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SIASA project
This project is funded by the European Union and implemented by EASA.
TE.GEN.00409-001
Maintenance Program ImplementationChristian DELMAS Director‐Maintenance Programs EngineeringAirbus Customer Services
Technology Evolution – Impact on Airworthiness23‐24 September 2014, Windhoek, Namibia
Introduction
Maintenance Program process implementation at Type Certification Holder and Operator level
• A standard process
• Consistent with new technologies and regulations
Complete, Available and Accessible documentation
Easy access to Airbus support & services
Objective of the Presentation:
Page 2
Maintenance Schedule Development
Initial Maintenance Program Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 3
Initial Maintenance Program Development
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 4
Maintenance Program Development
Fatigue Analysis
Safe Life Airworthiness
Limitation Items
Safe Life
Damage Tolerant Airworthiness
Limitation Items (ALI)
Fail safe - Damage Tolerance Analysis
SystemSafety Assessment
(pre DSG)+
MSG3 Analysis
Certification Maintenance
Requirements (CMR)
Aging System Maintenance
(ASM)
SystemSafety Analysis
(Post DSG)+
MSG3 Analysis+
System Life Limits
Fuel Airworthiness
Limitations(FAL)
Fuel Tank Safety Analysis
FuelStructureEASA/FAR 25-571 EASA/FAR 25-981
SystemsEASA/FAR 25-1309 (mainly)Regulations
Maintenance Program Development
Page 5
MaintenanceFAA AC121-22
EASA MRB Work Instructions / IO11 Maintenance Review Board Team
Maintenance Analysis(MSG3)
Maintenance Review Board Report
Data / SoftwareJAR 25-1301
Aircraft Information System Security
(AISS)- A380 -
Maintenance Program Development
Page 6
MWG 1 MWG 3 MWG 2
MWG 6 MWG 5MWG 4
MPP
ISC: Industry Steering CommitteeMWG: Maintenance Working GroupMPP: Maintenance Program ProposalMRB: Maintenance Review Board
•Policies•Procedures•Evolutions for new MRBR rev•…
The MRBR Process
ISC
The ISC - owns the MRBR process (policies, targets…) - validates the content of the MRBR and submits to MRB
MRB
ISC
Maintenance Program Development
Page 7
M12
Type Certificate
M13
1st MSN EIS
1st MSN operational
A/C Production
Last MSN operational lifeLast MSN EIS
A/C Devlpt
(5, 6 years)
A/C IN SERVICE > 50 years MAINTENANCE
MRB Process …
Safety + availability & reliability at minimum cost
Maintenance Program Development
Page 8
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2001.1
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2002.1
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2(1993)
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2003.1
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2005.1
A380
A400M
ATA MSG-3Operator/Manufac
turer
Scheduled Maintenance Development
Revision 2007.1
A350
XWB
The Tool: MSG3 - evolutions
Maintenance Program Development
Page 9
ATA MSG-3Operator/Manufacturer
Scheduled Maintenance Development
Revision 2007.1
A350Scheduled
Maintenance
Policy and ProceduresHandbook
Relationship of MSG-3 Document and PPHThe Tool: MSG3 – Policy & Procedures Handbook (PPH)
The ATA MSG-3 document• no procedures/details necessary for analysis• Additional guidance on details of analysis procedures required
• Interpretation of rules, interval selection, etc.• Form sheets • Detailed work steps, responsibilities and scheduling
Maintenance Program Development
Page 10
Applicability (e.g A320Fam)- A320-110 with CFM 56 Series engines,- A320-210 with CFM 56 Series engines,- A320-230 with IAE V2500 Series engines,- A320-250 with CFM LEAP-X Series engines,- A320-270 with PW 1100G Series engines,- A321-110 with CFM 56 Series engines,- A321-130 with IAE V2500 Series engines,- A321-210 with CFM56 Series engines,- A321-230 with IAE V2500 Series engines,- A321-250 with CFM LEAP-X Series engines,- A321-270 with PW 1100G Series engines,- A319-110 with CFM56 Series engines,- A319-130 with IAE V2500 Series engines,- A319-150 with CFM LEAP-X Series engines,- A319-170 with PW 1100G Series engines,- A318-110 with CFM 56 Series engines,- A318-120 with PW 6000A engines.
Aircraft Utilisation Assumptions 1800 to 4400 FH per year1000 to 2500 FC per year
Maintenance Program Development
Page 11
Before launching the MRB process with the customers, the TC Holder can call for MRB kick off meetings to:
• Present the project
• Present the major content of the PPH
• Identify any show stopper
• Set up an acceptable PPH quality level before presentation to the customers
The PPH must be approved by the ISC and accepted by the MRBs before starting the technical activities
Maintenance Program Development
Page 12
Once the training is completed, the PPH may need to be revised according to feedback from the Q&A sessions and validated by the ISC
The detailed MWG activities can start
44 45 46 47 48 49 50 51 52 53DocumentsMRB AI MeetingISC 2 3CMCCTraining SessionsWG 1 Hydraulics & F/CWG 2 EnvironmentalWG 3 Powerplant & APUWG 4 Avionics - GeneralWG 5 StructureWG 6 Zonal & L/HIRFWG 7 FuelWG 8 Landing GearsWG 9 Interior
4
E1 E2 E3 E4
111
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43week
A350 Planning - 2009
Training sessions
Maintenance Program Development
Page 13
Maintenance analysis processes
Systems & Powerplant
StructureZonal & L/HIRF
The three processes are both complementary and concurrent
The PPH and the MSG3 analyses
Maintenance Program Development
Page 14
The MRB Report
Systems & Powerplant
StructureZonal & L/HIRF
Maintenance Program Development
Page 15
Maintenance Program Development
Page 16
Systems & Powerplant
Structure
Maintenance Program Development
Page 17
Maintenance Program Development
Page 18
Zonal & L/HIRF*
(*) L/HIRF_Lightning / High Intensity Radiiated Fields
Even before the start of the MRBR process Maintenance Engineers get involved in Aircraft design development
Maintenance Program Development
Page 19
Information is available on line and/or on physical media (DVD)
On Line access available via AirbusWorld
Maintenance Program Development
Page 20
“Maintenance & Engineering” Page
Access to MRBR or ALS
Maintenance Program Development
Page 21
“Prepare MaintenancePrepare Maintenance Program”
Maintenance Program Development
Access to MRBR or ALS
Page 22
Easy access to scheduled maintenance data per aircraft program and document
Maintenance Program Development
Page 23
New MRB Report or ALS document revision notification by dedicated communication
Maintenance Program Development
Real time information
Page 24Page 24
Page 25
MPD
The Maintenance Planning Document
AMM
Non approved repository of repetitive scheduled maintenance requirements
Link between requirements and procedures (AMM)
Additional information (access, m.h, skill…)
MSG3Analyses
MRBReport
ALS Part 4
ASMDocument
ALS Part 2
DT-ALIDocument
ALS Part 3
CMRDocument
System Safety
Assessment(SSA)
ALS Part 5
FALDocument
Test results
Damage TolerantAnalysis
+Full Scale Fatigue
Test results
EASA Certification Approved
ETOPSCMP
Maintenance Program Development
Source for maintenance program & planning operators to develop a customized scheduled maintenance program.
The AIRBUS MPD Envelope repository document Tasks from other source documents
MPD: neither a CONTROLLING document nor an APPROVED document.
Maintenance Program Development
Page 26
The MPD covers maintenance, which is
scheduled, not unscheduled maintenance.
on aircraft level, not on component level.
routine maintenance, not troubleshooting/defect correction.
repetitive, not one time inspections / tasks.
already mandated or recommended by various source documents, not any additional stand-alone
maintenance requirements.
MPD Presentation
Page 27
Maintenance Program Development
MSG3
AnalysesMRB
Report
D
ALS Part 4
ASMDocument
Document
ALS Part 2
DT-ALIDocument
Document
ALS Part 3
CMRDocument
AMM
MPD
System Safety
Analysis
(SSA)
+ -
D
ALS Part 5
FALDocument
Fatigue Test
Damage Tolerant
Analysis
+
Full Scale Fatigue Test
results
AOT
SIL
SB
AD
/
CN
In service experience feedback
Manufacturer - EASA CS 25
- Consolidation over the different sources
- Revised each time the “MPD baseline” source document is revised at the exception of Life Limited
Parts
- Consolidation over the different sources
EASA Certification Approved
ETOPSCMP
Maintenance Program Development
Page 28
MRBALI
Page 29
Maintenance Program Development
T : 12 YEI : 6 YE
Page 30
Maintenance Program Development
T: 3200 FC I: 8000 FC
Page 31
Maintenance Program Development
T : 12 YEOR
32000 FCI : 6 YE
OR8000 FC
Page 32
Maintenance Program Development
This section includes all the scheduled maintenance tasks related to the aircraft systems and components, the APU and the powerplants.
MPD Presentation: System, APU & Power Plant
Page 33
Maintenance Program Development
MRB 9=
MRBR FEC 9(hidden / non safety)
FEC=Failure Effect Category (from MSG3)
This section provides the basic scheduled maintenance tasks and frequencies applicable to the aircraft structure
MPD Presentation: Structure
Page 34
Maintenance Program Development
CPCP
This section provides the General Visual Inspection (GVI) requirements for each aircraft zone to inspect system and powerplant installations for security and general condition, structure for general condition and Electrical wiring installation for general condition
MPD Presentation: Zonal
Page 35
Maintenance Program Development
MPD
AirN@v / PlanningCommon AirN@v layoutInteractivity with AirN@v / Maintenance
EXCEL
TSDF SGML
Easy Data Manipulation Filtering, Sorting, Calculation
“Digital Paper” Printing capability
Specific ASCII for MIS and Database uploadProvided with data specification
MPD Presentation: MPD Deliverables
Page 36
Maintenance Program Customization
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 37
Why MPD customization is needed ?• MPD = envelope document• Different aircraft configurations some MPD tasks
are not relevant to a given fleet, sub fleet or MSN
How to select MPD tasks ?
Select tasks according to Applicability column using the above listed documents
What are the information needed to customize MPD ?- Aircraft type - Weight variant
- Engine type - APU type
- Mod Status - SB status
- Cabin Layout - Emergency equipment list
Work Scope
Maintenance Program Customization
Page 38
Page 39
OMP
Approved by local AA
Airlinetasks
National Requirements
MSG3Analyses
MRBReport
MPD
ALS Part 4
ASMDocument
ALS Part 2
DT-ALIDocument
ALS Part 3
CMRDocument
System Safety
Analysis(SSA)
ALS Part 5
FALDocument
Test results
Damage TolerantAnalysis
+Full Scale Fatigue
Test results
EASA Certification Approved
Manufacturer Operator
A/C configuration
Customization
ETOPSCMP
Maintenance Program Customization
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Maintenance Schedule Development
Page 40
Page 41
MSG3Analyses
MRBReport
MPD
ALS Part 4
ASMDocument
ALS Part 2
DT-ALIDocument
ALS Part 3
CMRDocument
System Safety
Analysis(SSA)
ALS Part 5
FALDocument
Test results
Damage TolerantAnalysis
+Full Scale Fatigue
Test results
EASA Certification Approved
OMP
Approved by local AA
Airlinetasks
National Requirements
Manufacturer Operator
A/C configuration
Customization
Planning Mtce Checks
ETOPSCMP
Maintenance Schedule Development
Maintenance Concept Definition
Work Packages
Aircraft utilization
- Seasonality/Charter- Low Aircraft Utilization- Long or Short Haul- Scheduled- Freighter
Fleet Age
- Structural Items Threshold- Additional ageing program- Fatigue Structural findings
Aircraft Ground Time -Airlines Policies
- Return to main base - Night stop- Outstation capability
Manpower Skills and availability- Task Man-hour - Access Man-hour - Preparation Man-hour
Fleet Size- Facilities- Manpower- Materials- Maintenance Planning
Number of M/HOr
Number of Tasks
Maintenance Events
Page 42
Maintenance Schedule Development
Equalised maintenance Concept
Block-like maintenance Concept
Maintenance concept
development
Maintenance concept
development
Perform tasks as they become due
One flexible maintenance program Numerous maintenance concepts
etc.
Flexible Maintenance Program
Usage parameter task intervals
Flight hours
Flight cycles
Calendar time
Maintenance Schedule Development
Page 43
7500FH Maintenance
Check22%drop outs
6000FH Maintenance
CheckOR
45%drop outs
30Mo Maintenance Check
54%drop outs
2%drop outs
24Mo Maintenance Check
Communication on Maintenance Checks: Special Attention !
Maintenance Schedule Development
Page 44
30 Month C check communication correct but:
• About 50% drop out tasks
• Only if aircraft utilization < 3000FH/year
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 45
In Service experience collection and analysis is required in the frame of “Continued Airworthiness” (EASA Part M AMC 302 & FAA AC N°120-17A)
In Service Experience Feedback
At operator’s level
Keep OMP up to date according to fleet in service experience feedback
Optimize maintenance costs and aircraft availability
At Manufacturer’s level
Keep ICAs up to date according to fleet in service experience feedback
Page 46
Reliability Control program :
Is used to monitor the effectiveness of the Maintenance Program
Is an essential Quality System process
Contribute to the optimization of maintenance costs (scheduled / unscheduled)
Reliability program is imposed by the Regulatory Authorities, which require an Operator to establish a program for continuing analysis & surveillance of its operations.
Reliability Control Program
In Service Experience Feedback
Page 47
Actions & Follow-Up
AnalysisAnalysis
Performance Measurement & Reporting
Performance Measurement & Reporting
Corrective Actions &
Decision Making
Corrective Actions &
Decision Making
SupplierManufacturer
In Service Experience Feedback
Page 48
The MRB Report represents the initial maintenance program
Maintenance Checks
Initial MRBR intervals are often conservative
Operator can adjust tasks and intervals according to their own experience
Analysis of maintenance check results is associated to the Reliability Control Program
In Service Experience Feedback
Page 49
Data shared in real time
MRBR Updates
Unique Airbus Data collection Template
(with CPCP)
« XML Format, No volume limitations »
Customized studies -
Benchmarking
Data Collection on an “On-Going” Basis
DatabaseAirlines
In Service Experience Feedback
Page 50
In Service Experience Feedback
Page 51
Maintenance Checks – Data Collection
TASKNUMBER
100%INT
Date at inspection(ONLY DATE
FORMAT)
FH(ONLY
NUMBER)
FC(ONLY
NUMBER)
531101-01-1 10 YE
531102-01-1 6 YE
531104-01-1 10 YE
IS CORRESPONDING TASK APPLICABLE
TO MSN AND PERFORMED DURING
CHECK?(Y/N)
Reported inspection(Aircraft Status at inspection) Check
Package Type
Approved Interval
(Interval actually approved by the local
Authorities)
MPD task reference
Nber of Months
(ONLY NUMBER)
Nber of FH(ONLY
NUMBER)
Nber of FC(ONLY
NUMBER)
Date at inspection(ONLY DATE
FORMAT)
FH(ONLY
NUMBER)
FC(ONLY
NUMBER)
Previous inspection(Aircraft Status at previous inspection)
Actual interval(interval since the previous inspection)
Mandatory
Actual interval
information
Finding?(Y/N)
Details of finding(e.g corrosion Level, component/element which failed and how
did it fail, possible reasons for defect)
Type of Findings Associated Corrective Action
Task Result(to be filled if finding found during the task accomplishment)
Task findings / nil findings and
corrective actions Assistance: [email protected]
In Service Experience Feedback
Page 52
Page 53
Operator A300 A300-600 A310 A320 fam. A330 A340XXX >> >> >>
Benchmark my finding rates with IDOLS for Scheduled Maintenance
In Service Experience Feedback
Page 54
Page 55
MSG3Analyses
MRBReport
MPD
ALS Part 4
ASMDocument
ALS Part 2
DT-ALIDocument
ALS Part 3
CMRDocument
System Safety
Analysis(SSA)
ALS Part 5
FALDocument
Test results
Damage TolerantAnalysis
+Full Scale Fatigue
Test results
OMP
Approved by local AA
Airlinetasks
National Requirements
Manufacturer Operator
A/C configuration
Customization
Planning Mtce Checks
ETOPSCMP
In Service Experience Feedback
Maintenance Program Revision
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 56
1st A/C operational life # 30 years
A/C Production # 20 years
Last A/C operational life # 30 years
Last EIS
A/C IN SERVICE MAINTENANCE # 50 years
1st EIS
A/C Devlpt
(5-6 years)
Type
Certificate
Program Launch
Maintenance Program Process
Page 57
Maintenance Program Revision
2 possibilities for maintenance program evolution
OPERATOR
Operator Fleet
In‐service experience
Local AirworthinessAuthorities
MANUFACTURER / ISC (MRBR)
World Fleet
In‐service experience
FAA/EASA/TCCA
MRB ProcessCustomized
WHO INITIATES?
TARGET
JUSTIFICATION
APPROVAL BY
Manufacturer Maintenance Program (MRBR, ALS, MPD) evolution exercise
Customized maintenance program evolution
Maintenance Program Revision
Page 58
Customized/Operator Maintenance Program Evolution exerciseOperator’s Maintenance Programme must be kept up to date according to
Evolution of Aircraft configuration (e.g modification / SB)
In service experience feedback (e.g AD, Reliability Control Program, feedback from maintenance events)
Evolution of Maintenance Program Source Documents (e.gALS, MRBR)
Maintenance Program Revision
Page 59
3 main reasons for MP (MRBR, ALS, MPD) evolution
Regulation Change (CPCP, EWIS, FTS, TLOD…)
Design Change
In service experience feedback (fleet survey, DSG/ESG, reliability, findings/nil findings…)
Manufacturer Maintenance Program Evolution exercise
Maintenance Program Revision
Page 60
Scope:
Ensure that the MRB Report remains efficient according to in service experience feedback
Review the MRB Report initial conservative figures
The evolution process can be extended to the Maintenance Planning Document (MPD) tasks (Limitations excluded)
Interval adjustment means optimisation and not necessarily escalation!
MRBR evolution- In Service Experience Feedback:
Pre Requisite: In service experience feedbackReports from previous maintenance visits (findings and nil findings)Representative sample of the worldwide fleet:
aircraft agedifferent operations, different environmentsVolume, amount of data
Page 61
Maintenance Program Revision
Page 62
Guidance
Up to end 2007: different approaches from manufacturers
From 2008: MRBs have set up a “common approach” applicable to future evolution exercises IMRBPB Issue Paper 44 (IP44)
Principle: Justify the evolution exercise on a task by task basis thanks to a suitable statistical analysis of in service data supported and validated by engineering judgement
Effectivity: all evolution exercicesto be finalized after April 2009
MRBR evolution- In Service Experience Feedback:
Maintenance Program Revision
Applicable to customized or fleet wise revision
Maintenance Program Revision - Summary
Page 63
Maintenance Program Revision
Revision:• Adaptation to aircraft configuration• Adaptation to regulations• In Service Experience Feedback / Reliability Control Program• Task by task basis approach
Maintenance Program Optimization
Maintenance Programtask interval Escalation only
Maintenance Program Optimization
Maintenance Programtask interval Escalation only
=
Page 64
Maintenance Program Revision
Maintenance Program Revision
Page 65
Initial Maintenance Program Development
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Airbus Assistance
Airbus Assistance
Page 66
Training Service:ScheduledMaintenance Program Seminar
Maintenance Engineering Services: Exceptional one time deviations Maintenance program optimization Corporate Jet Operations
Airbus Assistance
Page 67
Airbus Assistance
The aim of the seminar is:to familiarize you to Scheduled Maintenance Requirements development and evolution,to give basic guidance on maintenance concept to develop the appropriate maintenance program and planning
Airbus maintenance engineering offers a dedicated Scheduled Maintenance Program (SMP) seminar.
If you are interested please contact us or your CSD or
Sched‐[email protected]
Scheduled Maintenance Program Seminar
Page 68
Due to unforeseen exceptional circumstances it happens that amaintenance task cannot be performed at the due date.
Refer to MPD introduction for guidance for exceptional variations
Exceptional one time extensions (1/3)
NOTE: Exceptional Variations should not be used to compensateplanning shortcomings!
What can you do
STEP 1
STEP 2 Beyond MPD allowance contact us for Airbus Statement of Airworthiness Compliance:
ASAC
MPD
Page 69
Airbus Assistance
MPD
STEP 1
Exceptional one time extensions (2/3)
Page 70
Airbus Assistance
ASAC
An Airbus Statement of Airworthiness Compliance ASACcould be issued by Airbus on demand
STEP 2
Exceptional one time extensions (3/3)
An ASAC is not an approved document
An ASAC is an official document issued by Airbus to support operators demand for exceptional deviation in front of the NAA
Page 71
Airbus Assistance
Airbus can support operators in their efforts to optimize maintenance program efficiency
Customized Maintenance Program Optimization
Availability of supporting data is essential
Different levels of support can be offered depending on operators’ priorities
Page 72
Airbus Assistance
We can help operators to manage their maintenance program & planning!
First contact: the Airbus Representatives: FSR, FSM, CSD
[email protected] scheduled maintenance questionsManage Special situations e.g. deviations, return to service, storage…Manage Task interval evolution
[email protected] task [email protected] Special trainings (SMP Seminar)[email protected] customized programDevelop Maintenance Schedule
Technical support and assistance
Page 73
Airbus Assistance
Initial Maintenance Program Development
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Conclusion
Page 74
Initial Maintenance Program Development
Initial Maintenance Program Development
Maintenance Schedule Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Different StepsDifferent Actors
To control the ScheduledMaintenance process
Page 75
Airbus Scheduled maintenanceprocess and documents
adapted support + customized services=
safe operationsoptimized aircraft availability at reduced cost
Page 76
Compliant with latest regulations and Industrial Standards Adapted to technology evolutions Revised according to in service experience Updated all along aircraft life
Easily accessible on Line
Flexible to adapt to any operation or maintenance strategy
Adapted to operators’ needs
Compliant to Instructions for Continued Airworthiness (CS25.1529 app.H)
Maintenance Schedule Development
Initial Maintenance Program Development
Maintenance Program Customization
In Service Experience Feedback
Data Collection and analysis
Maintenance Program Revision
Page 77
© AIRBUS S.A.S. [2014] All rights reserved. Confidential and proprietary document.
This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by the delivery of this
document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS
S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied.
The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to
explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M, ACJ are registered trademarks