Aviation Maintenance Safety | Aircraft Maintenance Safety Issues

Aviation maintenance safety | Aircraft maintenance safety issues

Aviation maintenance safety | Aircraft maintenance safety Issues, how important is aircraft maintenance safety?

How important is aircraft maintenance safety?

Because the aviation maintenance profession involves some inherent on-site risks, it is critical to follow proper aviation maintenance safety procedures. Aviation maintenance specialists must always keep their own and their coworkers' safety in mind because to the enormous equipment, heights, and specialized tools they operate with.

You have several tasks as an aviation maintenance manager at any given time. But there's no more important continuous responsibility than cultivating a working culture that prioritizes the safety of your aviation maintenance workers.

The persistent risk of complacency is, of course, one of the greatest obstacles to this attempt. And everything a technician does, from wearing the proper protection gear to utilizing the proper aviation equipment, is the result of a technician making a responsible decision at the correct time.

We'll look at some of the risks in the aviation maintenance industry, as well as some simple ways to prevent complacency and promote excellent safety procedures among your employees, in this post.


What is Aircraft Maintenance?

Any aviation business requires proper aircraft maintenance. It's critical for keeping a fleet in top shape, from daily maintenance to overhauls, and keeping your maintenance staff safe and healthy leads to more thorough work. A well-functioning and motivated maintenance team guarantees that aircrafts are properly serviced.

Your maintenance experts' job saves lives, so they require the right tools, equipment, and a foolproof maintenance plan. You can only fully protect your technicians and your aircraft by fine-tuning your maintenance, repair, and overhaul (MRO) routine.

Let's look at some of the potential risks that your maintenance crew might face and how to avoid them.

Safety Issues in Aircraft Maintenance

Mechanics are more at risk than other professions because of the potentially risky work environment of aviation repair. Working on an aircraft entails working high above the earth, moving large objects, operating strong machinery, and working in close proximity to hazardous chemicals, not to mention the long-term risk of vibration and noise exposure. Your mechanics, on the other hand, can considerably reduce the risk of injury with the correct equipment and safety precautions.

So, despite perfect maintenance routine planning and suitable equipment, why do accidents still occur? It almost usually boils down to employee laziness and a failure to follow procedures.

While no amount of planning will guarantee that a mistake will not occur, ensuring that your mechanics are in good health, following safety standards, and not cutting corners will dramatically lower the chances of them being involved in an accident.

The effect of' shift work' is one risk for any worker in a potentially dangerous field like aircraft maintenance. Workers who work set shifts may be required to work despite not being physically or psychologically fit. Furthermore, because some aircraft maintenance procedures have mechanics working irregular hours, the chances of employees not being physically and mentally prepared to conduct safe job are substantially higher. It's critical to recognize your maintenance team's limitations and make necessary adjustments. Shift work can provide a number of risks, including:

Fatigue and Sleepiness: 

If your mechanics work irregular hours, they may not receive enough sleep. When this is combined with extended or strenuous maintenance, it might result in inefficient and ineffective work.


People's personal and professional lives might be stressful, causing them to think about matters other than the task at hand. If a technician isn't paying attention to a detailed repair job, being distracted from tension can be deadly.

Medical Issues: 

Interruptions induced by irregular work hours might create health problems such as gastrointestinal and cardiovascular disorders.


Older employees may have a harder difficulty adjusting to fluctuating schedules or irregular work hours.

It's important to communicate with your staff in order to discover any issues they may be experiencing. The finest MRO managers figure out ways to make work more efficient while keeping maintenance professionals healthy and happy.


Planning is the greatest method to avoid accidents and assure high-quality aircraft maintenance. For thorough maintenance and employee safety, detailed planning is essential.

Additionally, regular employee safety training is the most effective strategy to educate and keep your team aware. Here are some safety themes to consider in your aircraft maintenance training and overall safety plan.

Review Your Risk Management Techniques

Employees should try their best to avoid distractions and anything that will divert their focus away from their work while on the job - even the most experienced mechanics can become sidetracked. Technicians can avoid small mistakes that can lead to serious mishaps by adopting risk management techniques. Remind your employees that even simple maintenance activities should be double-checked to ensure that nothing is forgotten.

Follow the Procedures Completely

When executing any maintenance operation on aircrafts/equipment, maintenance technicians should always use/follows approved data and procedures. Service/maintenance manuals are valuable resources that provide extensive instructions on how to execute each activity as well as any specific items required. Also, keep in mind that for maintenance items that aren’t included in your maintenance manuals, it’s a good idea to find references for your technicians/engineers so that they are all using the same standardized, approved procedure.



Reminder of safety protocol is a good idea. That's why having plainly visible signs reminding technicians to stick to the basics like wearing a safety harness when working on top of wings and fuselages is a cost-effective and consistent way to keep safety in the forefront of their minds. Also, keep in mind that using safety flags and other caution markings is an excellent method to increase safety while your specialists are working in a familiar environment.


Just because your hangar hasn't had an accident in a while doesn't imply your crew won't have one tomorrow. You'll go a long way toward being proactive rather than reactive if you hold frequent safety meetings and bring up safety issues whenever you transmit vital information to your employees.

It's usually a good idea to ask your employees if they have any suggestions for making their job safer. Your employees will appreciate having their input appreciated & implemented, and fostering a safe work environment can help to avoid complacency.


You must be prepared to respond to incidents when they occur, from properly designated eyewash units and first aid supplies to fire suppression equipment and emergency exits. Also, ensure that everyone on your team, from the most senior to the most junior, is adequately trained in the usage of emergency equipment, since this is critical for being prepared in the event of a disaster. Always keep in mind that during an emergency, every second matters.


Always use the right maintenance procedure with right tools & equipment , the following tips will help to reduce hazard and brings a good safety culture:


Aircraft contain a lot of sharp edges and moving parts, as well as poisonous fuels and other liquids. The human body, on the other hand, is unprotected from severe heat, sharp metal objects, and caustic or toxic fuels and fumes. This is why emphasizing the usage of personal protective equipment (PPE) on a regular and consistent basis is at the top of this list.

If you lose your sight, hearing, or well-being due to unprotected contact with heated surfaces, flying metal fragments, or toxic chemicals, you won't be able to replace it. As a result, technicians must wear safety goggles, hearing protection, strong gear, and even breathing devices when necessary.


Because of their familiarity and vast experience on the job, it's simple for seasoned mechanics to forsake standard safety precautions. However, everyone should exercise caution when working on landing gear sections or replacing brakes. Asbestos is present in several regions, which can lead to the development of asbestos-related disorders including mesothelioma. Because there is no immediate danger, some technicians refuse to wear respiratory protection, yet long-term exposure can create major health problems.


It's just as important to provide your maintenance staff with the right ground support equipment as it is to provide them with the right tools. Any repair operation requires safe access to a work area, and aircraft maintenance stands are the sole solution for aviation work. They give mechanics safe access to even the most inaccessible places. Slips, falls, and other industrial hazards can all be avoided by using aircraft equipment that is particularly suited for the activity at hand.

The significance of this issue is backed up by statistics from the Bureau of Labor Statistics, which show that falls in the workplace caused 17 percent of occupational fatalities in 2017.


Specific maintenance jobs may necessitate the use of specialized  equipment. While your mechanics may undoubtedly adapt and finish the work, specialist tools exist for a reason: they aid in the completion of the job correctly. It's critical to communicate to your staff that it's preferable to notify you about the requirement for a tool rather than attempting to do the task without it, as improvising can result in a damaged aircraft.

If you only require task-specific tools on a regular basis, you might be able to rent them instead of buying and keeping them.


It's a good idea to return all tools to their respective storage spaces when your technicians finish a work day or a task. If a misplaced tool ends up in the wrong portion of an aircraft, it might be dangerous. We propose making a checklist for all tools needed for a task so that they can be accounted for when they're put away, or at the very least so that the mechanics may check the list to make sure nothing is missing.

A fire extinguisher is an essential item that should always be readily available to your technicians. While this is self-evident, the fire extinguisher is frequently out of reach or non-existent. Everyone requires simple access to fire prevention equipment for personal safety and the protection of important possessions.


You've probably seen a training video or two with images of hands with missing fingers as a result of technicians failing to remove wedding rings before working on planes. These visuals should suffice as a warning, but make sure to supplement them with regular reminders to your personnel to remove all jewelry (ornaments) before beginning any maintenance work.


Nothing is more important than the health and happiness of your employees. There are several steps you can take to maximize their health and safety in addition to providing them with the appropriate tools and equipment. You can reduce the hazards associated with employee weariness and complacency by using these techniques:


Ensure that your staff do not work for too long in a single shift. While working overtime is occasionally required, it should be limited to a bare minimum if at all possible. When an employee works more than 12 hours, OSHA (Occupational Safety and Health Administration) cites a 37 percent increase in the risk of harm.

After working for too long, not only does exhaustion set in, but complacency and lack of concentration are also likely, which can lead to blunders and counterproductive labour. Set daily limitations for your staff and strive to ensure that no one continues to work if they are unable to focus fully.


Employees who work late at night or at irregular hours have a higher risk of losing concentration and causing mishaps. Injury and accident rates during night shifts are 30 percent greater than during day hours, according to OSHA. During evening shifts, they're also 18% higher.

When you don't get enough sleep or your mind can't focus on the task at hand, it's much easier to make mistakes. As a result, limit personnel to no more than two consecutive night shifts, with a few days of recovery time in between.


The longer an employee works without taking a break, the more likely they are to make mistakes, especially in highly detailed and delicate tasks such as Aircarft maintenance. Try to arrange appropriate breaks for all employees so that they can recharge and refocus before returning to work.


Even with sufficient breaks within the workday, working numerous days in a row can take a mental and physical toll. Allow staff to take days off as needed and recharge on vacation days.


It all boils down to the people that work for you. They may not always feel comfortable expressing their concerns until prompted, so it's always a good idea to check in and make sure they're feeling healthy, well-equipped, and well-protected.

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