People are now travelling more than ever, always hopping from one flight to the next. And while we’re used to seeing pilots and cabin crew at the start of our journeys, there’s another team working quietly behind the scenes to make every flight possible: the engineers. Without them, no plane would ever leave the ground.

Words by Melanie Caruana

A DAY IN THE LIFE OF A KM MALTA AIRLINES ENGINEER

At KM Malta Airlines, they have engineers covering both the day and night operations 24/7. Their day shift starts at around 07:30HRS, overlapping with the night shift for a 15-minute handover. This ensures continuity so that whatever was started during the night shift can be continued seamlessly into the day shift. With a fleet of eight aircraft, the goal is simple: every plane must be kept ready to fly and be on time.

Did you know that engineers start preparing your flight two hours before take-off?

The plane is powered up so that all systems can be tested and departments, like catering and luggage handling, rely on this time to get the aircraft ready too. During this time window, engineers perform what’s known as ‘a pre-flight inspection’, checking the aircraft for fluid leaks, dents, or other issues that could affect your safety. The role of the whole team is to minimise delays, however, it’s far better to delay a flight and ensure every system is fully operational than to take even the smallest risk.

The first flight departs at 06:00HRS, after which all flights begin their routes towards different destinations operated by KMMA. Whilst the aircraft are in the sky, the engineers are busy preparing for the upcoming night shift maintenance. This includes, live-monitoring aircraft systems and engine performance through the Airbus Skywise data platform, getting ready for aircraft transit checks.

Later in the day, when the aircraft start to return from their trips, the process repeats: as soon as an aircraft parks and shuts down, KM Malta Airlines engineers perform a turnaround inspection while passengers disembark. This involves a walk-around the aircraft. They meet with the cabin and flight crew to check whether there are any issues with the cabin equipment or aircraft systems. Any faults or observations are recorded by the cabin and flight crew in the respective logbooks; such faults are referred to as “open entries”. The engineer will close these entries once the issue has been resolved. An aircraft can only operate its next flight once all open entries have been cleared by the engineer.

After the inspection is finished, the engineer gives the final all-clear and signs the aircraft’s technical logbook, declaring that the aircraft is ‘airworthy’, meaning that the aircraft is fit to fly. The captain also signs, but only after the engineer’s approval. While the captain has ultimate authority for the flight, he relies on the engineers’ expert technical assessments to ensure the aircraft’s airworthiness. However, if the engineer does not sign, the plane cannot depart.

At the end of the day shift, there is another 15-minute handover for the next engineers coming in at night for another 12-hour shift. During the night, incoming planes usually have a night stop at the airport, and the daily check takes place to ensure that everything continues running smoothly.

At KMMA Engineering, various types of checks are performed by engineers. These include Daily Checks, Weekly Checks, and A-checks. The Daily Check, as the name suggests, is carried out on a daily basis and includes several routine inspections of the aircraft in its entirety, for example, checking wheel wear and verifying fluid levels. The Weekly Check, performed once per week, involves more extensive maintenance, testing, and inspections.

A-checks are carried out every 1,000 flight hours or 182 days, whichever comes first. These include routine inspections, functional and operational tests, and preventive maintenance tasks such as engine oil servicing, system servicing, and lubrication.

In addition to these checks, KMMA Engineering also performs major tasks such as engine replacements, structural repairs, and aircraft or engine modifications.

They also have a dedicated team of engineers who perform borescope inspections on their engines (similar to endoscopy in the medical field) to assess the condition of internal engine components. Every two years, the aircraft undergo a more extensive inspection known as a C-Check. These checks are performed by specialised MROs (Maintenance, Repair, and Overhaul organisations). Engineers from the team are sent to these MROs as technical representatives to oversee the checks, monitor the work being carried out, and ensure that their standards are maintained throughout all maintenance operations.

REASSURANCE OF SAFETY

And so, although it might surprise people, flying is the safest mode of transport - much safer than driving your car! Aircraft are designed with safety and comfort in mind, backed up by multiple layers of redundancy. If one computer fails, another immediately takes over. If one engine malfunctions, the second keeps the plane in the air. Preventive maintenance, like the work undertaken by the airline engineers, means that every system is constantly checked physically, monitored, and fixed well before there is any risk to you or your trip overseas.

Even though our engineers have years of experience, they must still perform all work in accordance with the approved aircraft manuals, using the latest version. Engineers carry a great deal of responsibility and are legally accountable for certifying that each aircraft is airworthy.

THEIR TRAINING

As the safety of every passenger depends on an engineer’s signature, there is a regimented process to become a ground engineer in Malta. It starts with training and studying at MCAST or a private institution, followed by the attainment of licences from Transport Malta (the local civil aviation authority) and years of hands-on experience. Only after they have completed a dedicated ‘type course’ from their aircraft manufacturer does the company authorise an engineer to sign off work on planes. With that signature comes important responsibility: the safety of every passenger depends on it. Apart from this, engineers are legally bound to attend several refresher courses every two years.

So, the next time you board a plane, remember that behind every smooth takeoff and safe landing is a team of highly trained engineers. Their extensive training and attention to detail mean that the safety of every passenger truly rests in their hands - a responsibility they uphold every day, even when no one is watching.