbel Distribution
  • Hyper-exponential Distribution
  • 3 Parameter Weibull
  • Weibull Distribution
  • Reliability Monitoring and Benchmarking


RCM's senior management would work with the airline to define the problem statement, scope, requirements, output file content and report structure.

RCM would provide a detailed review regarding how our services would meet the airline's internal requirements and those of the regulatory authorities.

Results Clients Can Expect To Realize:

By escalating the A-Check from 400 to 600 hours, and the C-Check from 4,000 to 6,000 hours, airlines implementing this service can expect the following benefits:

  • 21 fewer A-Checks over a period of 10 years
  • 2 fewer C-Checks over the same period
  • Dramatic savings in scheduled maintenance costs
  • Less aircraft downtime due to scheduled maintenance
  • Zero impact on operational reliability


Airlines typically use a variety of reliability measures to assess the performance of their operations. One of these, and the most widely quoted in press releases, is the Completion Rate.

The Completion Rate is basically a function of cancellations and diversions. And while it may average up to 99.00%, it does not reflect the accurate or complete picture of any airline’s more

One of the basic truths in the airline industry is that a lack of Arrival and Departure Punctuality is costing airlines millions.

Airlines are losing money every time an aircraft is not flying per schedule. Delays as little as 10 minutes can, depending on a number of related factors, cost airlines more

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