Airbus Helicopters Integrates Human Factors to Enhance Safety

This article is based on an official press release from Airbus.

Airbus Helicopters Integrates Human Factors to Boost Maintenance Safety

Airbus Helicopters has unveiled a strategic initiative to enhance aviation safety by integrating ergonomics and human factors directly into the design phase of its rotorcraft. In a detailed company statement released Monday, experts Dr. Fabien Bernard and Raphaël Paquin outlined how improving maintainability can significantly reduce the risk of accidents caused by maintenance errors.

The initiative addresses a critical safety statistic: maintenance errors are currently the second leading cause of helicopter accidents, trailing only pilot error. By focusing on the “human factor”, the interaction between technicians, their tools, and the aircraft environment, Airbus aims to create designs that inherently reduce the likelihood of mistakes during routine service and pre-flight checks.

The Complexity Challenge

Helicopters present unique engineering challenges compared to fixed-wing aircraft. According to the Airbus experts, the density of mechanical systems in a rotorcraft creates difficult working conditions for maintenance crews.

“It is often said that a helicopter has the complexity of an aircraft but in the size of a car. Accessibility to areas is often a challenge. This can make the work arduous.”

— Raphaël Paquin, Airbus Helicopters

To address this, the manufacturer is employing a scientific approach to ergonomics. Dr. Fabien Bernard explained that the team analyzes three key dimensions defined by the International Ergonomics Association: the physical aspect (posture and effort), the cognitive aspect (mental workload and memory), and the organizational aspect (workflow and cooperation).

Designing for Variability

One of the primary difficulties in aviation maintenance is the variability of the workforce and the environment. Unlike a controlled factory floor, maintenance tasks are performed by individuals of varying physical sizes, training levels, and cultural backgrounds, often under difficult conditions such as poor lighting or time pressure.

The Airbus team is using physical and digital simulation tools to anticipate these variations during the design process. A concrete example provided by the company involves the optimization of pre-flight inspections. By redesigning integrated steps and handles to be the correct size and in the optimal position, designers can ensure pilots and technicians can safely check critical components like rotor blades and flight controls without physical strain or risk of falling.

Economic and Safety Synergies

While safety is the primary driver, the initiative also offers financial benefits for operators. Paquin noted that maintenance costs throughout an aircraft’s operating life are a major factor for customers. By making components easier to access and service, the manufacturer aims to reduce the time and labor required for upkeep, ultimately lowering the total cost of ownership.

AirPro News analysis

This initiative marks a maturing of aviation safety culture. Historically, safety enhancements focused heavily on cockpit design and pilot training (Crew Resource Management). The shift toward “Maintenance Resource Management” and “Safety by Design” acknowledges that maintenance technicians are human and prone to fatigue or distraction. By engineering out the possibility of error, rather than simply blaming technicians when errors occur, manufacturers like Airbus are addressing the systemic roots of aviation incidents.

Sources

• Airbus