Flight Airworthiness Support Technology - Airbus

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Airbus technical magazineAugust 2016#58FASTFlight Airworthiness Support Technology

The choice is yoursFAST 2016 QTR 2- 25 years of flight operational commonality- Flight recorders data inspectionFAST 2016 QTR 1FAST October 2015FAST 2015 QTR 4- Virtual Reality & 3D for Technical Data- Augmented Reality in AirbusA330 Family OverviewIncremental Development- TAT Optimizer- ACE by name, ACE by natureFAST 2015 QTR 3FAST 2015 QTR 2- Managing airframe aerodynamic performance - Stealthy building panels- L-ion batteries- Head-Up Display systemFAST 2015 QTR 1- Ground Support Equipement and tools- Scheduled maintenance requirementsFAST 2014 QTR 4FAST 2014 QTR 3FAST 2014 QTR 2- Additive layer manufacturing- Inflatable tents for engine maintenance- Structure Health Monitoring- Importance of reporting event from the field- Telemetry Centre- Greener solutions: cleaner chemicalsSpecial EditionFAST magazine is also available as a media-enriched app,downloadable to the tablet of your choice.

Airbus technical magazine#58FASTFlight Airworthiness Support TechnologyPublisher: Bruno PIQUETDesign: PONT BLEUCover image: Hervé GoussetPrinter: AmadioAuthorisation for reprintingFAST magazine articlesshould be requested by email:fast.magazine@airbus.comFAST magazine is available on internetwww.airbus.com/support/publicationsand on tabletsISSN 1293-5476 AIRBUS 2016All rights reserved. Proprietary documentBy taking delivery of this Magazine (hereafter ‘Magazine’), you accept on behalfof your company to comply with the following. No other property rights are grantedby the delivery of this Magazine than the right to read it, for the sole purpose ofinformation. This Magazine, its content, illustrations and photos shall not be modifiednor reproduced without prior written consent of Airbus. This Magazine and thematerials it contains shall not, in whole or in part, be sold, rented, or licensed to anythird party subject to payment or not. This Magazine may contain market-sensitiveor other information that is correct at the time of going to press. This informationinvolves a number of factors which could change over time, affecting the true publicrepresentation. Airbus assumes no obligation to update any information contained inthis document or with respect to the information described herein. The statementsmade herein do not constitute an offer or form part of any contract. They are based onAirbus information and are expressed in good faith but no warranty or representationis given as to their accuracy. When additional information is required, Airbus can becontacted to provide further details. Airbus shall assume no liability forany damage in connection with the use of this Magazine and the materials it contains,even if Airbus has been advised of the likelihood of such damages. This licenceis governed by French law and exclusive jurisdiction is given to the courts and tribunalsof Toulouse (France) without prejudice to the right of Airbus to bring proceedings forinfringement of copyright or any other intellectual property right in any other court ofcompetent jurisdiction. Airbus, its logo, A300, A310, A318, A319, A320, A321, A330,A340, A350, A380 and A400M are registered trademarks.Photo copyright AirbusPhoto credits: Airbus Photographic Library, Airbus Group Corporate Heritage, Master Films,Céline Sadonnet, Philippe Masclet, Hervé Goussé, A.Doumenjou,ACJ cabin design and illustrations courtesy of Plus 33 Design StudioFlight operational commonality04Celebrating 25 yearsFlight recordersdata inspection12Simpler testing methodsVIP Kit solutions16to optimise A330 and A340 aircraft24OPTIMAOptimisation of Performance by Task IntervalMaintenance AssessmentSWITS30Smart Wiring TroubleshootingHealth monitoringand prognostics36FAST from the past42Around the clock,around the world43Where you see these icons,videos or slide shows are availableon the iPad, Android & Windowsapp versions of FAST magazine.03 FAST#58Chief Editor: Emma MUNDAY ALVARADO

Celebrating 25 yearsof flight operationalcommonality between Airbusfly-by-wire aircraft04 FAST#58With the inception of the A320,Airbus laid the foundation fora truly integrated family of aircraftwith synergies in the area of flight trainingand operations. The application of a coherent cockpitdesign philosophy and the use of fly-by-wire technologythroughout have been key in achieving this.Airlines that operate several members of the familyare thus able to reduce flight training expenditureand to increase pilot productivity, gaining a competitiveedge over operators of disparate fleets.

25 years of flight operational commonalityArticle byGerrit VAN DIJKTechnical Marketing DirectorAircraft OperationsCustomer AffairsAIRBUSgerrit.van-dijk@airbus.comContact for Operator DifferenceRequirement (ODR) and OperationalSuitability Data (OSD) requests:Régine VADROTHead of Training and Operational CertificationEngineering - Product IntegrityAIRBUSregine.vadrot@airbus.comA brief history of Airbus flight operational commonalityWhen, four years after the A320, the A340 took to the sky in 1991, it became possiblefor the very first time to benefit from extensive cockpit, systems and handling commonality between a short-range 150 seater and a long-range widebody aircraft twiceits size. Until then, so-called flight operational commonality had been a design featureof aircraft of comparable configuration and mission capability only, such as the A300/A310 Family or 737 series.The A340 incorporated the A320’s pioneering digital fly-by-wire controls and glasscockpit layout with side sticks instead of yokes. Airbus has used this technology in allsubsequent programmes as well, offering a consistent man-machine interface acrossthe A320, A330, A340 families, A350 XWB and A380.The importance of fly-by-wire and ECAMAirbus fly-by-wire aircraft have electrical rather than mechanical signalling of primaryflight controls: The pilot’s input to the control surfaces is sent via a side stickand rudder pedals through computers that use control laws Control laws convert this input into an aircraft responseand largely determine the aircraft’s handling characteristicsFly-by-wire enables handling and procedures similarity between aircraft as far apart asthe two-engine A320 and the seven times heavier four-engine A380.Pilots receive systems information through an Electronic Centralised Aircraft Monitor orECAM, the heart of any Airbus glass cockpit. If a malfunction occurs, the ECAMdisplays the fault and lists the actions required of the crew. The read-and-do approachthat follows facilitates the harmonisation of abnormal and emergency procedures,even though systems behaviour may vary somewhat from one aircraft type to another.Same Type RatingA single licence endorsementfor related aircraft sharingthe same Type Certificate.SFFSingle Fleet FlyingOne pool of pilots flying relatedaircraft under a single licenceendorsement.Same Type Rating and Single Fleet FlyingFlight operational commonality between a basic aircraft model and its lengthened/shortened fuselage variants can be virtually total. A good example is the single-aisleA320 Family comprised of the A318, A319, A320 and A321. In addition to sharing thesame Type Certificate, these models have been assigned a Same Type Rating (FAAdesignation) or single pilot licence endorsement (EASA terminology).True for any two Airbus models sharing a Same Type Rating, pilots qualified on one ofthem need only a few hours of e-learning to fly the other model as well. Neither fullflight simulator sessions nor a Type Rating check are mandatory in this case.One pool of pilots flying multiple Airbus models under a single licence endorsement isreferred to as Single Fleet Flying (SFF). SFF is both practical and cost effective since: Take-offs and landings in one model count towards recency of experienceon all when it comes to satisfying the regulatory requirement of at least threetake-offs and landings at the controls over a 90-day period Recurrent training, proficiency checks and line checks in one model are valid for all05 FAST#58STR

25 years of flight operational commonalityFlight operational commonality due to a consElectronic CentralisedAircraft Monitoring(ECAM)Fly-by-wireFlight control s Crew QualificationShortened insteadof full transition training toacquire an aircraft Type Rating.Flight operational commonality between Airbus aircraft having separate Type Certificates and requiring separate Type Ratings varies from 40% for the A320-A380 to 90%for the A330-A340 combination, measured as a reduction in pilot transition trainingdays relative to a standard Type Rating course duration.Mixed Fleet FlyingThe remaining transition training from one Airbus type to another is known as CrossCrew Qualification (CCQ). It consists of a reduced ground phase and a limited numberof full flight simulator sessions (handling phase) followed by a Type Rating check. AnA320 pilot needs five simulator sessions to qualify on the A380, for instance, whereaspilots without previous Airbus fly-by-wire experience typically have nine sessions.One pool of pilots flying relatedaircraft that require separatelicence endorsements.CCQ may lead to Mixed Fleet Flying (MFF). Airbus defines MFF as the operation ofmultiple aircraft types – requiring separate licence endorsements – with a pool ofmulti-qualified pilots. MFF with Airbus aircraft is also practical and cost effective since:MFF06 FAST#58Cross Crew Qualification and Mixed Fleet Flying Take-offs and landings in one type count towards recency of experience on othertypes, provided that one take-off and landing is performed in each type every 45days (the A330-A340 combination does even better only one take-off andlanding in one and two in the other every 90 days) Recurrent training, proficiency checks and line checks may alternate between types

25 years of flight operational commonalitysistent man-machine interface across typesThe length of Airbus Type Rating coursesFlight Crew Licensing (FCL) compliant training and exam days(base training not included)Days25MORE time for revenue flyingREDUCED training cost2040 to 90% time saving15with Cross Crew Qualification1050FullTransitionTraining*A320 or A330or A340to A380A320 or A340to A350A320 to A330or A340& vice versaA380 to A350A330 to A340A340 to A330* 23 days for A350, 25 days for A38007 FAST#58All courses include full flight simulator sessions and a Type Rating check

25 years of flight operational commonalityCTRCommonType RatingA single licenceendorsement forrelated aircraft havingseparate TypeCertificates.Common Type Rating and Single Fleet FlyingThe A330 and A350 have separate Type Certificates, but their handling characteristicsare so similar that they have been granted a Common Type Rating (FAA designation)or single licence endorsement (EASA terminology).Nevertheless, pilots qualified on the A330 need differences training for the A350,essentially because of the increased functionality and interactivity that the A350cockpit offers. It involves four days of laptop based systems knowledge acquisitionand procedures training plus four sessions in a non-moving Flight Training Device(EASA Level 2, FAA Level 6). Expensive full flight simulator sessions are not mandatoryand neither is a full Type Rating check. That is why flight operational commonalitybetween the A330 and A350 is expressed both in terms of pilot training days reduction(65%) and tuition savings (80%), relative to a standard A350 Type Rating course.The A330 and A350 may be operated by one pool of pilots under a single licenceendorsement (SFF) with the following credits: Take-offs and landings performed in any A330 or A350 counttowards recency of experience on both Line and proficiency checks in any A330 or A350 are valid for both,provided that differences have been addressed in recurrent trainingAn integrated familyof aircraft08 FAST#585 aircraft types with synergiesin flight training and flight operations

25 years of flight operational commonalityA350 flight trainingdevice for differencestrainingRegulatory aspectsPilots qualified on one Airbus (a ‘base’ aircraft) can be trained on another Airbus(the ‘candidate’ aircraft) based on system and manoeuvre comparisons presented inOperator Difference Requirement (ODR) tables. Differences for each aircraft combinationare listed and graded from A to E level according to their severity, which determinesthe corresponding training and checking needs. Airbus ODR tables are available uponrequest.Regulations and recommendations with regard to the use of ODR based trainingprogrammes, such as CCQ courses, and the implementation of SFF and MFF canbe found in Operational Suitability Data (OSD) documents published by Airbus andapproved by EASA. Since the introduction of a new rule in Part 21 pertaining to OSD,EASA no longer publishes operational evaluation results as Operations EvaluationBoard reports. Existing reports disappeared from the EASA website at theend of 2015; from that date those with an Airbus content are managed by Airbusand released to operators on an ad hoc basis, as is the case for approved OSDdocuments today.The FAA equivalent of Operations Evaluation Board reports and now OSD documentsis the Flight Standardization Board (FSB) report. FSB reports continue to be publishedon the FSIMS website of the FAA.Equipped with full size cockpit panelsand all controls, switches and knobsthat physically replicate the aircraft.* Non-moving Flight Training Device(EASA Level 2, FAA Level 6)A pilot’s perspective on flight operational commonalityThe skills and experience accumulated in one Airbus aircraft can be carried overto another one, which enhances proficiency. Pilots benefit from greater mobility too:an airline looking for, say, A330 qualified pilots may also invite A320 pilots to apply,since the cost of A320 to A330 CCQ is relatively low.Those who practise SFF and/or MFF gain access to a larger part of the network, sotheir work environment is more varied. This could mean alternating long haul with shorthaul trips, which provides more take-off and landing opportunities and may lead to abetter balance between work and private life compared with purely long haul flying.Complacency is less likely and motivation tends to improve as well.09 FAST#58A330 to A350 training may bedone with an FTD2* insteadof a full flight simulator, whichreduces the training mediainvestment significantly.

25 years of flight operational commonalityThe value of flightoperational commonalityRecent developmentsGenerally, airline pilots get to fly various aircraft models and/or typesduring their professional life, because of:The integration of the A350 into theAirbus family of fly-by-wire aircraft is afine example of Airbus’ ability to combineinnovation with commonality. Followingregulatory approval of a Common TypeRating for the A330 and A350 as well asCCQ from the A320 Family in 2014,A340 to A350 and A380 to A350 CCQcourses are now available too.Flight operational commonality betweenthe A350 and A380 in particular is animpressive 80%, resulting in a CCQduration of only five days and a recencyof experience requirement in MFFoperations equal to that of theA330-A340 combination. Career incentives that make them move to bigger equipmentand change from the right- to the left-hand seat Aircraft replacement initiated by their employer A change of employer A combination of the aboveIt is not uncommon for a pilot to experience six to eight equipment changesin total at a typical retraining cost of US 30,000 per event in 2016 economicconditions. Add around one-and-a-half months of downtime for each changeand it becomes obvious that this is costing the airlines collectively severalbillions of dollars every year. Those with an Airbus fleet, however, can reducepilot retraining cost by two-thirds on average when using ODR based trainingprogrammes.In addition to that, airlines can take advantage of SFF and MFF in many ways:As for the A320neo, EASA and the FAAhave concluded that the installation ofPW1100G-JM or CFM LEAP-1A enginesdoes not really change the handlingcharacteristics in comparison with theCFM56 or V2500 powered A320ceo.Henceforth, the A320neo can beconsidered a variant of the A320ceounder a single pilot licence endorsement(Same Type Rating) designated ‘A320’. From creating an integrated fleet management structureand multi-qualifying their flight instructors/examiners To using single-aisle first officers as augmentation pilotson long-range widebody aircraft or even multi-qualifyingreserve crews and ordinary line pilots at largeSFF and MFF offer rostering flexibility, which results in greater pilot productivity.Smaller airlines benefit from powerful economies of scale that were theprivilege of big operators before. Depending on the mix of fleet and the natureof an airline’s flight operations, annual revenue flying time per pilot mayincrease by 5 to 15% with SFF and MFF.Airbus flight operational commonality has been demonstrated to save up toUS 8 million per aircraft in present value terms over a 15-year period.Greater pilot productivity due to flight operational commonalityCrewsperaircraftA350 stand-aloneA330 stand-aloneEconomiesof scaleand less timein trainingWith A330-A350 SFF*SFF & MFF effectTypically5-15%CCQ effect10 FAST#580102030more revenueflying timeper pilot4050Steady state relationship observed at various airlines* In combination with CCQ from the A320 for instance60708090Fleet size

25 years of flight operational commonalityLarge-scale CCQ and MFF are unique to Airbus and much appreciated by its customers:Operating both A320 Familyand A330 aircraft doesnot create any operationaldifficulties for our pilots butonly benefits with regardto crew planning and savingresourcesCathay Pacific AirwaysThe MFF is most usefulfor flexibilityWindrose AirlinesOur airline has employedCCQ/MFF for a numberof years now, which hasturned out to be effectiveand successful. We tookfull advantage of the strongfunctional commonalityestablished by ODR tablesand Operations EvaluationBoard reportsCCQ is really a plusand training is facilitatedby the Airbus approachBrussels AirlinesMFF is very beneficial formid-size companies like ours.We would like to congratulateAirbus on thisOnur AirGulf AirThomas Cook Airlines’CCQ is a realityat more than 60 operators,35 of which havealso implemented MFF.Be one of them!CONCLUSIONAll Airbus fly-by-wire airliners have been designed with flight operational commonality in mind,which has resulted in exceptional handling and procedures similarity between even the smallestand the biggest of those aircraft.Over the past 25 years, numerous operators around the world have discovered the benefits of this:optimised flight training and unprecedented crew rostering flexibility coupled with enhanced pilotproficiency and motivation.Airbus remains strongly committed to offering this valuable feature to its customers, as demonstratedby the successful integration of the A350 and A320neo into the Airbus product line.11 FAST#58‘One of the attractionsof going for MFF was theadvantages it would bringin terms of mixing longand short haul flying andthis has been very popularwith our pilots in termsof maintaining recencyand competency

Flight recordersdata inspectionby AirbusThe flight recorders or “black boxes” might be the mostfamous avionics units in an aircraft. They do not make anaircraft fly; they do not participate to passenger comfort.However, black boxes are well known by the publicbecause they contain something precious: flight data.Whenever an aircraft accident occurs, an investigation islaunched to determine its root causes. For that, investigators need lots of flight data. The more accurate thedata, the more precise the investigation results will beand the more benefits will be derived for aviation safety.12 FAST#58This is why black boxes draw

The A340 incorporated the A320’s pioneering digital fly-by-wire controls and glass cockpit layout with side sticks instead of yokes. Airbus has used this technology in all subsequent programmes as well, offering a consistent man-machine interface across the A320, A330, A340 families, A350 XWB and A380. The importance of fly-by-wire and ECAM

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