Aircraft Maintenance and Repair
Ensuring Flight Stability Is Achieved Beyond the Sky—On the Ground
An aircraft, as one of the most complex engineering systems created by humans, is a combination of hundreds of mechanical, electronic, hydraulic ,and
software systems.
During flight, these components operate under extreme physical conditions , including high pressure , temperature fluctuations , intense vibration , and
dynamic loading. Therefore, aircraft maintenance and repair is not only a technical activity, but it is also the key to flight safety , airworthiness, and
the economic efficiency of the aviation fleet.
This article examines the importance, types, processes, challenges, and solutions for improving aircraft maintenance and repair.
The Importance of Aircraft Maintenance and Repair
Maintaining Flight Safety
Timely maintenance and repair significantly reduce the risk of air accidents. Even the smallest defect in one of the systems can lead to a catastrophe.
Compliance with International Standards
All aircraft must be maintained and repaired according to the manufacturer’s(OEM) instructions and under the supervision of international organizations
such as ICAO, FAA, and EASA.
Increasing Equipment Lifespan
Proper execution of maintenance programs can extend the lifespan of expensive aircraft components and structures , reducing the need for premature
replacement.
Operational and Economic Efficiency
An airworthy aircraft is a profitable one. Proper maintenance reduces AOG (Aircraft on Ground) time and increases flight hours.
Types of Aircraft Maintenance and Repair
Aircraft maintenance is generally divided into two main categories:
Line Maintenance
Daily or pre-flight inspections
Checking the performance of the engine, electrical, and hydraulic systems
Replacing consumable parts such as filters, lights, and oil
Performing simple tests and resolving minor issues during short stops
Base Maintenance
Periodic checks: A, B, C, and D checks
Dismantling and inspecting internal aircraft components
Testing and calibrating flight, navigation, and control systems
Replacing or overhauling major parts (e.g., engines or gearboxes)
Full structural inspections and repainting of the aircraft
Maintenance Planning
Maintenance and repairs must be scheduled according to long – term and short – term plans , either calendar-based or based on usage (Flight
Hours/Cycles). For example:
A-Check: Every 600–800 flight hours or every 6 weeks
C-Check: Every 18–24 months or after 4,000–6,000 hours
D-Check (Heavy Check): Every 6 to 10 years – complete aircraft overhaul
This scheduling is defined in technical documents such as the AMM ( Aircraft Maintenance Manual ) and MPD ( Maintenance Planning
Document).
Main Stages of Aircraft Maintenance and Repair
Receiving Reports and Initial Diagnosis
Review of pilot reports (PIREP), automated fault recording systems (BITE), and cockpit warnings.
Technical and Visual Inspection
Visual checks for cracks, leaks, corrosion, cable wear, control systems, and component connections.
System Functional Testing
Ground testing of systems such as engine, landing gear, electrical, hydraulic, and navigation systems.
Replacement or Repair of Faulty Parts
Using certified spare parts and carrying out precise installation procedures according to IPC and AMM.
Calibration and Final Testing
After repairs, the system must be calibrated and tested in real or simulated operational conditions.
Complete Documentation and Return-to-Service Approval
Recording all actions in technical logs, airworthiness certification forms, and aircraft technical documents.
Required Infrastructure and Tools
Standard repair hangar
Specialized testing equipment for engines, hydraulics, and electronics
Maintenance management software (CMMS such as AMOS, Ramco)
Non-destructive testing (NDT) tools
Spare parts bank with certified components
Specialized team with Part-66 or equivalent licenses
Challenges of Aircraft Maintenance in Iran
Aging Fleet
Over 40% of domestic aircraft are more than 20 years old and require heavier maintenance.
Import Restrictions
Sanctions have made it difficult to procure both sensitive and consumable parts, prolonging repair times.
Shortage of Skilled Personnel
Some airports lack sufficient technicians with international certifications (e.g., Part-66 or equivalent).
High Maintenance Costs
Heavy checks like the D-Check are costly. If not performed, the aircraft must be removed from service.
Solutions for Improving Maintenance and Repairs
Training and Increasing Skilled Manpower
Conducting international training programs, supporting local technical-aviation centers, and sponsoring training abroad.
Localizing Parts and Repair Technologies
Collaborating with knowledge-based companies to produce high-use components and implement reverse engineering.
Establishing National and Regional MRO Centers
Developing and equipping specialized maintenance centers in Tehran , Mashhad , Tabriz , and Shiraz to service both domestic and foreign fleets.
Implementing Digital and Data-Driven Technologies
Utilizing systems such as FDM, predictive maintenance, and performance data analysis to predict failures before they occur.
Developing Spare Parts Logistics Infrastructure
Establishing regional spare parts banks to reduce procurement times for grounded aircraft.
Conclusion
Aircraft maintenance and repair is not just a technical task but a vital foundation for safety , efficiency , and sustainability in flight operations.
Given the specific conditions of Iran’s domestic fleet , the development of technical infrastructure , enhancement of repair knowledge,
and strengthening of human resources and logistical support are essential steps toward a safer and more stable future in the country’s
aviation industry.
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