1. 1 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 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

2. The Boeing Company Agenda Predictive WorkPaul RehearsalPaul Test Day PrepRalph ExecutionFrank Test ConductBrooke VideoFrank Predictive WorkPaul RehearsalPaul Test Day PrepRalph ExecutionFrank Test ConductBrooke VideoFrank

3. The Boeing Company 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. 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.

4. 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 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

5. The Boeing Company Test Preparation/Rehearsal Factors/Trades:

6. 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) 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)

7. The Boeing Company Test Preparation/Rehearsal

8. The Boeing Company Test Preparation/Rehearsal Specific benefit example: 777-200LR / GE90-115BL 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 ! Specific benefit example: 777-200LR / GE90-115BL 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 !

9. 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 –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

10. 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 Develops team working together skills 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 Develops team working together skills

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

12. 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 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

13. 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 Engine Restart 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 Engine Restart

14. The Boeing Company Test Director Roles Test Conduct

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

16. 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 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

17. The Boeing Company Test Conduct Conduct test –Get wind check CP from Windy –Call brake releaseP on test frequency –Add power slowlyP –Track center lineP –Feet off pedals prior to cutP –Non flying pilot cut fuel at cut speedCP –React to nose movementP –Full / rapid rudder applicationP –Condition over at knock it off call or at pilot discretionAnalysis/CP/TD/P –Accomplish recovery procedureP –NWS circuit breakers in below 100 knots with pilot callCP/TD –Engine relight per briefed procedureCP/TD –Determine status of tires and brakes for cooling.P/CP/TD Conduct test –Get wind check CP from Windy –Call brake releaseP on test frequency –Add power slowlyP –Track center lineP –Feet off pedals prior to cutP –Non flying pilot cut fuel at cut speedCP –React to nose movementP –Full / rapid rudder applicationP –Condition over at knock it off call or at pilot discretionAnalysis/CP/TD/P –Accomplish recovery procedureP –NWS circuit breakers in below 100 knots with pilot callCP/TD –Engine relight per briefed procedureCP/TD –Determine status of tires and brakes for cooling.P/CP/TD

18. The Boeing Company 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 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

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

20. The Boeing Company Roles and Responsibilities – Engineering -Laptop -Works the spreadsheet to make post- condition calls -Takes notes -Laptop -Works the spreadsheet to make post- condition calls -Takes notes

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

22. 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.

23. The Boeing Company Questions?