CRM Its More Than Just The Cockpit Frank

CRM: It’s More Than Just The Cockpit Frank Santoni Chief Pilot, Boeing Brooke Shindler Flight Test Analysis, Boeing Paul Bolds-Moorehead Principle S&C Engineer, Boeing Ralph Mohr Flight Test Safety, Boeing 5/9/07 1

Agenda • Predictive Work Paul • Rehearsal Paul • Test Day Prep Ralph • Execution Frank • Test Conduct • Video The Boeing Company Brooke Frank

FAR Requirements • Vmcg – Minimum Control Ground Speed – Governed by FAR 25. 149 (e) • It must be demonstrated that, when the critical engine is suddenly made inoperative at Vmcg during the takeoff roll, the airplane is safely controllable if the takeoff continued. • During the demonstration, the airplane must not deviate more than 30 ft. The Boeing Company

Test Preparation/Rehearsal • Extensive prediction of flight characteristics – Begins approx. one year before flight – Multiple variabilities examined for VMCG testing – Key factor: pilot reaction time (PRT) – Other factors: Crosswind, Initial Yaw Rate, Rudder Input Rate, Runway Condition, Hydraulic System Failures The Boeing Company

Test Preparation/Rehearsal • Factors/Trades: The Boeing Company

Test Preparation/Rehearsal • Team assigned early – Representatives from all disciplines (pilots, program engineering, test engineering) – Start early discussions on procedures and data metrics • Full team rehearses maneuver in engineering simulator – Fine tune test procedures – Establish abort criteria – Stated requirement that pilots involved in the test must practice in the simulator (part of risk alleviation) The Boeing Company

Test Preparation/Rehearsal The Boeing Company

Test Preparation/Rehearsal • Specific benefit example: 777 -200 LR / GE 90 -115 BL VMCG test – Originally planned for light weight, Flaps 20 (as all previous 777’s had done) – “Conservative” build-up planned: start fast for less deviation, then fuel cuts at slower speeds until >30 ft lateral deviation achieved – Determined that airplane was basically airborne and rolling during simulator rehearsal – Test safety an issue ! The Boeing Company

Test Preparation/Rehearsal – So…… the test plan was adjusted to Flaps 5, mid weight (after analytically showing insignificant effect on resulting VMCG speed) – Rather than traditional build-up, start testing AT predicted VMCG speed, then obtain points on either side to generate required data – Resulted in much safer test, successfully completed The Boeing Company

Test Director Roles • Test Planning – Coordinates with supporting groups • Flight Crew – Understands any crew comments or concerns • Analysis – Understands the test plan & requirements • Instrumentation – Data monitoring and preflight • Weights – Fuel & Ballast Loading Requirements • Ground Ops & Shop – Configuration, support, release time – Participates in rehearsals / dry-run simulator cab sessions The Boeing Company • Develops team working together skills

Test Director Roles • Test Sequencing – Risk Assessment – Risk Alleviation – Special Test Requirements – Sequence of Events / Procedures • Before APU Start • Engine Shutdown The Boeing Company

Test Director Roles • Test Briefing – Test Crew – Wind Station Operator/Photo – Review Sequence – Discuss Lessons Learned – Discuss Technique – Discuss Monitoring Requirements – Discuss Knock-it-Off Criteria – Cabin Safety & Egress Brief – All participants required to be in attendance The Boeing Company

Test Director Roles • Test Conduct – Test Director responsible for ensuring team readiness • Comm Check – all the way around – Read & Do – run the procedure like a checklist • Initial Setup The Boeing Company Engine Restart

Test Director Roles • Test Conduct The Boeing Company

Test Director Roles • Post Test Debriefing – Discussion of events – Capturing lessons learned • Reporting – Operations Summary The Boeing Company

Test Conduct – Cockpit Brief • Align the airplane on runway – slight offset for wind • Receive condition card from Analysis • Brief condition – Call 100 kts – Cut speed – put “bug” on speed tape – Ignore engine surge – Pilot apply full rudder – when the nose moves – Knock it off call - review • Normally from back end when A/C cg turns around • If deviation is greater than 50 feet – 2 blocks (25 ft. each) • If data freezes • Pilot decides to – Review recovery procedure • Idle thrust • Control to parallel center line • Speedbrakes up • Max reverse – Brief when to put the nose wheel steering breakers back in – Check that team is ready The Boeing Company

Test Conduct • Conduct test – Get wind check – Call brake release – Add power slowly – Track center line – Feet off pedals prior to cut – Non flying pilot cut fuel at cut speed – React to nose movement – Full / rapid rudder application – Condition over at knock it off call or at pilot discretion – Accomplish recovery procedure – NWS circuit breakers in below 100 knots with pilot call – Engine relight per briefed procedure – Determine status of tires and brakes for cooling. The Boeing Company CP from Windy P on test frequency P P P CP P P Analysis/CP/TD/P P CP/TD P/CP/TD

Roles and Responsibilities – Engineering • 3 Flight Test Engineers - ADAMS (Data) station - Overall responsibility for running the test in the back - Initial setup of data programs - Run trap - Monitor Lateral Deviation - Knock it off call The Boeing Company

Roles and Responsibilities – Engineering - Stripchart - Back up on knock it off - Makes quick condition qualities calls (reaction time and max deviation) The Boeing Company

Roles and Responsibilities – Engineering - Laptop - Works the spreadsheet to make postcondition calls - Takes notes The Boeing Company

Roles and Responsibilities – Engineering - Program Engineers • Provides intimate knowledge of trade studies and predictive work The Boeing Company

Decision Time! On test day everyone has a different level of conservatism. Everyone needs to come to next fuel cut decision as a group. The Boeing Company

Questions? The Boeing Company