Optimising the management of repetitive system defects - evaluation and process development within a CAMO environment

Abstract

Repetitive system defects (RSD) demand urgent intervention to mitigate potential safety risks. In the absence of explicit regulatory guidance, Continuing Airworthiness Management Organisations (CAMOs) have developed disparate processes for managing such defects. Unlike deferred or carried-forward defects, which remain open and highly visible in technical logbooks, RSD are typically closed after each occurrence, reducing transparency. This raises a critical question: should the pilot-in-command, who has responsibility for accepting or rejecting an aircraft, be informed when an aircraft may not be fully technically airworthy, thereby introducing additional operational risk? This study focuses on short-term actions for addressing RSD rather than long-term reliability monitoring. It examines effective handling of RSD from both CAMO and flight crew perspectives, highlighting deficiencies in process, terminology, and communication. A mixed-methods approach was employed, combining questionnaires and interviews for Maintenance Control Centre (MCC) engineers, while commercial pilots completed an online questionnaire. Findings confirm inconsistent terminology and regulatory practices across CAMOs and authorities. MCC engineers regard pilots as key contributors to troubleshooting, recognising that information shared with cockpit crew can expedite technical resolution and support in-flight decision-making. Pilots, in turn, expressed a strong desire to be informed of their aircraft’s technical status to assess risk and consider operational and technical factors in real time. The introduction of rogue components into aircraft affected by RSD is also a significant concern. This research underscores the criticality of effective RSD management. Several recommendations are made, including the definition of a repetitive system defect as 3 or more occurrences within 25 sectors. An optimal process framework for CAMOs is presented, alongside recommendations for National Aviation Authorities.