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OCR for page 1
Introduction and Summary
of Recommendations
In creating the Federal Aviation Administration (FAA) 22
years ago, the U.S. Congress directed the agency to as-
sure "the highest degree of safety" in flight.1 With
respect to airworthiness, i.e., the physical integrity
of the airplane, the FAA carries out its mandate in a
number of ways:
It establishes, at its headquarters office,
technical design standards and regulations
through its rule-making powers.
It assures, in its regional offices, that each
new type of aircraft (e.g., the Boeing 747, the
McDonnell Douglas DC-10, or the Lockheed L-1011)
is designed and manufactured in accordance with
the rules and standards set forth in the estab-
lished Federal Aviation Regulations (FARs), and
is subject to a process that ultimately awards
the manufacturer a design Type Certificate and
a Production Certificate.
It establishes, also in the regional offices, a
system for reviewing the fabrication of air-
planes and for issuing an Airworthiness Cer-
tificate for each one.
It employs a system of inspections and surveil-
lance, at district offices within the regions,
of the flight operations and maintenance pro-
cedures of the airlines to make sure that each
aircraft adheres to FAA standards of continuing
airworthiness.
1
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IMPROVING AIRCRAFT SAFETY/2
In addition, the FAA approves repair and overhaul
stations, and licenses some mechanics who work on the
equipment or who inspect the work of others. During the
course of production and maintenance, it reviews and
approves the processes and procedures of the manufac-
turer and airline. If violations are found at any stage,
the FAA has the authority to enforce its regulations
through warnings, fines, or revocation of licenses and
certificates.
The FAA is organized into 12 regions reporting to its
Washington headquarters. Its total employment is 57,490,
with the largest segment of the staff assigned to air
traffic control. The airworthiness function, which is
the subject of this report, employs approximately 3,000
people.2
Large jet transport aircraft are produced in the
United States by three companies, Boeing, Douglas, and
Lockheed, 3 and operated in passenger service by some
30 U.S. air carriers. In addition, aircraft produced by
two European concerns (British Aircraft Corporation and
Airbus Industrie) and one Japanese company (Nihon) are
also operated by U.S. carriers. Aircraft types range
from the smaller twin-engine B-737 and DC-9 to the three-
and four-engine wide bodies, the L-1011, DC-10, and
B-747.
The United States can be proud of its air transpor-
tation system, with an industry at the forefront of
technology and innovation that employs more than half a
million people, and a favorable trade balance from air-
craft exports that approached $10 billion in 1979.4 A
passenger airliner takes off or lands somewhere in the
United States on the average of every three seconds,
around the clock, every day of the year. In 1979, 318
million passengers flew a total of 256 billion miles
--some 1 million times the distance to the moon. The
number of passengers carried by domestic airlines has
risen 75 percent in the past decade.
Out of a total of 301 million passengers, 350 people
died in U.S. commercial aviation accidents last year,
with a passenger fatality rate of 0.115 per 100 million
passenger-miles flown; this compares to 16 deaths in
1978 and 460 in 1974, the worst year in the past decade
(0.005 and 0.197 passenger fatalities per 100 million
passenger-miles respectively).5 Since the introduc-
tion of jet-powered commercial flight in 1958, U.S. air
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3/Introduction and Summary of Recommendations
carriers have been involved in 216 accidents resulting
in fatalities. Only 16 of these were attributed pri-
marily to failures of a jet aircraft or its equipment
(see Appendix C), according to data from the National
Transportation Safety Board, which is responsible for
investigating and assigning "probable cause" to airplane
accidents.6 The balance was attributed to the cate-
gories of human error in flight and the air traffic
control system.
Indeed, it is these three elements that contribute
to the safety of aviation: (i) the airplane itself--how
it is designed, built, and maintained; (ii) the national
aviation system--the airports, airways, and the control
of air traffic; and (iii) the airline flight operations
that deal with the control of the aircraft. Although
these elements are interrelated--how the airplane is
flown depends on the handling qualities of the aircraft
and on the instrumentation available to the pilot--they
can be and often are addressed separately.
Even though the airworthiness of the machine itself,
the subject of this study, accounts for a relatively
small portion of all aircraft fatalities, it is evident
that even a single fatal accident of, say, a wide-body
transport carrying hundreds of passengers is a matter
for great concern and soul-searching. In the aftermath
of the American Airlines' DC-10 accident over Chicago on
May 25, 1979,* in-depth accident and engineering inves-
tigations were performed by the safety board and the FAA,
and hearings were held by various Congressional commit-
tees. The accident lent added urgency, for instance, to
an ongoing study by the U.S. House of Representatives'
Government Activities and Transportation Subcommittee of
the Committee on Government Operations, the May 7, 1980
report of which addresses many of the same matters
considered here.
Aircraft safety demands a "forgiving" design that
tolerant of failure, careful production that is of the
highest quality, and excellent maintenance that gives
painstaking attention to detail throughout the life of
the airplane. The rare fatal accident that involves
*When incidents or accidents are used as examples, they
are referred to in the text as necessary. Further infor-
mation on two accidents is found in excerpts from the
official reports in Appendix B.
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IMPROVING AIRCRAFT SAFETY/4
airframe or equipment is almost without exception the
result of a failure of at least two, and occasionally
all three, of these factors. For example, in the 1977
accident of a Dan-Air, Boeing 707 aircraft in Lusaka,
Zambia,* a redundant or backup structural element in
the horizontal stabilizer failed to carry the load after
the primary element failed. This was clearly a design
fault. Yet if more thorough inspection techniques had
been used, or if knowledge of fatigue problems had been
more widely shared, fatigue cracks would have been found
before they grew to critical size.
Individual failures of a significant nature are
relatively rare and combinations of failures that lead
to serious accidents are unlikely. Yet with the vast
number of flight operations that take place over the
period of a year, even the unlikely event can occasion-
ally occur.
The achievement of our air transportation safety
record has its basis in the development, over the past
half century, of necessary strengths on the part of both
the federal government and the air transport industry.
Even so, as described in the body of the report, and
summarized below, the committee finds that the technical
competence and up-to-date knowledge required of people in
the FAA have fallen behind those in industry. As air-
craft become more sophisticated, complex, costly, and
numerous, and as the generation of government engineers
and inspectors, who gained broad knowledge and experi-
ence as the industry was developing, begins to retire,
the FAA staff face fewer challenges and reduced expecta-
tions, a situation characteristic of a second generation
situation characteristic ot
regulatory agency.
Many of the committee's specific conclusions and
recommendations for improving the airworthiness system
flow from this central finding.
-
Is the excellent safety
record a goon predictor or the continued safety of large
transport aircraft in the future? Not necessarily. How-
ever, we hope that the recommendations that follow, many
of which concern the need for personnel and organiza-
tional improvement, will help to make it so.
A report such as this, with many recommendations,
necessarily emphasizes shortcomings and opportunities
for improvement. We urge the reader to bear in mind,
*See Appendix B.
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5/Introduction and Summary of Recommendations
therefore, that we have discovered nothing in the course
of this study that would lead us to conclude that the
confidence gained in the airworthiness of our nation's
transport aircraft is unwarranted. In this respect, the
safety record speaks for itself. But, as reassuring as
this record should be to passengers and purchasers of
such aircraft alike, we do not counsel complacency for
the decisionmakers who are responsible for continued
flight safety. The airworthiness system can and should
be improved.
Type Certification and Rule Making
The processes by which the FAA seeks to assure the
inherent safety or airworthiness of aircraft are type
certification and rule making. Type certification in-
volves assuring that the manufacturer's new design for a
particular type of aircraft complies with the statute
and all applicable rules and standards. Rule making
consists of establishing the regulations and technical
standards that must be met by manufacturers and airlines
in the course of designing, producing, operating, and
maintaining the aircraft.
The FAA's engineering staff needs to be strong in
order to deal effectively with its counterparts in
industry. The organizational and technical qualities
that are desirable in rule-making personnel are similar
to those required for making the critical governmental
judgments in applying the rules and standards to the
certification process for a new type of design. A1-
though there are many motivated and dedicated members of
the FAA's airworthiness engineering staff, the regional
structure of the agency, and other factors have contri-
buted to a lesser technical competence in the FAA, espe-
cially in the offices where type certification is per-
formed, than in the aircraft industry. Consequently, the
level of technical oversight is becoming superficial.
Moreover, this structure accounts, at least in part, for
fragmenting the work of engineering specialists among
many different functions, for inconsistent interpreta-
tions of regulations, from one regional office to an-
other, and for a lack of communication among regional
office and headquarters personnel on matters of co~,~,,on
interest and experience. It also contributes to the
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IMPROVING AI RCRAFT SAFETY/6
agency's evident difficulty in attracting a sufficiently
capable cadre of highly qualified engineering experts
and specialists--a difficulty, the committee recognizes,
that is neither unique in the federal government to the
FAA nor easily remedied.
In the committee's view, however, the availability
IS
of outstandingly qualified airworthiness specialists
the sine qua non of the FAA's airworthiness activities.
Specialists of high calibre are not likely to be at-
tracted to the current organization. A centralized engi-
neering organization is thus needed, led initially by a
cadre of 20 to 30 senior experts, and charged ultimately
with the following tasks: (i) the accomplishment of rule
making in relation to airworthiness matters, including
the interpretation of existing regulations and the iden-
tification of related research needs; (ii) the respon-
sibility for the key governmental decisions affecting
the design philosophy and criteria involved in the type
certification of new aircraft and supplemental type
certification, thus assuming the functions of the Type
Certification Boards but not replacing the regional
offices' project teams that work, on a day-to-day basis,
with the applicants and their "designees"; and (iii)
other related tasks calling for combining specialized
and expert technical knowledge and seasoned judgment.
ire committee therefore recommends that the FAA
estahZish a oentraZ engineering organization, staffed
with teohnioaZ personnel of the highest competence,
responsible for type certification and participation in
rule making. [pp. 20-29]*
FAA engineers cannot review each of the thousands of
drawings, calculations, reports, and tests involved in
the type certification process; yet the agency must be
certain that each design for a new airplane meets all of
the regulatory requirements. The present system thus
depends not only on the quality of the FAA staff but also
on the assistance rendered by aircraft company employees
called Designated Engineering Representatives (DERs) who
review the design and design process to make sure, on
behalf of the FAA, that all aspects of the regulations
are complied with. The "designees" are senior engineers
*Page numbers refer to the place in the report where the
recommendation is discussed.
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7/Introduction and Summary of Recommendations
employed by the manufacturers who possess detailed know-
ledge of the design, based on a daily involvement that is
not practical or for FAA personnel to achieve.
Accordingly, the advantages of the designee system
as an extension of the limited FAA staff are apparent.
Yet the system is often criticized. The possible disad-
vantage is the appearance, if not the existence, of a
lack of independent objectivity--i.e., a form of conflict
of interest for the designee who is in the position of
serving two masters, the aircraft manufacturing firm that
pays him, and the FAA to which he is expected to report
problems. The committee finds, however, that potentials
for conflict are checked in the following ways: (i)
engineers are ethically motivated to maintain their repu-
tation for technical integrity and professionalism; (ii)
recognizing the stake of the manufacturer in assuring a
safe, serviceable, and reliable airplane, the company's
designees perform traditional engineering review tasks
for the FAA that would, by and large, be performed for
the company as well; (iii) the designees perform their
work under the supervision of the FAA staff; and (iv)
the FAA reserves to its own staff the most critical
design decisions and approvals.
As the system is presently organized, therefore, the
committee concludes that the designee system for aug-
menting the capability of the FAA to review and certify
the type design is not only appropriate but indispens-
able. The oorrenittee, therefore, re~orr~nends that the FAA
continue to use Designated Engineering Representatives
to perform the functions non delegated to them. [pp.
29-33 ]
~~ ~
Of greater concern, however, is the identification
of what appears to be a trend toward placing more and
more reliance on the manufacturer in the course of type
certification. Toward the end of the certification pro-
cedure, for instance, the designees submit large amounts
of reports and calculations to their FAA counterparts for
approval. While the requirement to make such submissions
has value in assuring airworthiness in most cases the FAA
staff performs only a cursory review of the substance of
this great volume of documentation. Further, the process
invites a review that focuses, however superficially, on
the details, often at the expense of closely examining
overall design concepts.
The introduction of a more thorough and different
kind of review than is now performed by the Type Certifi-
cation Board is needed. Such a review should be con
OCR for page 1
IMPROVING AIRCRAFT SAFETY/8
ducted at key certification milestones or checkpoints,
and by more knowledgeable, experienced, and specialized
FAA staff of the kind recommended for the centralized
engineering group.
Special emphasis should be placed on
the review, early in the process, of fundamental design
concepts. Recognizing that this objective cannot be
accomplished immediately, the committee concludes that,
over time, the introduction of such ungraded milestone
reviews would lend the high degree of technical quality
in the FAA design review that is now lacking. The oom
~_ ~, _ ~
mitten thus recommends that the FAA adopt a Longer range
objective to improve the type certification process
through a series of milestone reviews of the design data
to examine fundomentaZ Concepts and to assure oompZianoe
with the fuZZ intent of safety regulations as ~eZZ as
with their specific details. [pp. 31-33]
While the principal guarantors of safe flight are, of
necessity, the builders and the operators of the air-
planes, the airworthiness system of checks and balances
depends on the establishment and updating of the govern-
ing safety standards for design, production, and main-
tenance. The committee finds that the FAA's rule-making
activity is primarily reactive to the needs of safety as
determined from accidents. What is lacking most is
initiative--a systematic means for anticipating needs,
for identifying and ranking priorities, and for assuring
the necessary technical base, where absent, for rule
making. Updating of rules to eliminate obsolescent ones
is also needed. 7he committee recommends that the Fig
take more initiative in identifying the need for new
rules and in establishing objectives, priorities, plans,
and sokeduZes for rule making and that it sponsor annual
ruZe-making review conferences to support this activity.
[pp. 33-40]
As it studied the record of aircraft accidents, as
well as present design philosophies, the committee came
to recognize a serious shortcoming in the current regu-
lations and in how they are applied. The problem has to
do with the interpretation of the regulations that per-
mits a manufacturer to demonstrate in the design of an
aircraft that certain failures simply cannot occur and
that, once demonstrated, the consequences to other
structure and systems of such an "impossible" failure
need not be taken into account.
in how they are applied.
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9/Introduction and Summary of Recommendations
This practice, however, fails to take into account
an important consideration: structures designed not to
fail when subjected to conditions within the design
environment sometimes do fail, usually as a result of
hazardous conditions _utside the design environment.
Examples of such hazardous conditions might include
maintenance-induced damage, hard impact by ground
servicing equipment, cargo-induced damage, or perhaps
even faulty quality control during manufacturing. The
simple fact is that during the long life of many fleets
of aircraft, with millions of operations, one cannot
guarantee that such damage will not occur.
In the committee's judgment aircraft design
principles should take into account the potential of
structural damage caused by conditions outside the
design environment, and should seek to prevent
catastrophic effects resulting from such damage. Of
course, this theory cannot apply to the consequences of
the kind of damage that by itself prevents the airplane
from continuing to fly, such as a wing torn off in a mid-
air collision. Specifically, the committee recommends
that the FAA develop a rule requiring assuronoe that an
aircraft is designed to continue to fly after struoturaZ
foiZure, unless that faiZure itseZf.prevents the airoroft
from flying. [pp. 40-44]
In the course of certificating the design of a new
aircraft, certain kinds of rule-making decisions (e.g.,
Special Conditions, exemptions, and the retroactive ap-
plication of recent amendments to the regulations) are
often made without benefit of public knowledge and com
ment that are a part of normal rule making. Often, such
decisions involve questions of cabin safety, crew com-
plement, cockpit design, and landing and takeoff limita-
tions--matters of concern to the crew and public as well
as the FAA and the affected applicant. In order to pro-
vide a legitimate measure of openness in this decision-
making process, consistent with the need to preserve the
confidentiality of proprietary information. the ~mmiLL
recommends that the FAA publish,
Federal Register, the avaiZabitity of the FAA-approved
preZiminary reguZatory and certification bases for new
aircraft type design, with subsequent puLZioation of
changes thereto, to permit time Zy review and comment by
the public and response from the FAA. [pp. 44-46]
as a notice in the
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IMPROVING AIRCRAFT SAFETY/10
Production and Maintenance
While standards and design are necessary to establish
the concept of a safe new airplane, it is in the produc-
tion and continuing maintenance phases, which involve
the labors of thousands of individuals with scores of
differing skills, that the opportunities are greatest
not only for assuring that aircraft are built and main-
tained to established safety standards, but also for
introducing (as well as avoiding) faults that could have
later consequences.
The means for assuring the adequacy of the production
system involve various levels of company and FAA quality
control surveillance. FAA inspectors review and approve
the company's manufacturing procedures and quality con-
trol systems, with the aid of company-employed Designated
Manufacturing Inspection Representatives (DMIRs). From
time to time, the agency also conducts detailed audits
by quality assurance teams.
While the procedures work quite well and are gener-
ally well conceived, lapses in production have occurred
and warn against complacency. Accordingly, the committee
recommends that the FAA increase its emphasis on quality
assurance in aZZ phases of the production process by
increasing the frequency of Crudity Assurance Systems
Analysis ond Review beam visits to atZ Production Certi-
ftoate holders, and by expanding the responsibiZities of
FAA inspectors and quality assurance teams to inoZude
the observation of actual hardware. [pp. 50-53]
Once a new aircraft leaves the manufacturer's plant
for service with a carrier, the airline accepts respon-
sibility for maintaining it. At the same time, the day-
to-day FAA activity also shifts from the manufacturing
review staff of the regional office to air-carrier in-
spectors in the respective district offices, located near
the principal airports of the country.
The committee found wide differences in the practices
of the FAA maintenance and avionics inspectors, espe-
cially with respect to the extent of direct observation
of the aircraft, the level of their maintenance inspec-
tion activity, and their assertiveness. While the regu-
lations make-them responsible for approving the carriers'
maintenance programs, and changes thereto, the committee
sees the system as allowing, and even encouraging, them
OCR for page 1
11/Introduction and Summary of Recommendations
to view this responsibility as a passive one. Further-
more, the committee finds that the detailed quality con-
trol audit teams formerly employed to augment the in-
spectors' ability to monitor the airlines' maintenance
programs have been reduced to more infrequent visits.
Because of the importance of maintenance to the
continued airworthiness of the carriers' aircraft, the
committee recommends that the FAA increase its surveiZ-
Zanoe of air Zine maintenonoe operations, making use of a
team approach for frequent ond unonnounoed inspections,
and encouraging its air sorrier inspectors to give higher
priority to strategioaZZy seZeoted on-site visits and
hardware observations, both ranZomZy during aZZ shifts,
and for specific maintenonoe procedures that they deem
espeoiaZZy oritioaZ or imp or ton t. [pp. 53-58]
With the exception of the flight crew, no group has
a greater effect on aircraft safety than the maintenance
workers at the airlines. It stands to reason that the
_
skill levels of mechanics and inspectors should be of
high quality and appropriate to the type and complexity
of the particular aircraft on which they are working.
Development over the past 30 years of the techno-
logically sophisticated modern jet transport with in-
creasingly complex components has led to rapid changes in
the level of skills and knowledge required to maintain
aircraft. The committee considers the current FAA sur-
veillance and certification procedures for licensing
mechanics and approving their training to be outdated
and of limited effectiveness. There is no stringent
standard comparable, for instance, to that for flight
crews, for establishing the initial experience level or
periodic upgrading requirement of the skills of mechan-
ics who repair or service aircraft. Further, mechanics
working on advanced avionics are not required to have
special credentials. Considering these factors, the
committee recommends that the FAA relies ond update the
Licensing ond training certification requirements for
air Zine maintenance personnel ond consider designating
avionics as ~ sepo rate area for licensing, [pp. 58-60]
FAA personnel must interact with their opposite
numbers in the companies and airlines in a reviewing and
approving (i.e., regulatory) mode, yet they must possess
independence and objectivity. There is concern that too
close and prolonged an association with the same com-
pany's personnel poses the possibility that the requi-
site characteristics of independence and objectivity
OCR for page 1
IMPROVING AIRCRAFT SAFETY/12
will be eroded. Reassignment to other companies could
provide the advantage of fresh perspectives and new
learning experiences. Accordingly, the committee re~om-
mends thot the FAA adopt a system for reassigning its
personnel on a periodic basis to deal with different
manufacturers and Worriers. [pp. 60-61]
While the designer participates directly in the
preparation of the initial maintenance program, once the
carrier begins to make modifications to it, the FAA does
not require that the manufacturer holding the Type Cer-
tificate be consulted before changes are made. Further,
the FAA office responsible for approving such changes is
not necessarily the same one that originally certificated
the aircraft.
It is possible, then, that some changes in the
maintenance program, or modifications of the aircraft,
will degrade the safety of the airplane in subtle ways
that only the aircraft designer is likely to recognize.
Procedures for removing and reattaching major components
may have such significance, as may different aircraft
jacking or towing conditions, or changes in liquids and
gases used for servicing, purging or cleaning. In some
cases, the manufacturer will have more detailed knowledge
than the carrier of the inherent strength of the aircraft
structure and its major components or their suscepti-
bility to damage. A requirement that the FAA seek and
obtain formal review by the manufacturer of any proposed
significant modification, or variation in maintenance
procedures, before the agency approves it, should in-
crease the likelihood of early warnings of any dangers.
With such considerations in mind, the committee
recommends that the FAA assure that the monufaoturer
(type oertif:oote ho idea) have continuing know Ledge of
an operator Is maintenance procedures by obtaining the
manufaoturer's forma Z review prior to authorizing any
significant deviation from the approved maintenance
program. SimiZorZy, it recommends that the FAA assure
that the manufacturer be made aware of an operator's
oppZioation for a ~:uppZementaZ Type Certificate by
obtaining the monufacturer's format review prior to
authorizing any significant deviation from the approved
design. [pp. 61-64]
Procedures for reporting safety-related incidents
and service difficulties, and the information and indi-
cation of trends that such reports provide, should be
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13/Introduction and Summary of Recommendations
among the principal tools of all airworthiness personnel
within the FAA and the industry. The present procedures
are inadequate. While the FAA now recognizes this fact
and has begun a five-year effort to develop a modern,
comprehensive information-gathering and data-processing
system, the committee views the pace of development as
too leisurely. Hence, the committee recommends that the
FAA acceZerote its development of on effective informa-
tion-gothering and data system. This system should
inoZude assess to the oppropriate elements of the
monufaoturers' and worriers' records [pp. 64-68]
Information systems are no better than the informa-
tion fed into them. The committee found excessive
confusion in the current procedures for reporting occur-
rences involving structural damage to the aircraft. The
confusion extends to the matter of what to report,
whether to report it at all, when to report, and to whom
the report must go. The maintenance-induced damage to
the aft pylon bulkhead on two DC-10 aircraft of Conti-
nental Airlines prior to the American Airlines Chicago
accident, which was not required to be reported, illus-
trates this dilemma. To reduce this important source of
confusion, the committee recommends thot the FAA require
that any damage to the primary structure of an aircraft,
regordZess of bow the dotage was housed, be reported.
[pp. 68-70]
Leadership and Advice
Because the FAA regulates an industry that works at
the frontiers of technology, it must be a leader in its
field. It needs to be able to develop and apply new
standards for rapidly changing technology. To ensure
that the agency provides such technical leadership, the
administration requires access to the advice of the fore-
most aviation specialists in the nation. Accordingly,
the committee recommends that the administrator appoint
a senior advisory committee of experts from government,
industry, and universities to advise on the adequacy of
teahnioaZ programs and on the direction of future deveZ-
opments. [pp. 73-74]
As an agency of the U.S. Department of Transpor-
tation, the FAA operates under the oversight of the
Secretary of Transportation. Given the fact that the
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IMPROVING AIRCRAFT SAFETY/14
FAA regulates a single, relatively cohesive industry,
where the similarities of training and perspective of
industry and agency people far outweigh their differ-
ences, the secretary needs an objective group of policy
advisors to review the FAA periodically and to address
issues related to his oversight responsibility. The
committee recommends, therefore, that the Seoretory of
Transportation appoint on independent aviation safety
polity boord, reporting to him ond responsible for
advice on ma.ior safety ond oozing issues; for oov~nseZ on
~ ~ v . ~
oversight of the FAA; and for recommendations of
candidates for the positions of administrator and deputy
administrator. [pp. 74-76]
The rapid turnover of senior FAA officials in recent
years has resulted in several new approaches to long-
standing problems with each change in administration.
Particularly in organizations concerned with safety
regulation and high technology, of which the FAA is both,
there is a decided value in continuity for programs and
policies to be tested for effectiveness. Beyond con-
tinuity, the administrator and deputy administrator need
to possess high technical, professional, and administra-
tive competence. Accordingly, the committee recommends
that the President select the administrator on, deputy
administrator from a state of condidates recommended by
the proposed aviation safety policy board or a simiZor
group of experts and that strong consideration be given
to reappointment when opproprzate.
- a,
· [P. 761
In the final analysis, no matter how proficient the
FAA is, the safety of an aircraft depends on the people
who design, produce, and maintain the machine--the air-
craft manufacturers and air carriers. In any endeavor
involving human beings, mistakes can be and often are
made. The only known way to minimize them is through a
system of checks and double checks.
There are already many checks and balances present in
the industry's work to design, build, and maintain air-
planes. But some companies lack a separate internal
safety organization, akin to an internal audit staff, to
assure management on a continuing basis that the proper
processes and procedures are in place, that personnel
are fully trained and qualified, that adequate controls
exist, and that the product is indeed as good as it is
stated to be.
OCR for page 1
15/Introduction and Summary of Recommendations
The Committee, therefore, recommends that each
industrial firm involved in the design, production, or
maintenance of oommeroiaZ transport aircraft consider
having an internal aircraft safety orgonization to
provide additionaZ assuronoe of airworthiness to Company
management. [pp. 76-77]
Concluding Remarks
Although this study was conducted under a severe time
limitation of six months, the committee has completed a
rather detailed examination of the process of certifica-
ting the design, production, and maintenance of large
commercial transport aircraft. The results of this exa-
mination, including many specific findings, are centered
in its recommendations. While each of these is considered
important, the committee considers that the following
conclusions warrant special attention:
The FAA needs highly competent, dynamic lead-
ership, with terms of sufficient duration to
provide stability and continuity.
.
The FAA needs an improved technical staff of
greater competence, which can be attracted only
if significant organizational changes are made.
The FAA needs a committee, reporting to the
administrator, to provide advice on the appli-
cation of new technologies to the work of the
FAA. The Department of Transportation needs a
board reporting to the Secretary of Transpor-
tation to provide advice on FAA policy matters
and to recommend candidates for the positions
of administrator and deputy administrator.
These three conclusions deal with people and
organizational matters. An entirely different kind of
conclusion concerns the philosophy of aircraft design:
Aircraft can be designed to be more tolerant of
failure, and should be able to land safely even
after some severe structural damage.
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IMPROVING AIRCRAFT SAFETY/16
There is a final thought that concerns the attitudes
of all those engaged in aviation and in the welfare of
the flying public.
The airworthiness standards in the Federal Aviation
Regulations are a set of minimum standards arising from
experience with aircraft operation and accidents. The
regulations cannot cover everything that might have an
important bearing on safety. What is prescribed is based
largely on past failures and readily predictable future
ones and therefore is not all that is necessary to ensure
safety. Indeed, the Federal Aviation Act states first
that the administrator must find that the aircraft is of
proper design, construction, and performance for safe
operation and then that the aircraft also meets the
minimum standards. In practice, this requirement of
judgment means that to improve the present system will
call for an exceptional capacity to imagine unlikely
problems, and thus to anticipate the need for further
rules and practices, before the unpredictable accident
strikes. This idea is the basis for the admonition that
pervades most of the committee's recommendations to the
FAA. It must take more initiative in every aspect of
its work and, to do so, it must improve the expertise
and quality of the technical staff and advisors upon
whose judgment it relies.
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