Human Factors in Maintenance: A Twenty Year Progress Report

1. Federal Aviation Administration Human Factors in Maintenance: A Twenty Year Progress Report …and still counting William B. Johnson Chief Scientific & Technical Advisor for Human Factors in A/C Maintenance Systems bill-dr.johnson@faa.gov

2. Agenda • AVS Chief Scientist Program (1 slide) • Report card on early recommendations (14 slides) • Maintenance Human Factors Presentation System (MHFPS) (6 slides)

3. Aviation Safety Organization CSTAs Report here Over 6700 Employees dedicated to Aviation Safety

4. What Year? “In June of this year, the FAA sponsored a meeting of representatives of the aviation industry to review problems associated with aging aircraft. While much of this meeting addressed issues of hardware, metal fatigue, and corrosion, there was a discussion of human factors. Today’s meeting reflects that growing interest in human factors and its potential contribution to continuing aviation safety.” Dr. Bill Shepherd FAA Office of Aviation Medicine October, 1988

5. Recommendation Topics from 1988 • Communication must be improved • Build error data bases • Improve FAA 147 school curricula • Supply of qualified maintenance personnel is inadequate • Training technologies must advance • “Gate time” pressure must be controlled • Conduct task analysis of mechanic/engineer job • Establish a R&D centers/process • Technical manuals

6. Communication must improve • Meetings like this one • 18 International Conferences on HF in Maintenance • Pick up any aviation magazine • New Guidance, OPS Manual, Web Sites and HF Guide • Go to any conference • Standard terms like: • Dirty Dozen • Swiss Cheese • Voluntary reporting • Just culture • Safety Management Systems

7. Build error data bases • Boeing MEDA • UK Confidential Incident Reporting Programme (CHIRP) • NASA Aviation Safety Reporting System (ASRS) • FAA’s Aviation Safety Reporting System (ASAP) • Recent ICAO SMS activity • But we can still do a better job of sharing

8. Improve FAA 147 school curricula • Good progress in Europe? • HF Training required for certification • Recurrent training • Poor progress in US • HF not required • Thanks for 1200+ EASA certificates in US

9. Supply of qualified maintenance personnel is inadequate • An international challenge for sure • Supply of qualified maintenance personnel is inadequate • Desire or glamour is gone – holidays, weekends, less pay & benefits, etc. • Cost to obtain license and time required is equivalent to BA degree • Confounded by layoffs and contract maintenance in US • Labor shortage affects the work environment • Human resources • Fatigue potential • Increased risk • Does this belong on an HF checklist?

10. Recommendation Topics from 1988 How are we doing so far ??? • Communication must be improved • Build error data bases • Improve FAA 147 school curricula • Supply of qualified maintenance personnel is inadequate • Training technologies must advance • “Gate time” pressure must be controlled • Conduct task analysis of mechanic/engineer job • Establish a R&D centers/process • Technical manuals ?

11. Training technologies must advance • Desktop simulation (with real time) • Improved CBT • Improved embedded training systems • Improved manufacturer documentation for training • Good examples of WBT have emerged • ….however, in US, type-training is reduced

12. “Gate time” pressure must be controlled • Improved staff awareness of error • Improved procedural design and compliance • Becoming more complex due to decrease in manpower • Pressure is there…threats are there • Safety Culture is critical • Plan for Mx & Ramp LOSA

13. Conduct task analysis of mechanic/engineer job • Completed by university in US • Approved maintenance organizations can do • Software products and process available • Should be an SMS component • M-LOSA may help • There are opportunities for improvement

14. Establish a R&D center/process • FAA Mx HF R&D program • European Adams2 and HILAS programs • Airbus, Boeing and other manufacturer attention to Mx HF • FAA established HQ ASI – with budget • FAA established Chief Scientific & Technical Advisor • EASA searching for “Human Factors Expert”

15. Technical manuals • Much improved since 1988 but more needed • Standardized formats across manufacturers • New on-board tech. pubs. for new aircraft • Web-based distribution • …and “Not following published procedures remains the #1 challenge”

16. Final scorecard from 1988 • Communication must be improved • Build error data bases • Improve FAA 147 school curricula • Supply of qualified maintenance personnel is inadequate • Training technologies must advance • “Gate time” pressure must be controlled • Conduct task analysis of mechanic/engineer job • Establish a R&D centers/process • Technical manuals

17. Did not make 1988 list • “These mechanics, working at starting wages, find it difficult to make ends meet and often require second jobs.” • “…shortage of mechanics…..This leads to overtime and longer than normal hours and again, contributes to the fatigue of an employee and associated vulnerability.” • “…night maintenance….The mechanic has to do his business during the day and often goes to work tired as a result.” Norman Grubb VP Engineering Henson Airlines

18. Agenda • AVS Chief Scientist Program • Report card on early recommendations • Maintenance Human Factors Presentation System (MHFPS)

19. MHFPS System Contents • Approximately 170 PowerPoint Slides (Many with speaker notes) • 11 FAA Video Snippets (produced in 2007) • 38 Animations (produced by Lufthansa Technical Training) • A short, medium, and long presentation • 7 content specific presentations (e.g., HF Overview, Fatigue, Error, etc.)

20. Launch Menu on DVD

21. 2 History of Human Factors

22. Mx Human Factors has Evolved in 20+ Years!

23. 3 Human Factors Spectacles

24. What did you Learn about Human Factors Spectacles from the Introductory Video? What was the premise of the human factors spectacles video? List 10 things that you see while driving with your human factors spectacles List 10 things that you see in this class with your human factors spectacles List 10 things that you see at work with your human factors spectacles List 11 things that see at home with the human factors spectacles? List ……. in the mirror?

25. The Maintenance Human Factors Presentation System - MHFPS In US: aam520-mmpi-2@faa.gov In EU: sec@ifairworthy.com

26. Summary • AVS Chief Scientist Program • Report card on early recommendations Maintenance Human Factors Presentation System (MHFPS)

27. Thank you, Bill Johnson 10.08.08