June 2, 2022 - No. 27 In This Issue : Why The Human Factors of Aviation Maintenance Matter : FAA Modernizes Aviation Maintenance Technician School Curriculum Requirements : Aerospace industry order uplift as recovery continues : Collins Aerospace launches FlightHub™ Electronic Flight Folder with access to new fuel savings application : Collins Aerospace selected to outfit the next generation of space explorers Why The Human Factors of Aviation Maintenance Matter Frequently, aircraft maintenance professionals are placed in uncomfortable situations when maintaining aircraft. The alarm sounds at 0605 local, and I barely register that I am alive, let alone awake. Struggling to my feet, I dress and move slowly toward the kitchen, where my mother greets me with a red-and-white 16-quart Igloo Playmate cooler, packed with all three meals I would need for the next 18 hours and snacks. I shoulder my faded black Jansport backpack, hoist my Sears Craftsman toolbox into the truck, and fight to stay awake on my early morning drive to airframe and powerplant (A&P) school. A&P school concludes at 1500. Next, my shift starts at the ATL T Gates. As a mechanic’s helper, my duties ranged from interior cabin work to hauling Lockheed L-1011 tires and nitrogen bottles. We sometimes entered aircraft logbooks into the computer. Yes, I am L-1011 years old. The second shift on International Line Maintenance ends at 2300, time to clean up, gather tools, and board the crew bus for the parking lot. It will be well past midnight before my head hits the pillow, and it will hit hard. At 0605 the following day, it starts all over again. Lather, rinse, repeat. One weekend a month, I rise at 0505 and report for my U.S. Naval Reserve duty at Attack Squadron (Atkron) VA-205 on Naval Air Station (NAS) Atlanta. Monday morning, it begins again. The above scenario was my life for three years. It is not a sustainable schedule for an aircraft mechanic. I was also one tired human, and that factored into my work. The human factor—hey, we may be onto something here. A Short History of Human Factors Studying human factors has roots in the 1940s, but it was far from the buzzword we recognize today. What are human factors anyway? The FAA defines human factors as a “multidisciplinary effort to generate and compile information about human capabilities and limitations and apply that information to equipment, systems, facilities, procedures, jobs, environments, training, staffing, and personnel management for safe, comfortable, and effective human performance.” (FAA Order 9550.8A) I can tell you that in 1991 I never heard, nor was anyone aware, that the study of human factors existed, let alone carry the importance it does today. Working long hours was just something you did to get ahead. Not a soul ever asked us if we were too tired to work on airplanes, and doubtful any of us would admit it anyway. When I was in AMS A School in Millington, our battle cry was that we should sleep when we were dead, and we will still pull duty and stand watch. Frequently, aircraft maintenance professionals are placed in uncomfortable situations when maintaining aircraft. Not every job is at 1000 on a Tuesday in a climate-controlled hangar. Airplanes are fickle and will break whenever it pleases them. They usually fail in a remote location, at night, while cold and rainy, with an angry owner blowing up your phone. Or so I have been told. Mark Clowdus from Clowd Works facilitating a engine install during winter on the ramp at DeKalb-Peachtree Airport (KPDK), in Atlanta. [Courtesy: Richard Scarbrough] The early ’90s was a time for significant changes in aviation. Some of the old legacy carriers ceased operations, like Eastern Airlines, Pan American World Airways, and Midway Airlines, just to name a few. Some airlines have struggled to compete in the new world for a little over a decade since deregulation. Other changes were on the horizon, as well. Gordon Dupont developed a system for recognizing 12 human error elements that contribute to unsafe conditions in the great white north at Transport Canada. The Dirty Dozen makes its way worldwide, evolving and adapting to specific missions as needed. In November of 2012, the FAA Safety Team published content about the Dirty Dozen in this infographic. Continuing on the work started by Mr. Dupont, the FAA sought to arm pilots, safety representatives, and mechanics with the knowledge and tools needed to navigate aerospace’s tricky landscape. The Dirty Dozen? The Dirty Dozen contributing factors or preconditions to human error are: 1. Lack of Communication This topic is number one for a reason. Effective communication is the cornerstone of every success story. Expand the method of communication beyond verbal, use a checklist, and use call and response if necessary. 2. Complacency One should expect to find errors, and do not assume something is airworthy just because it flew in like that. Unlike the judicial system, airplanes are grounded until proven airworthy. 3. Lack of Knowledge Carl Sagan remarked, in The Demon-Haunted World: Science as a Candle in the Dark that, “every question is a cry to understand the world.” Training is your best defense against a lack of knowledge. If you are unclear on a task or maintenance action, please raise your hand. 4. Distractions A recent AAA study shows that odds of a driver being involved in a crash nearly doubled when they were engaging in all visual-manual cellphone tasks taken together and more than doubled when they were texting. How often have you been knee-deep in a project, only to have your mobile phone ring just as you were about to set a critical piece? Keep tabs on your work progress and retrace your steps if necessary. 5. Lack of Teamwork There is no “I” in a team, but people often like to hoard information, feeling like it makes them irreplaceable. This action was especially true in older generations, who mainly operated on tribal knowledge. The underlying thread of teamwork is trust. A solid team should strive to make each other better, thereby ensuring success for the mission. 6. Fatigue I was one tired human and survived because I was in my early 20s, hungry for work, and coffee in the line shack was jet black and free. Fatigue applies to mental and physical exhaustion. But I was not bringing my best self to my work. Use the buddy system to cross-check each other before calling for inspection. 7. Lack of Resources Enlist in the Navy and learn all about the lack of resources. Air Force types can skip this part, as it will seem a foreign concept to you. All kidding aside, a resource could be a tool, technical publication, spare part, or even lighting in the hangar. You cannot inspect what you cannot see. Plan your work ahead of time to ensure all the pieces are in place to perform maintenance. 8. Pressure Ever heard: “Sign it off and taxi out. We have a full bird and a departure deadline to meet”? Again, physical, psychological, and mental pressures are at play here. Never be afraid to say, “No, I am the deciding factor, and this bird is not going.” 9. Lack of Assertiveness If you lack the assertiveness to perform proper maintenance, find another line of work. There is no place for a job half done in aerospace. 10. Stress Take breaks. Tell the boss that breaktime is necessary to realign your chakras, but please don’t burn incense in the hangar; they will drug test you for sure. 11. Lack of Awareness What do you mean there is a difference between inch-pounds and foot-pounds? I just set any torque wrench I have handy to the number 35. Read the manuals first! Once you have a clear path forward and the necessary resources, only then open the toolbox. 12. Norms The kiss of death during any inspection is: “Not sure; that is just the way we have always done it.” Passing down bad habits is a thing. Break the cycle. Challenge the status quo; only don’t get crazy. You have the Dirty Dozen now, with a bit of color commentary from yours truly. Human Factors in MROs The role of human factors in aviation organizations, especially those that perform aircraft maintenance, is crucial to the entity’s success. It is also most likely to meet resistance from the people with the most to gain. Aircraft folks may be “old school” and not have time for newfangled ideas that take up time and create more forms to fill out. I spent some time with Sam Lee at Integra Aerospace Ltd trying to get to the root cause of the matter. Why are some aviation maintenance types so averse to change, even if the change helps them? LEARN MORE: Previous editions of “Maintaining Your Airplane” “From my experience, the one most significant challenge that maintenance repair and overhaul (MRO) shops have is making human factors relevant and providing tangible individual value to those participating,” Lee said. “They find the training mundane and often feel like they are just ‘tick-in-the-box’ and cannot see the benefit.” When we discussed ways to solve this, he said: “The answer to this is to make it relevant through activities that get the participants to investigate the human factors that directly affect them today and their influence on their unique work environments and role. Also, use scenario-based activities that use occurrence reports to illustrate real-life events relevant to that organization.” Scottish philosopher David Hume once said, “Human Nature is the only science of man; and yet has been hitherto the most neglected.” I interpret that to mean that we go to great lengths to preserve these incredible flying machines in our charge, scrutinizing the most minute detail. Yet, when it comes to our own physical and mental health, we are quick to circumvent established parameters and may even act recklessly. Don’t be that person. Raise your hand, ask questions, and take breaks. Read the manual. https://www.flyingmag.com/why-the-human-factors-of-aviation-maintenance-matter/ FAA Modernizes Aviation Maintenance Technician School Curriculum Requirements A new rule from the Federal Aviation Administration (FAA) will improve and modernize the training requirements for aviation maintenance technician schools (AMTS). A new rule from the Federal Aviation Administration (FAA) will improve and modernize the training requirements for aviation maintenance technician schools (AMTS). This will ensure that new aviation technicians learn from curriculums that align with current industry standards. “These improvements will help us educate the future workforce and meet the demands of the evolving aviation community,” said FAA Deputy Administrator A. Bradley Mims. The previous requirements for AMTS were almost 50 years old, which limited schools from aligning curriculums with modern industry standards. The new rule will enable schools to teach students with a curriculum that incorporates new innovations and technologies. In the Aircraft Certification, Safety, and Accountability Act of 2020, Congress directed the FAA to adopt new requirements for issuing AMTS certificates and the associated ratings. This rule adopts those requirements and revises the general operating rules for the holders of AMTS certificates and ratings. The final rule takes effect 120 days after it published in the Federal Register. https://www.aviationpros.com/education-training/press-release/21269295/faa-modernizes-aviation-maintenance-technician-school-curriculum-requirements Aerospace industry order uplift as recovery continues Global aircraft orders for April have seen a continuation of the strong order books seen at the start of the year and a continuation of recovery in market demand and confidence. 138 single-aisle and six wide-body aircraft were ordered, the highest April for new orders since pre-pandemic 2018. Aircraft manufacturers delivered a total of 83 aircraft, 70 single-aisle and 13 wide-body, an improvement of 34 per cent on April 2021. Compared to orders, deliveries are below pre-pandemic trends but in line with the ADS forecast of 2022 global deliveries reaching 997 aircraft. UK aerospace manufacturing output remains significantly weaker than February 2020, with output 40.5% smaller. The contribution to UK industrial value from the wide-body market segment is higher than for single-aisle aircraft. However, the April data alongside aircraft manufacturer production rate ramp ups remains a positive sign of recovery and is expected to feed through into overall manufacturing data later this year. Latest flight data continues to show encouraging signs of recovery with UK flight arrivals and departures remaining stable following the upward trends attributed to flights during the Spring break and now recovering to under a 20 per cent reduction from comparable data in 2019. The backlog of aircraft remains above 13,000 for the fifth consecutive month and continues to rise with demand and market confidence and represents several years’ worth of work worth around £190 billion to the UK aerospace industry. ADS chief executive, Kevin Craven, said: “The continuation of an order uplift is a very welcome sign of the continuation of recovery seen in recent months and I look forward to seeing it feed through into aerospace manufacturing output data. “To ensure the recovery feeds through into aerospace manufacturing, ADS will continue its work with Government, industry and members through ongoing supply chain and labour issues to support planned production rate ramp ups. “With the return of Farnborough Airshow in July, we will see a major opportunity for the UK to showcase its world-leading green aerospace technology to manufacturers as they look to invest and develop greener and cleaner aircraft.” www.adsgroup.org.uk https://www.aero-mag.com/aircraft-industry-orders-01062022 Collins Aerospace launches FlightHub™ Electronic Flight Folder with access to new fuel savings application • Collins Aerospace is advancing digital aviation solutions that make flight more efficient and sustainable with FlightHub, its new Electronic Flight Folder accessible from an aircraft’s Electronic Flight Bag. • FlightHub centralizes data sources and workflows into one single stream for pilots and airlines • Will include integration with Flight Profile Optimization solution for real-time route recommendations that reduce CO2 by saving fuel and time • Scalable solution that supports needs of airlines now and in the future ANNAPOLIS, Md. (June 1, 2022) – Collins Aerospace is advancing digital aviation solutions that make flight more efficient and sustainable with FlightHub, its new Electronic Flight Folder accessible from an aircraft’s Electronic Flight Bag (EFB). FlightHub centralizes data sources and workflows for pilots and airlines, coordinating the lifecycle of an entire flight from start to finish. Collating information into a single stream, FlightHub gives customers fast and easy access to all their flight information, from pre-flight documents, like flight plans and weather information, to post-flight summaries with actual timing and fuel burn reports. FlightHub customers will also get access to Collins’ new Flight Profile Optimization (FPO) solution that delivers real-time route recommendations throughout a flight to help reduce CO2 emissions by saving fuel and time. Set for release later this year, FPO provides flight path information taken from multiple aircraft and ground sources for more up-to-date information than what is generally obtained from the operational flight plan (OFP) and the flight management system (FMS), which can be several hours old. In aggregate, airlines using FPO could see up to 1% annual savings on fuel per year. “We’ve created FlightHub to reduce workload and streamline the experience for pilots, by cutting out unnecessary time sorting through multiple data sources. The application is also a quick and easy installation for airlines, which is key when implementing new technologies,” said Jen Schopfer, president of Connected Aviation Solutions for Collins Aerospace. “Flight Profile Optimization is the first of many features we will be introducing into FlightHub as we build and implement the right solutions to help our customers operate more efficiently and more sustainably.” FlightHub supports the integration of airline and third-party applications and can operate as a stand-alone system or connect to the aircraft’s IP network to receive real-time updates. It’s one of many Collins applications designed with its unique data and analytics capabilities to provide value and efficiency to its customers across the aviation industry. About Collins Aerospace Collins Aerospace, a unit of Raytheon Technologies Corp., is a leader in technologically advanced and intelligent solutions for the global aerospace and defense industry. Collins Aerospace has the extensive capabilities, comprehensive portfolio and broad expertise to solve customers’ toughest challenges and to meet the demands of a rapidly evolving global market. For more information, visit CollinsAerospace.com. https://www.collinsaerospace.com/newsroom/News/2022/06/Collins-launches-FlightHub-Electronic-Flight-with-access-to-new-fuel-savings-application Collins Aerospace selected to outfit the next generation of space explorers Collins-led team to provide new spacesuit for ISS crew and Artemis moon missions CEDAR RAPIDS, IA (June 1, 2022) – Collins Aerospace, a Raytheon Technologies (NYSE: RTX) business - along with teammates ILC Dover and Oceaneering - have been selected to produce NASA’s next-generation spacesuit, which astronauts could wear when working outside the International Space Station and – within the next decade – on the moon. The new suits were designed by astronauts for astronauts and offer enhanced mobility and weigh less than the current generation spacesuits, allowing for increased mission times. The suits are also designed to accommodate nearly every astronaut body type and can rapidly incorporate new technologies. “Astronauts returning to the moon and venturing beyond need a spacesuit that’s as modern as their new missions,” said Dan Burbank, senior technical fellow at Collins Aerospace and former NASA astronaut. “The next-gen spacesuit is lighter, more modular, a better fit and easily adaptable, which means that wherever the journey into space may lead, our crew will be ready.” Collins Aerospace designed the first spacesuit that allowed astronauts to walk on the moon, as well as the suit NASA astronauts currently use when operating outside the International Space Station. “Collins was there when the first man walked on the moon, and we’ll be there when humankind goes back,” said Phil Jasper, president of Mission Systems for Collins Aerospace. “We are excited to return to the Moon and build on our 50-year legacy of supplying EVA suits to NASA from the Apollo program to today on the International Space Station,” said Patty Stoll, president of Space Systems at ILC Dover. “We look forward to partnering with NASA as their lunar spacesuit provider and inspiring the next generation through Artemis as we work to send the first woman and next man to the Moon.” About Collins Aerospace Collins Aerospace, a unit of Raytheon Technologies Corp. (NYSE: RTX), is a leader in technologically advanced and intelligent solutions for the global aerospace and defense industry. Collins Aerospace has the extensive capabilities, comprehensive portfolio and broad expertise to solve customers’ toughest challenges and to meet the demands of a rapidly evolving global market. For more information, visit CollinsAerospace.com. About Raytheon Technologies Raytheon Technologies Corporation is an aerospace and defense company that provides advanced systems and services for commercial, military and government customers worldwide. With four industry-leading businesses ― Collins Aerospace Systems, Pratt & Whitney, Raytheon Intelligence & Space and Raytheon Missiles & Defense ― the company delivers solutions that push the boundaries in avionics, cybersecurity, directed energy, electric propulsion, hypersonics and quantum physics. The company, formed in 2020 through the combination of Raytheon Company and the United Technologies Corporation aerospace businesses, is headquartered in Waltham, Massachusetts. About ILC Dover ILC Dover is a world-leader in the innovative design and production of space exploration technology including spacesuits, space habitats and inflatable landing systems. The company’s spacesuits, Launch, Entry, and Abort (LEA), Extravehicular Activity (EVA) and Planetary Exploration Suits, have been worn during more than 250 space flights, six Moon landings, and over 3,000 hours of spacewalks without a single failure. Our customers will attest to our relentless dedication to high value products, advanced technology, and responsive service, as our visionary solutions have improved efficiency while safeguarding people, product, and infrastructure in hazardous conditions through flexible protective solutions since 1947. For more information on ILC Dover, please visit http://www.ilcdover.com. https://www.collinsaerospace.com/newsroom/News/2022/06/Collins-Aerospace-selected-to-outfit-the-next-generation-of-space-explorers Curt Lewis