Improvements/Achievements of PIA Engineering and Maintenance - department 2001-2004

When the new management took over in May 2001 the Engineering department was in a bad shape as the financial condition of the corporation depicted.
The department had no International accreditation and the only technical certification was from the local Air worthiness authority, Civil Aviation Pakistan.
The engineering and maintenance activities were seized to such an extent because of financial constraints (over 24 million dollars was owed to various vendors and bills had not been paid as far back as 1994), that operational schedules of the fleet were difficult to meet.
Only 60% of the aircraft fleet was serviceable, with most of the Airbuses and B742 grounded for lack of engines, Landing gears and other vital spares. Overall, the situation was alarming.
Through the efforts of the new management and strict financial controls, engineering deptt was able to achieve the following by end 2003:
-- Reducing financial expenditures by 22% as compared to 2002, whilst achieving its stated functions, and yielding a saving of 1.2 billion Rupees to PIA's exchequer in 2003.
-- Over and above this, through Sales of Engineering services to outside agencies both external (Indonesia and Sri Lanka) and other internal airlines in Pakistan, PIA engineering was able to earn 500 million Rupees in 2003.
-- In 2002-2003 Highest dispatch regularity was achieved in the last fifteen years.
-- Successfully completed Hajj Operation 2002 and 2003 with highest ever dispatch regularity of over 98.5%.
-- Achieved target of 90% serviceability of aircraft throughout year 2002-03.
-- Maximum ever extra sections successfully provided, in addition to the normal schedule of operations.
-- 435 in 2003, 421 in 2004, 196 in 2001, and 247 in 2000.
-- Reduced volume and dollar value of Aircraft on Ground (AOG) orders for aircraft spare parts.
-- Avg. 300 parts/month in 2000 reduced to 80 parts/month by 2003.
-- Reduced volume of Repairable abroad by 50% and recovered 800 LRU's sent abroad more than 5/6 years ago.
-- From 2200 Open repair orders in 2001 reduced to 950 Open repair Orders by end 2003.
-- Reduced Technical Hold-ups at International Stations (due engineering) by 60%
-- 65 Night Stops in 2000
-- 75 Night Stops in 2001
-- 30 Night Stops in 2002
-- 22 Night Stops in 2003
-- Successfully compiled first ever Master Man hours Plan for Engineering Department.
-- Introduced man-hour accounting/rework assessment proformas in all work centers.
-- Undertook first ever task of stock taking, re-warehousing, renovation of stores and inventory control of all technical stores.
-- Approximately 2.25 lakh items
-- Task accomplished by end August 2003.
-- Total stores reduced from 22 to 12 2003 was also a good year when the Civil Aviation Authority of Indonesia & Sri Lanka gave their approval to engineering deptt as an approved Maintenance Organisation.
An extensive training program was launched and 600 engineering personnel were trained for B-777 / A310 aircraft and were also provided with Human Factor and Air Legislation training required for Part-145 approval from European Aviation Safety Agency.
The deptt is now ready with trained certifying engineers for the new A310 aircraft with P&W engine, and the new B777 fleet.
Two and half years later as we fly the new B777 aircraft, the fleet renewal plan is in hand, and the engineering department sparkles both physically and mentally. A very important project of International certification from the Joint Aviation Authorities (JAA) now called European Aviation Safety Agency (EASA) was commenced in October 2001, and the year 2002 was spent in streamlining procedures and defining requirements, renewing training skills, and defining what tools and equipment was required to support the fleet upgrade plan.
Extensive training both in Management and specialist field areas was conducted.
The JAA authorities accepted the engineering deptt's application for international certification. The Maintenance Organisation Exposition (MOE) ie the Quality Manual was written and submitted to JAA authorities in May 2003.
In October 2003 the European agency approved and passed the Maintenance Organisation Exposition (MOE) with a remark that "It was a near perfect document". On January 13 three auditors from Civil Aviation France (GSAC) deputed by EASA arrived in country to audit the Engineering deptt.
This extensive audit covered all eight divisions of engineering deptt, and lasted for ten days. The review audit by the same team was held from 21st, 24th February 2004.
In their debrief to the Chairman-PIAC, and to the DMD (Operations) the auditors expressed their extreme satisfaction on the existing state & affairs of engineering deptt, grading it as far above average, and definitely in harmony with it's Maintenance Organisation Exposition (MOE).
In March 2004 PIA engineering deptt received International certification of JAR-145 (Part-145) from EASA. This is a major step forward because engineering deptt is now an approved Maintenance Organisation (MRO) of equal if not better standard of any agency in Europe.
Immediately after receiving international certification, PIA Engineering signed a contract with "Fly Air" of Turkey to perform "C" Checks on ten A300-B2 aircraft and overhaul of their CF650C2 engines and landing gear systems.
This is the first step in an aggressive Programme to make PIA Engineering Deptt. a profit earning center.
In addition to its established clientele, PIA Engg expects to expand its outside party work by a target of US $4 million in 2004 over and above earnings of 2003 (Rs 500 M).
Through efficient management and dynamic control year 2004 will Inshah Allah be an excellent year and will add to the glory of PIA. Achievements for the first quarter of 2004 are as following:
-- Successful JAR-145 (Part-145) Audit and the review audit.
-- Part-145 Certification Approval received in mid March 2004.
-- Successful completion of Hajj Operation 2004.
-- Total Flights Pre Hajj=329, Dispatch Regularity=97.6%
-- Total Flights Post Hajj = 312, Dispatch Regularity = 98.4%
-- Successful Induction of three B777 Aircraft in PIA Fleet.
-- Successful Induction of three additional A310 lease aircraft in PIA Fleet.
-- Targets in hand for the year 2004:
-- Human resource Rationalisation of Engineering Department (biggest department of PIA, employing nearly one third of the total employees).
-- Ground breaking ceremony of the new "WIDE BODY HANGER" for Boeing 777 aircraft.
-- Commissioning of B747-300 Landing Gear Overhaul facility.
-- Up gradation of the Engine test cell to overhaul CF680C2 engines in country.
(The author is Amir Ali Technical Assistant to Director Engineering)