Sofema Aviation Services (SAS) www.sassofia.com considers the key aspects of the Safety Management System Interface within the Flight Test Environment
Introduction
Safety Management Systems (SMS) within the Flight Test Environment should engage with all challenges due to the inherent risks involved in testing new aircraft designs or modifications.
Multiple risks may arise from:
- The need to explore the boundaries of the flight envelope,
- Assess the performance and reliability of new systems and
- Perform unconventional manoeuvres that may exceed the standard operational limitations.
Key Challenges
- Unpredictable Hazards: Unlike routine operations, flight tests often push aircraft to their limits, which introduces a high degree of unpredictability.
>> This may include encountering unexpected flight characteristics or handling issues when near or outside the design envelope.
>> Managing the risks associated with these tests requires a robust hazard identification process and real-time risk management during flight.
- Complex Coordination: Flight tests involve coordination between multiple departments, including
>> Design,
>> production and flight operations. Effective communication between these departments is crucial to ensure that the flight test program proceeds safely and as planned. Poor coordination can lead to delays or safety incidents, especially if all stakeholders are not aligned on the flight test objectives, procedures, and safety measures.
- Crew Competence and Training: The success of flight test operations heavily depends on the expertise of the flight test crew, including both pilots and engineers. Crew members must be experienced in handling abnormal situations, be well-versed in the relevant Certification Specifications (CS), and apply risk mitigation strategies during flight operations. Inadequate training or insufficient experience can result in mismanagement of critical in-flight situations, posing a serious safety risk.
- Risk of System Failures: Since many flight tests are conducted on prototype or modified aircraft, there is an increased risk of system malfunctions.
>> could include issues with newly integrated avionics, control systems, or engines that have not been fully validated under real-world conditions.
>> These malfunctions may lead to dangerous situations, such as loss of control, engine failure, or even structural damage to the aircraft.
- Regulatory Compliance: Ensuring that all tests comply with regulatory requirements (e.g., EASA Part 21) adds another layer of complexity. Compliance extends beyond just the technical aspects of the test, requiring documentation of all test procedures, risk assessments, and safety management actions.
Best Practices
- Structured Risk Management: A Flight Test Operations Manual (FTOM) should be in place that outlines the risk assessment and mitigation procedures.
>> This manual needs to address the safety management policy, the composition of the crew, the coordination between various departments, and emergency procedures.
>> The FTOM should also include detailed provisions for the management of defective or missing equipment and guidelines for real-time risk management during flight tests and Currency Requirements
Note – Flight test crews must undergo specific training for the category of flight test they are performing.
- Category 1 flight tests (which involve the highest levels of risk) require pilots and flight test engineers with advanced training and significant in-flight test experience.
- Best practices include continuous training and regular assessments to ensure crew members maintain proficiency in managing the unique demands of flight testing.
Data and documentation: Thorough documentation of each test flight, including risk assessments, test results, and flight crew reports, is essential.
- This documentation ensures regulatory compliance, supports post-flight analysis, and provides a record that can be used to improve future test operations.
- The FTOM should specify the procedures for maintaining control over all flight test documents.
Pre-Flight Risk Assessment: A comprehensive risk assessment should be conducted.
- This assessment should cover potential hazards, including unexpected handling characteristics, system failures, and operational limitations.
- The FTOM must also outline contingency plans for dealing with these hazards during the flight test.
Example List of Risks to Consider in the EASA Part 21J Flight Test Environment
- Unpredictable Flight Characteristics
>> Risk: Encountering unexpected handling issues when pushing the aircraft beyond the design envelope.
>> Mitigation: Pre-flight simulations, robust hazard identification, and real-time monitoring during flight tests.
- System Failures or Malfunctions
>> Risk: Failure of unproven systems such as avionics, engines, or control systems, leading to dangerous in-flight situations (e.g., loss of control, engine failure, or structural failure).
>> Mitigation: Redundant systems, detailed pre-flight testing, and fail-safe procedures for critical systems.
- Complex Departmental Coordination
>> Risk: Miscommunication or misalignment between design, production, and flight operations departments.
>> Mitigation: Clear communication protocols, regular coordination meetings, and a comprehensive Flight Test Operations Manual (FTOM).
- Pilot and Engineer Competence
>> Risk: Inadequate training or experience of flight test crew, leading to incorrect decisions in abnormal situations.
>> Mitigation: Advanced and continuous training, certification in specific flight test categories, and regular assessments.
- Overstretching Flight Envelope Boundaries
>> Risk: Exceeding operational limitations during unconventional manoeuvres, which could cause structural failure or loss of control.
>> Mitigation: Conduct gradual envelope expansion tests and implement in-flight real-time risk management.
- Regulatory Non-Compliance
>> Risk: Failure to comply with EASA Part 21 regulations, which could result in legal penalties or test cancellations.
>> Mitigation: Ensure detailed documentation, maintain regulatory oversight throughout testing, and conduct internal audits.
- Human Factors and Fatigue
>> Risk: Fatigue or cognitive overload of test pilots and engineers during long or stressful flight tests, impacting decision-making.
>> Mitigation: Crew rotation, time management strategies, and pre-flight briefings to identify potential fatigue risks.
- Emergency Response and Contingency Planning
>> Risk: Unpreparedness for in-flight emergencies such as control loss or system malfunctions.
>> Mitigation: Detailed contingency plans, emergency procedures embedded in the FTOM, and rehearsals for emergency scenarios.
- Data Integrity and Documentation Errors
>> Risk: Incomplete or inaccurate data collection, which could compromise future testing and regulatory compliance.
>> Mitigation: Strict data collection protocols, real-time recording of flight parameters, and thorough post-flight debriefs.
- Environmental and Weather Risks
>> Risk: Adverse weather conditions during testing that can exacerbate flight control issues or mask system failures.
>> Mitigation: Pre-flight weather analysis, flexible scheduling, and risk-adjusted test planning to avoid weather-related hazards.
Each of these risks should be addressed in the Flight Test Operations Manual (FTOM) and included in pre-flight risk assessments, ensuring both safety and compliance throughout the flight testing process.
Next Steps
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Aviation Safety Management System (SMS), Contingency Planning, human fatigue, Departmental Coordination, Crew Competence, Complex Coordination, Flight Test Environment, EASA Part 21 J, Aviation Best Practices, Risk Management, SAS blog, Risks, Flight Test, Cabin crew training, Emergency Response, Mitigation, human factor
