- Before
- Copies times from flight data, the tower tape, statements and logbooks into a spreadsheet, then writes the report over weeks.
- Now
- Scrubs the replay to see what every source says at each second and where they disagree, asks the agents to test her theories, and decides what goes in the file.
Aviation safety investigation management, one rejected takeoff at a time
On Tuesday, October 6, Corvane flight 404, a Boeing 737-8 (N812CV) with 162 passengers and 6 crew, rejected its takeoff from LaGuardia runway 13 after the right engine surged. It is Friday, October 16, day 10 of a 30-day Level 2 investigation. Here is how the safety investigation runs, screen by screen, in the working solution: the investigator works with the agents in conversation, decides every finding, and sees the evidence behind each one.
- 01Friday morning
The agents found the clue maintenance missed
Rachel Dunmore · Lead safety investigatorRachel leads four of the eight open investigations. Her Today screen opens on CV 404: maintenance control said “no prior history”, but the same engine was written up two days before and closed as could not duplicate. Four proposed factors and two contradictions wait for her; three deadlines fall in the next seven days, and three recommendations are overdue.
“The agents propose it as a contributing factor. 4 factors and 2 contradictions are waiting for you.”
- 02The replay
The takeoff roll, with every source stacked at each tick
Timeline BuilderThe event is drawn on runway 13 from line-up to the stop, with time ticks on the path. At 07:14:22 ENG 2 N1 drops from 94.8% to 71.3% and EGT jumps from 912 to 1,018 °C, limit 1,060, at 132 knots. The captain brings the thrust levers to idle at 134 knots, 7 below V1, and the aircraft stops with 1,180 feet of runway left. Under each tick sit the flight data, the ATC tape, the crew, the weather and maintenance, each linked to its source.
Timeline Builder: “41 entries from 11 sources. The tower clock ran 2 seconds ahead of the flight data; I aligned it.”
- 03Two days before
The same engine, written up at O'Hare on October 4
Contradiction FinderA dashed tick before the flight shows the October 4 pilot report: an ENG 2 EGT fluctuation of +40 °C in the climb at FL180. Work order WO-88213 records one ground run, could not duplicate, returned to service. The engine trend shows the margin falling from 42 °C to 24 °C in 9 days, with no alert because the alert fires only below 20 °C. On October 6 maintenance control logged “no prior ENG 2 history”.
The maintenance card is marked “Differs · C2”.
- 04Statements
Each crew statement split into claims and checked against the data
Statement AnalystCapt. Marcus Hale's statement is split into seven claims. Five agree with the flight data and the tower tape. “At about 125 knots there was a loud bang” differs: the surge came at 132 knots, the reject at 134. “First thought we had hit a bird” cannot be checked from the data. The agent drafts neutral follow-up questions for the claims that differ.
“The agent drafts neutral questions about the claims that differ or cannot be checked. Nothing is sent without you.”
- 05Contradictions
Five places where sources disagree, side by side
Contradiction FinderThe agent compared 21 claims from 4 statements with the flight data, the tower tape, the logs and each other, and found five disagreements; two are still open. For C2 it proposes, with high confidence, that the logbook is the record: maintenance control looked only at open deferrals, not closed write-ups. Rachel can resolve with a reason, ask a follow-up or open the proposed factor.
“The report cannot go for signature while one is open.”
- 06One question
“Check the fleet: is any other engine dropping the same way?”
Rachel Dunmore and the Theory TesterRachel asks in the conversation beside the replay. The Theory Tester plans the check and shows its five steps: 128 engines on the 64 737-8s read for an EGT margin drop of 10 °C or more within 10 days. Two more match: N809CV ENG 1, 13 °C in 8 days, and N826CV ENG 2, 11 °C in 10 days. N809CV also had a could-not-duplicate write-up on October 9. Borescope requests are drafted as interim action R4.
The requests go to Maria Castell only when Rachel clicks “Send to Maria Castell”.
- 07Her decision
She adds the factor to the file; every sentence links to its source
Rachel Dunmore · Lead safety investigatorRachel clicks “Add to the file”. The sentence appears highlighted in section 4 of the investigation file: the October 4 write-up was closed as could not duplicate after one ground run, without a trend review or borescope, while the margin had fallen 18 °C in 9 days. Each clause carries its citation to the tech log, the work order, the trend and the maintenance manual.
“F2 added to the file with R1.”
- 08Causes and fixes
Six factors at four levels, each with a drafted fix
Factor AnalystFactors sit under what was done, conditions, supervision and procedures, and the organization, each with evidence and confidence. F2 is in the file with R1: change Maintenance Manual 5.7.3 to require 30 days of trend review before a could-not-duplicate closure, owner Gary Lindqvist, due December 15. The bird-ingestion idea is tested and ruled out with confidence 0.92: no organic matter at the inlet, no remains on the runway, no bird activity reported.
Factor Analyst: “I propose; you decide, with a reason when you reject.”
- 09NTSB and FAA
Not reportable to the NTSB, and the clauses that say why
Notification AdvisorNo one was hurt, and damage limited to one engine and to tires and brakes is not substantial damage under 830.2. Section 830.5(a)(3) needs debris to escape other than through the exhaust; the borescope found none. A service difficulty report was owed under 14 CFR 121.703(c) and filed October 8 by Thomas Greer, inside the 96 hours. The test re-runs on its own when the engine teardown report arrives, expected October 28.
“What would change it: the teardown finding uncontained debris.”
- 10Before sign-off
The report in Corvane's format, checked before it reaches the Director
Report Checker and Thomas Greer · Director of SafetyThe draft follows the Corvane Investigation Report format, with 41 of 41 sentences linked to evidence. The Report Checker runs nine checks: no blame words, no confidential source used, the NTSB decision current. Two items block sign-off until Rachel decides them: an open contradiction and factors still proposed. The direct cause is marked provisional until the teardown. Thomas Greer then approves or returns the report with a reason.
“I sign it only if I can click any sentence and see where it came from.” — Thomas Greer