Tag Archives: IndiGo

802 Boeing Safety and Quality Plan

We take a look at the Boeing Safety and Quality Plan, the NTSB recommendations after the Southwest/FedEx near miss, the suspension of some ATC staff in India, Essential Air Service contracts, BARK Air’s lawsuit over airport-use restrictions, the sale of a B-17, and the NTSB inspection of the USAirways flight 1549 engines.

Aviation News

Boeing Safety & Quality Plan

Boeing had 90 days to deliver a comprehensive plan to the FAA to improve the company’s safety management and quality assurance, including in the supply chain. We look at The Boeing Product Safety and Quality Plan Executive Summary [PDF, 11 pages.]

The Plan includes the containment and mitigation actions Boeing took immediately after the accident. It also introduces Boeing’s new Key Performance Indicators (KPIs) of production system health and associated control limits for each KPI. Boeing intends that these metrics will provide “a continuous assessment of factory health and provide early warning of emerging quality and safety risks. They also will facilitate tracking of Boeing’s improvement under the Product Safety and Quality Plan and guide decisions about system readiness for rate increases.”

Boeing’s Immediate Containment and Mitigation

Improvements directed at the Boeing production system:

Photo of Admiral Kirkland Donald.
Admiral Kirkland Donald
  • Revised the build plans, training, maintenance planning, aircraft manual documentation, removal requirements and inspection criteria for the Mid-Exit Door (MED) plug;
  • Instituted additional controls to prevent defects in the MED plug and similar structures and assemblies;
  • Added conformance inspections to nine critical build points;
  • Processed fleet and production inspection findings through Boeing’s SMS and Quality Management System (QMS);
  • Published alerts on removals and rework, signed by all factory employees;
  • Hosted representatives from 737 airline customers to review Boeing’s production and quality procedures, and to provide feedback;
  • Appointed a recognized safety and quality leader, Admiral Kirkland Donald, to independently assess Boeing’s production system; and
  • Implemented a revised management and salaried compensation model focused on quality and safety, with aligned key performance indicators across all programs.

Improvements directed at the Boeing supply chain:

  • Instituted additional controls at Spirit to prevent defects in the MED plug and similar structures and assemblies;
  • Added new inspections at Spirit, as well as pre-shipment approval requirements on fuselages prior to shipment to Boeing;
  • Added competency assessments for all supplier mechanics doing structural work at Boeing sites; and
  • Issued supplier bulletins to strengthen focus on conformance and reduce the risks of defects being shipped.

Key Performance Indicators

A significant component of the Product Safety and Quality Plan is the identification of six critical, safety-focused production health KPIs:

  1. Employee Proficiency (measures share of employees currently staffed to commercial programs who are proficient);
  2. Notice of Escape (NoE) Rework Hours (measures rework due to Fabrication and supplier-provided escapes to Final Assembly);
  3. Supplier Shortages (measures Fabrication and supplier shortages/day);
  4. Rework Hours per airplane (measures total rework hours per airplane in Final Assembly);
  5. Travelers at Factory Rollout (measures jobs traveling from Final Assembly); and
  6. Ticketing Performance (measures average escapes per ticketed airplane).

Each KPI also has associated control limits and defined criteria that will trigger corrective action and SMS risk monitoring.

Product Safety and Quality Plan Attention Areas

Safety Management System three main initiatives: 

  1. Streamlining employee reporting channels; [Submissions are up 500%]
  2. Addressing traveled work risk; [implemented a “move ready” process—737 airplanes may not move to the next factory position until identified build milestones are completed, unless a Safety Risk Assessment (SRA) is conducted and a mitigation plan is in place.]
  3. Deepening the integration of Boeing’s SMS with the QMS.

Simplification of Processes and Procedures [To help employees better understand their obligations, execute work instructions, and deploy solutions to overcome roadblocks.]

Supply Chain Defect Reduction

  • Strengthening data and analytics capabilities to provide proactive notification of supplier issues, including the creation of an advanced analysis tool;
  • Standardizing supplier oversight actions to prioritize safety and quality, including through the implementation of a common supplier engagement model; 
  • Simplifying and improving supplier quality processes;
  • Driving industry change and dialogue about quality and safety issues.

Training

  • Planned enhancements in late 2024, 
  • New manufacturing and quality employees will receive up to two more weeks of foundational training, followed by enhanced structured on-the-job training (SOJT)

Production System Compliance

  • Foreign Object Debris (FOD) control; 
  • Tool control; 
  • Parts and materials control; 
  • Employees’ adherence to work instructions. 

Engagement and Communications

  • Holding full-day quality stand downs and Safety and Quality events across the Company;
  • Creating and supporting Employee Involvement Teams (“EITs”) to conduct weekly problem-solving sessions and review employee ideas for improving the production system; 
  • Establishing a leadership program for manufacturing, quality, and fulfillment managers;
  • Improving the Company’s messaging about safety, quality, and compliance.

Installation Plan Improvements [work plans]

Special Audit Items

  • For Boeing quality escapes; 
  • Boeing liaison engineering and Material Review Board (MRB) issues; 
  • and Boeing’s approach to Spirit-related findings

Expert Review Panel Recommendations

Boeing agrees with the findings and recommendations of the Expert Review Panel.

NTSB Proposes More Training, Tech After Southwest and FedEx Jets Near-Miss in Texas

In February 2023, Southwest Airlines and FedEx jets came close to colliding in Austin, Texas. After seeing the Southwest Boeing 737-700 plane at the last second, the FedEx pilots flew their Boeing 767-300 over the Southwest jet to avoid a collision. The two planes were only about 150 to 170 feet apart.

The NTSB determined the probable cause of the near miss was a bad assumption by the air traffic controller that the departing Southwest plane would be clear before the FedEx plane landed on the same runway.

 The Board also identified two contributing factors:

  • Southwest crew members failed “to account for the traffic on short final approach and to notify the controller” that they would need additional time for takeoff. 
  • The FAA did not require surface detection equipment at the Austin airport.

India’s Aviation Regulator Suspends Mumbai ATC Staff Involved In IndiGo & Air India Airbus A320neo Close Call

The IndiGo A320neo was on approach to Runway 27 at Chhatrapati Shivaji Maharaj International Airport (BOM) in Mumbai, India. The plane touched down seconds after an Air India A320neo had departed the same runway. The Directorate General of Civil Aviation (DGCA) is investigating and has “derostered” the ATC staff working at the time of the incident.

Video: Indigo a320 Landing and Air India a320 Takeoff at The Same time at Mumbai Airport

JetBlue Awarded First-Ever Essential Air Service Contract

JetBlue will serve Presque Isle under a two-year contract. 

Essential Air Service

The Essential Air Service (EAS) program was implemented to guarantee that small communities served by certified air carriers before airline deregulation maintain a minimal level of scheduled air service.

This is generally accomplished by subsidizing two round trips a day with 30- to 50-seat aircraft, or additional frequencies with aircraft with 9-seat[s] or fewer, usually to a large- or medium-hub airport.  The Department currently subsidizes commuter and certificated air carriers to serve approximately 60 communities in Alaska and 115 communities in the lower 48 contiguous states that otherwise would not receive any scheduled air service.

2024-6-3 Order Selecting Air Carrier

Posted by the Department of Transportation on Jun 4, 2024:

“By this Order, the U.S. Department of Transportation (the Department) selects JetBlue Airways Corporation (JetBlue) to provide Essential Air Service (EAS) at Presque Isle, Maine (Presque Isle), for the two-year term from September 1, 2024, through August 31, 2026. JetBlue will provide Presque Isle with seven (7) nonstop round trips per week from Presque Isle International Airport (PQI) to Boston Logan International Airport (BOS) using 100-passenger Embraer E190 (E190) aircraft for the first year and 140-passenger Airbus A220-300 aircraft for the second year. JetBlue will be compensated at the annual subsidy rates outlined below.”

BARK Air for dogs sued days after first flight

Westchester County sued BARK Air alleging violations of the county’s airport-use restrictions.  Those restrictions include a prohibition on the operation of commercial and chartered aircraft with more than nine seats from using the private jet terminal. BARK Air’s Gulfstream Aerospace GV jet has 14 seats. In a filing to the FAA, Westchester County said that the public charters “closely resemble” services offered by large, commercial airlines.

Michigan Flight Museum (former Yankee Air Museum) Sells Centerpiece B-17 ‘Yankee Lady’

The Boeing B-17G has been sold to an undisclosed buyer for an undisclosed price. For some 40 years, the museum generated revenue with rides on the B-17. The money from the sale will be invested to support the museum.

Mentioned

NTSB Docket No. SA-532 Exhibit No. 8-A

William (Bill) Anders, Apollo 8 astronaut, Killed in San Juan Islands Plane Crash

Apollo 8: Earthrise

Taken aboard Apollo 8 by Bill Anders, this iconic picture shows Earth peeking out from beyond the lunar surface as the first crewed spacecraft circumnavigated the Moon, with astronauts Anders, Frank Borman, and Jim Lovell aboard.
Taken aboard Apollo 8 by Bill Anders. Image Credit: NASA.

Hosts this Episode

Max Flight, Rob Mark, and our Main(e) Man Micah.

581 AERObridge and Disaster Response

AERObridge coordinates business and general aviation aircraft for disaster response in times of need. In the news, we look at airliner formation flying, IndiGo engine failures, Boeing’s hand in X-Wing drones, a volcanic eruption forcing a turnback, a jet blast injury, a bill to spur transportation careers, and slipping a president out of the country.

AERObridge disaster response.

Disaster response flight. Courtesy AERObridge.

Guest

Trevor Norman is the AERObridge national chapter coordinator. AERObridge is a non-profit organization that coordinates donated business and general aviation aircraft to provide disaster response in times of catastrophic emergencies. They transport critically needed items and personnel to where they are needed.

Trevor explains how AERObridge matches aircraft with emergency response teams and critical supplies. The organization delivers aid from donors like AirCare Alliance and Crossroads Alliance. We discuss how AERObridge coordinates with other organizations and local agencies, and how pilots are vetted and matched with missions that fit with their aircraft and their skills. Trevor describes how no two disasters are the same and the need to be flexible and change plans on a moment’s notice.

As a non-profit organization, AERObridge accepts donations of time, talent, and treasure.

Aviation News

Airbus Wants To Fly 2 Planes In Extra-Close Formation, Like Geese, To Save Energy

Geese fly in V-formations because they are aerodynamically more efficient than all of them flying alone. If airliners employ the same technique, they could find a 5 to 10% fuel savings on a long oceanic flight.

Pilots Revving Engines Too Hard Led to IndiGo’s Airbus Woes

IndiGo has been experiencing A320neo turbine failures in its Pratt & Whitney GTF engines and they’ve seen 13 engine shutdowns this year. Interestingly, Go Airlines India flying the same equipment has not seen these problems. India’s Directorate General of Civil Aviation says IndiGo’s practice of running up A320neo jets at full thrust right after takeoff could wear down the engines.

Disney’s Plan To Fly X-Wings Over Star Wars Park Speaks To Perception Manipulation Tactics

Boeing may have been working to help Disney Imagineers create ⅔ scale X-Wing drones based on Boeing’s NeXt Cargo Air Vehicle.

Watch: Cargo Air Vehicle Completes First Outdoor Flight

Volcanic eruption forces flight with large cargo of horses onboard to turn back

KLM flight KL685 from Amsterdam to Mexico City was heading toward volcanic activity from Popocatepetl, just outside their destination. Because of the “unfavourable flying conditions” and the cargo of horses, the flight had to return to Schiphol. “Landing at another airport was not possible, because of the visa requirements of passengers and as there was a large cargo of horses onboard.”

NTSB releases report on woman injured in jet blast incident, family shares video

A woman boarding a private jet in October at Augusta Regional Airport was seriously injured when the jet blast from another aircraft knocked her over. The National Transportation Safety Board released a preliminary report on the incident indicating that while the airport and the FBO had a protocol for aircraft being marshaled into the taxiway, there was no protocol for aircraft leaving the area.

Bipartisan bill would spur transportation careers

The Promoting Service in Transportation Act was recently introduced in the U.S. House of Representatives. The bill authorizes the U.S. Department of Transportation to develop and publish public service announcements in digital, print, and broadcast media which highlight the need for more professional airline pilots, safety inspectors, mechanics and technicians, air traffic controllers, and flight attendants, as well as railroad workers, truck drivers, and other transportation industry professionals. News release: Larsen, Young and Craig Introduce Bill to Promote Transportation Career Opportunities

What Aircraft Snuck Trump Out Of Florida On His Way To Afghanistan For Thanksgiving?

President Trump visited the Afghanistan combat zone, but he had to be whisked out of Florida without being noticed, possibly on a Senior Leader In-transit Pallet (SLIP).

Mentioned

Jacinda Ardern apologises for Air New Zealand Erebus tragedy at 40th anniversary event

The White Silence and Erebus Flight 901: Litany of lies? podcasts discuss the Erebus crash and its aftermath.

Recording screenshot

Clockwise from top left: David Vanderhoof, Max Flight, Lily the Cat, Trevor Norman.

446 Reliability Centered Maintenance for Aviation

Learn about what Reliability Centered Maintenance means for aviation from a well-known A&P/IA and the CEO of Savvy Aviation. In the news, first flights of the Boeing 787-10, the Airbus A319neo, the Antonov An-132D, and the Embraer E195-E2. Also, the Fairness for Pilots Act, important news for Continental engine owners, some talk about restarting the F-22 line, and an update from Airbus on an electric airplane.

Guest

Savvy Aviator CEO Mike Busch on Reliability Centered Maintenance

Savvy Aviator CEO Mike Busch

Mike Busch is the CEO of Savvy Aviation and a co-founder of AVweb. Mike is one of the best-known A&P/IAs in general aviation and he writes the monthly “Savvy Maintenance” column in AOPA Pilot magazine. He also hosts free monthly EAA-sponsored maintenance webinars. Mike was honored as “National Aviation Maintenance Technician of the Year” for 2008, he’s been a pilot and aircraft owner for 50 years with 7,500+ hours logged, and is a CFIA/I/ME.

Mike explains the origins of Reliability Centered Maintenance (RCM) and how it grew to be used by commercial, business and military aviation, but hasn’t fully trickled down to small general aviation.

RCM is an optimal maintenance program that differs from the old, traditional maintenance approach that follows the assumption that components start out reliable and become less so over time. RCM is a data-driven engineering method that assesses each aircraft component for possible functional failures, failure modes, failure effects and consequences. It then creates a maintenance plan that can even allow a component to run to failure. The result is lower maintenance costs and increased reliability.

Find many aviation maintenance resources at SavvyAviation.com, follow @SavvyAviator on Twitter, and like them on Facebook. See also:

Aviation News

IndiGo is Flying Their A320 NEOS at lower Altitudes over Engine Issues

Indian aviation regulator Directorate General of Civil Aviation (DGCA) is requiring a borescope test for Pratt & Whitney PW1100G engines at 1000 flight hours instead of the usual 1500. Meanwhile, IndiGo Airlines has set at a maximum altitude of 30,000 feet for its A320neos. All this is due to problems with the engine combustion chambers and an oil seal.

Video: Pratt & Whitney PW1000G PurePower Engine How It Works

Boeing 787-10 completes first flight in Charleston

First Flight of Airbus A319neo Finishes Hours Ahead of 787-10

Antonov completes first flight of An-132D

Embraer E195-E2 achieves first flight ahead of schedule

A number of first flights recently took place: The Boeing 787-10, the Airbus A319neo, the Antonov An-132D multi-purpose twin-engine turboprop, and the Embraer E195-E2 E-Jet.

Fairness for Pilots Act introduced

The Pilot’s Bill of Rights was signed into law in 2012. Now U.S. Sen. Jim Inhofe (R-Okla.) wants to broaden protections for general aviation pilots with the Fairness for Pilots Act.

Trump’s Secaf Pick Hints F-35 May Get New Rival—F-22

“President Donald Trump’s nominee to lead the U.S. Air Force wants the service to look at Lockheed Martin’s F-22 Raptor as a possible alternative to the F-35…”

Important News for Continental 520/550 Owners

An extremely costly AD may be in the works.

Airbus abandons E-Fan as electric tech moves on

Airbus will not be producing the electric E-Fan two-seater training aircraft because the technology has advanced so much in the past three years. However, Airbus is considering an E-FAN X with another order of magnitude jump in electric power.

The Airplane of the Week

The favorite airplane of David’s father was the P-61 Black Widow.

David and his father

David and his father

P-61 Black Widow

P-61 Black Widow

Mentioned

Fabulous Farnborough Airshow Photographs by Mary B. Lyons.

Aviation Hackathon #SkyHack – Open to college students 18 years of age or older, October 13-15, 2017.

Video: The Boneyard

Explaining the East/West Asymmetry of Jet Lag

Newest Bath Iron Works ship named after Korean War hero

Update: Our listener Utah Patrick wrote us with the following:

“Like Max, I was touched by the story related in the current episode about Thomas Hudner and Jesse Brown. So much so that I decided to dig a bit deeper into the story. Turns out Hudner received the Medal of Honor for his efforts to rescue his wingman. The part about leaving Brown’s body behind bothered me. I understand the reasoning but I wondered if it had ever been recovered.

“Turns out Brown’s body and his aircraft were napalmed to keep them out of enemy hands. However, figuring something was left behind, attempts have been made to retrieve remains including one attempt 63 years later by (and this really surprised me) Thomas Hudner himself.”

Patrick provided two articles that provide more details: U.S. veteran in North Korea to find remains of fellow aviator and Six Decades Later, a Second Rescue Attempt.

Listener Mick's new neighborhood

Listener Mick’s new neighborhood.

Credit

Intro music courtesy Brother Love from his Album Of The Year CD. Outtro by Bruno Misonne from The Sound of Flaps.

AirplaneGeeks 364 Aviation Stories

Uzbekistan by Paul Filmer

We look at the Logbook Podcast with aviation stories told by those who lived them, Uzbekistan Airways weighing passengers, a patent for variable seat pitch, IndiGo firms up a big A320neo order, the fatality rate in GA, a Delta flight pummeled by hail, Emirates launching a 17 hour, 35 minute flight, and an interesting aircraft of the week.

Guest

Lucas Weakley

Lucas Weakley

Lucas Weakley is an Embry-Riddle Aeronautical University student in the aerospace engineering program. Fascinated by flight from a young age, he’s a builder of model rockets and airplanes, and he hopes to one day design kit-built aircraft.

Lucas is also the creator of The Logbook Podcast, where pilots and enthusiasts tell their stories of aviation. He also produced a 23-episode tutorial series for Make Magazine titled Maker Hangar that teaches you everything you need to know to build and fly three custom R/C aircraft.

We also take the opportunity to learn a little more about Embry-Riddle and the aerospace engineering program.

Learn more at Lucas Weakley’s Blog, see his videos on his YouTube channel, and follow Lucas on Twitter at @L_Weakley.

Varga Kachina

Varga Kachina

News

Airline To Weigh Passengers Before Boarding, Travel Hits New Low

Uzbekistan Airways announced on its website that they would begin weighing passengers and carry-on baggage before boarding to ensure flight safety. The airline says, “After passing check-in on flight and prior to boarding into the aircraft, we will suggest you to pass the procedure of weighing with the special weighing machine placed in the departure gate zone. The weighing record will only contain the corresponding passenger category (i.e. male/ female/ children). As for the rest, the full confidentiality of results is guaranteed.”

This idea could solve the worst thing about air travel

B/E Aerospace has filed a patent application for airline seats that are adjustable for passenger height. Shorter passengers (like children) would get less legroom. Mary Kirby would get more. B/E Aerospace manufactures aircraft cabin interior products for both commercial aircraft and business jets: seating products, galley systems, oxygen, water and waste systems; de-icing, lighting.

Airbus says it takes ‘historical’ aircraft order

IndiGo firmed up a 2014 commitment by placing an order for 250 Airbus A320 new engine option jets. IndiGo has now ordered a total of 530 A320 family aircraft.

US general aviation reports highest fatal accident rate since 1998

According to the US National Transportation Safety Board (NTSB), the number of general aviation flight hours is at at all time low. But in 2014 the rate of fatal GA accidents was the highest it has been since 1998.

Delta Pilots Make Blind Emergency Landing

Baseball-sized hail pummeled the airplane, shattered the nose cone and windshield. The pilots were able to land the jet safely.

Emirates Flight To Panama Will Be World’s Longest Non-Stop Route

Emirates announced its plans to launch services to Panama City, beginning 1st February, 2016, with a 17 hour 35 minute flight time.

The Airplane of the Week

The Incom T-65. (It’s David’s segment and he can do what he wants!)

Mentioned:

Short final for runway 10 at St Barths in the Caribbean

Short final for runway 10 at St Barths in the Caribbean

Landing at St Barthelemy Airport (SBH-TFFH) | PrivateFly – Video of a DHC-6-300 Twin Otter landing at St Barts.

Crazy Cockpit Landing at St. Barths – Landing runway 10 at St. Barthelemy aboard a Winair DHC-6 Twin Otter.

The Aviation Historian – The modern journal of classic aeroplanes and the history of flying.

American Airlines’ New First Class Pet Cabins – From the Fly and Dine blog in Boarding Area by Jason Kessler.

U.S.-China aviation talks hit stumbling block on airport access – The US and China have been negotiating over limits on flights between the United States and China. The U.S. is worried its airlines will be get less attractive time slots for take-off and landing than the Chinese airlines. So the US negotiators won’t move forward until China looks at a different slot allocation system.

Men In Black Safety Defenders #AirNZSafetyVideo – It’s got international rugby stars, members of the All Blacks, even Rip Torn from MIB 1 and 2, and Frank the pug!

Credit

Uzbekistan Airways photo (c) and courtesy Paul Filmer.

Opening and closing music courtesy Brother Love from the Album Of The Year CD. You can find his great music at brotherloverocks.com.

 

Episode 131 – News, Listener Mail, and Politics

AmSafe

Max, Rob, Dan, and David discuss the week’s aviation news and spend time with listener mail. Steve and Grant from the Plane Crazy Down Under podcast have a great Australia Desk Report, and Pieter Johnson brings the European perspective with his Across the Pond segment.

The week’s aviation news:

Listener mail:

Seventeen year old Nick looks forward to being a commercial pilot. Keith introduces us to the HowItFlies.com aircraft directory. Jim asks about downloadable Airplane Geeks segments. Jordan has some questions about 787 delays and Boeing’s strategy. John points out the flight of the Chinese J-20 stealth fighter. Dawson explains PAPI lights. Alex comments on American security paranoia. Another Alex says the U.S. Government needs to chill out. Micah reports on the improving health of Harriet and her desire to fly away.

Mentions:

Follow the @AirplaneGeeks on Twitter and on Facebook, send us email at thegeeks@airplanegeeks.com, or leave a message on our listener line: (361) GEEKS01.

Opening and closing music is provided by Brother Love from the Album Of The Year CD. You can find his great music at http://www.brotherloverocks.com/.