Technical Flights - The AIRBUS view

February 2011

Presented byCaptain Harry NELSON / Experimental Test Pilot Captain Jean-Michel ROY / Test Pilot

Flight Safety Foundation – Functional Check Flight Symposium

FSF Functional Check Flight Symposium

Why the concern with Technical Flights?

February 2011FSF Functional Check Flight Symposium

Page 2

• Recent incidents and accidents

• We think we may be only seeing the tip of the iceberg

• Our experience with Customer Acceptance Flights

• Queries and questions from Customer Airlines

What we will cover today

February 2011FSF Functional Check Flight Symposium

Page 3

1. A common sense view on Check flights

• Planning and preparation• Execution

2. Crewing • Composition• Selection• Training

3. Technical Flight Familiarisation Course

4. Some thoughts on the way forward

1 Planning and Preparation

February 2011FSF Functional Check Flight Symposium

Page 4

Some practical things to think about

Aircraft

Airfield

ATC and Airspace

Weather

Checklists

Check Schedules

1 Planning and Preparation – Check Schedules

February 2011FSF Functional Check Flight Symposium

Page 5

Options include a. A detailed check schedule for each type of check b. A master check schedule with deletes c. We offer an “In Service Aircraft Test Manual” (ISATM)

• Associate warnings and limits with check to be done• Hard limits need clear DO NOT EXCEED warnings• Avoid writing a check sequence over two pages• Make them easy to handle. Not too big or detailed

1 Planning and Preparation – Check Schedules

February 2011FSF Functional Check Flight Symposium

Page 6

Production Aircraft Test Manual (PATM)

Customer Acceptance Manual (CAM)

In Service Aircraft Test Manual (ISATM )

1 Planning and Preparation – Check Schedules

February 2011FSF Functional Check Flight Symposium

Page 7

Production Aircraft Test Manual (PATM)

• Tests on new serial a/c after production

• The purpose of the PATM is to demonstrate that the aircraft:

* conforms with the type and individual certificate to a Certificate of Airworthiness Standard

* meets its specifications,

* meets the standards of quality required for delivery

• Under EASA Airbus Production Organisation Approval (POA) , accepted as such by the FAA and most other authorities.

1 Planning and Preparation – Check Schedules

February 2011FSF Functional Check Flight Symposium

Page 8

• Customer Acceptance Manual (CAM)

• The CAM is the compilation of check procedures agreed between Airbus and a Customer as part of the customer technical acceptance of a new aircraft. It is used to demonstrate technical compliance with a contract

• It covers both ground and flight checks but unlike the PATMit can be carried out in any order i.e. Flight before Ground Checks.

• It should not be used as an airworthiness demonstration• There is no control over the weather• Mixing the objective of the flight can create safety issue• There is a mixed background crew

1 Planning and Preparation – Check Schedules

February 2011FSF Functional Check Flight Symposium

Page 9

• In Service Aircraft Test Manual (ISATM)

• The ISATM is a manual containing the procedures for ground and flight tests to be performed by Airbus personnel on an in service aircraft (ex: after a working party or for an aircraft transfer between Airbus and another party)

• It must be performed in a specified order

• It is offered to Customers who request help, prior to a check flight, under letter of waiver as a PDF file, the intention being that they create their own check schedule from it, duly considering all the “local” issues.

1 Execution

February 2011FSF Functional Check Flight Symposium

Page 10

There are many elements to master in a check sortie.

Briefing Pre take off Take-off Switching CommunicationWorkload Different flight plans The day/night question Cabin

systems More difficult check points

1 Execution – More difficult check points

February 2011FSF Functional Check Flight Symposium

Page 11

•Identify which check points carry more risk

•Pre flight, plan how to fly them and then stick to your plan

•Decide and brief “break off” points

•If things don’t look right they are probably wrong – so stop

•Take care with breaks in the sequence

•Don’t be tempted to “take a look” at certification test points

1 Execution – More difficult check points

February 2011FSF Functional Check Flight Symposium

Page 12

….. Remember the old ZEN wisdom of

“Never test the depth of the water with both feet at the same time”

Be failure minded and always consider your escape plan

….. Which also leads us nicely to the other Zen wisdom of

“If at first you don’t succeed, skydiving is not for you”

2 Crewing - Composition

February 2011FSF Functional Check Flight Symposium

Page 13

• A small technical crew group

• Leadership

• Crew composition:• Technical Flight Engineer

• Cabin specialists

Have a strict no passengers policy

2 Crewing – Selection

February 2011FSF Functional Check Flight Symposium

Page 14

KNOWLEDGE

You can never have too much knowledge You should never stop learning You will never know it all

“I’ve been here before ” “it doesn’t feel right” “a good nose” ‘a healthy fear”

Aircraft Theory Role

SKILLS

ObservationInterpretation

AnalysisCommunication

Use of ALL senses

Airmanship and Teamwork

APTITUDE Approach Attitude

Logical Creative Flexible PersistentConsistent Variable

Asking Telling Learning Knowing

Under confidence Right Over Confidence

Manage these paradoxes

EXPERIENCE

Take care 10 = 10 or 1¹º

Better risk evaluation Better Prioritisation of task Less errors

To achieve the right balance

Motor skills

INTEGRITY

2 Selection – Summary

February 2011FSF Functional Check Flight Symposium

Page 15

February 2011 FSF Functional Check Flight Symposium

Egotistical XQuestionable integrity XIndecisive X Uninterested technically XTakes criticism badly XAvoids responsibility XImpatient XInflexible XRisk prone XLoner X

Good Communicator Technically inquisitive Determined to get answers Good flying ability Admits errors and learns Takes responsibility Patient Makes balanced judgments“Defaults” towards Safety Team player

Take time on people selection. It is the key to Take time on people selection. It is the key to achieving real safety in the checking process.achieving real safety in the checking process.

2 Crewing - Training

February 2011FSF Functional Check Flight Symposium

Page 16

1. If you have good test trained personnel, use them in the technical checking role

2. If you have experienced check or acceptance flight crew, review their real experience and currency in the task. Many are very good.

3. If you have neither, then you should train people or obtain the services of trained people

There are several short introductory courses available on the market, including the Airbus course called : “Technical Flight Familiarization (TFF) Course”

Purpose of the TFF course

February 2011FSF Functional Check Flight Symposium

Page 17

Provide crew members with information on Knowledge, Skills and Attitude to better contribute to :

• Technical flights (post maintenance, painting, etc.)

• Acceptance flights (deliveries) Familiarization course:

Attestation not a Rating

270°

Safety

Quality

Efficiency

TFF course: A bridge between Aviators

February 2011FSF Functional Check Flight Symposium

Page 18

TFF course: The instructors

February 2011FSF Functional Check Flight Symposium

Page 19

• An experienced team:• A Test Pilot, and

• A Flight Test Engineer

• Used to work/fly together

• Experienced:• Development flight tests

• Production flight tests

• Customer flights

TFF course: The trainees

February 2011FSF Functional Check Flight Symposium

Page 20

• Technical Flight Crew is a crew of 3:

• 2 PilotsPrerequisites: rated and current on Aircraft type with at least 6 month experience

• 1 Technical Flight Engineer (TFE)Prerequisites:

A third pilot, or A Flight Engineer who has followed a familiarization course on the type, or A Maintenance Engineer who has successfully followed the applicable maintenance type rating course as per Part 147 or equivalent, or A Flight Operations Engineer who has followed a familiarization course on the type

TFF course: The Syllabus

February 2011FSF Functional Check Flight Symposium

Page 21

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL

FFS FFS FLIGHT

Phase 1 Phase 2 Phase 3

TFF course: Ground school

February 2011FSF Functional Check Flight Symposium

Page 22

• Generic modules• Crew concept

• Weather

• ATC

• Technical Flight Order

• Pre-flight briefing

• Recording of in-flight results

• Post Flight Analysis

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL FFS FFS FLIGHT

TFF course: Ground school

February 2011FSF Functional Check Flight Symposium

Page 23

• Aircraft specific modules (from ISATM)• Ground checks

• Taxi checks

• In-flight checks:

• Flight controls

• AFS

• Systems (Pressurization....)

• High Speed

• Low Speed

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL FFS FFS FLIGHT

TFF course: Ground school

February 2011FSF Functional Check Flight Symposium

Page 24

• Training Documentation:• ISATM

• Course module hand-out

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL FFS FFS FLIGHT

TFF course: FFS

February 2011FSF Functional Check Flight Symposium

Page 25

• FFS is a great training device BUT:• Limited to reproduce flight acceleration

=> Motion ON or OFF according to checks

• Some “maintenance” functions not simulated (AIDS..)

• FFS 1 (4h): Normal system operation• Instructor pilot in RH seat (demo => practice)

• FFS 2 (4h): Some system malfunctions• Both trainee pilot in pilot seat (PF then PNF)

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL FFS FFS FLIGHT

TFF course: Flight

February 2011FSF Functional Check Flight Symposium

Page 26

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL FFS FFS FLIGHT

2 hours per pilot (*2) Instructor pilot in RH seat Normal system operation Use of AIDS

TFF course: Locations

February 2011FSF Functional Check Flight Symposium

Page 27

• At Airbus Training centers (Toulouse, Miami, Beijing, ...)

• At Customer Training center

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL FFS FFS FLIGHT

DAY 1 2 3 4 5

PHASEGROUND SCHOOL

GROUND SCHOOL FFS FFS FLIGHT

On customer aircraft at customer base

On Airbus development aircraft

TFF course: Experience & Customer feedback

February 2011FSF Functional Check Flight Symposium

Page 28

• First course in Sept 09 on A320

• 6 airlines/27 crew membersalready trained

• In TLS and at customer base

• Very positive feedback (videos)

TFF course: Looking forward

February 2011FSF Functional Check Flight Symposium

Page 29

• Course available now on all Airbus FBW aircraft

• Delivered on a monthly basistypically 2 crews (of 3) per session

4 Possible ways to go forward

February 2011FSF Functional Check Flight Symposium

Page 30

• Fully evaluate, discuss and recognize the issue

• Need for care with the solution i.e Pros & cons of regulation

OPTIONS

• Do nothing (a no change decision)• Publicize the issue across the industry• Regulate - If so at what level?

4 Possible ways to go forward

February 2011FSF Functional Check Flight Symposium

Page 31

Some things to be discussed

1. Responsibilities of Authorities, Manufacturers, Airlines, and individual Qualified Checkers

2. Qualification of Check flight courses and instructors3. Would any qualification be type specific or generic, or can the

course have both generic and specific elements?4. If so, what will be the validity of each?5. Would any qualification be “tied” to an airline or location6. How many checkers to qualify per fleet size?7. Check flight currency – Guidance or rules8. Check crew composition (position and qualification)9. Liability