A recent event shows just how valuable a defect report to the CAA can be to worldwide safety.
A New Zealand engineer was carrying out routine maintenance on a Guimbal Cabri G2 helicopter in February 2024, when they noticed a hairline crack on the main rotor swashplate. They immediately called the CAA’s South Island airworthiness Aviation Safety Advisor, Richard Lane (35+ years in engineering, PPL-holder).
“Given the direct and prompt communication from the somewhat concerned engineer,” says Richard, “I immediately contacted the CAA’s Chief Advisor Airworthiness, Warren Hadfield (two decades in large aircraft engineering), to discuss it with him.”
The CAA promptly contacted the manufacturer.
Thanks to these prompt actions, Guimbal quickly deemed that a fleet-wide inspection was necessary to detect any other failed parts.
“The CAA is able to engage with manufacturers and overseas regulators in a way that’s not possible for the individual operator or maintainer,” says Richard.
The CAA published Continuing Airworthiness Notice 27-027 Guimbal Cabri G2 Main Rotor Swashplate Assembly Cracking to raise awareness of the defect.
Continuing Airworthiness Notice 27-027(external link)
Then, direct discussions between Guimbal personnel and the New Zealand engineers who found the defect helped refine and clarify the details, ahead of the manufacturer issuing Service Bulletin SB24-001A.
Subsequently, the defect was the subject of Airworthiness Directive 2024-0071 from EASA [PDF 198 KB] (European Union Aviation Safety Agency), requiring global action to inspect the swashplate assembly.
Once again, our local engineers were sought out by EASA for their advice on the inspection criteria for the swashplate.
“The willingness of our New Zealand engineers to be open and forthright, and to support not only the CAA, but the manufacturers and other National Aviation Authorities, can save lives,” says the CAA’s North Island airworthiness Aviation Safety Advisor, John Keyzer (24 years rotary-wing engineering).
“It also contributes to a culture of honesty and safety first.” He credits Guimbal for being open to investigating the defect, in conjunction with regulatory and industry representatives.
Act straight away
Time is of the essence when a potential critical or major defect is first spotted, John says.
“If an engineer identifies something significant – and they are usually best placed to know – we prefer to hear about it immediately.
“Follow up with a CA005D and an investigation report as appropriate. This helps the CAA to expedite any actions it needs to take.”
Reporting a defect
Warren Hadfield acknowledges that investigating and reporting defects can be costly in time and dollars for the aviation industry.
“We’re grateful for all the reports we receive, and for the efforts of the engineers and support staff involved with both investigating and reporting.
“The Guimbal incident highlights just how important it is for engineers to let us know when they see something that needs our attention.”
Warren says even defects less dramatic than a cracked swashplate should be reported to the CAA. Then the data is collated and assessed to build a better picture of a problem and analyse trends over time. An issue that seems irrelevant today could be identified as part of a bigger pattern in coming months and years.
Include as much detail as you can when submitting a report – including part number, serial number and utilisation. Warren says photos of defects are incredibly valuable, especially if the CAA wants to share the findings with the original equipment manufacturer, or another national aviation authority.
If engineers have any questions or concerns about raising a report, they should contact the CAA aviation safety advisors or call the CAA on 04 560 9400.
John Keyzer says while there’s no room for complacency, he believes the recent Guimbal example indicates that New Zealand aviation maintenance engineers are among the best in the world in reporting airworthiness concerns.
“I’m very proud of the culture our aviation engineers have for reporting defects and sharing information and knowledge,” he says.
Aviation Safety Advisors
Contact our aviation safety advisors for information and advice. They regularly travel around the country to keep in touch with the aviation community.
Carlton Campbell – Operations, South Island
027 242 9673
carlton.campbell@caa.govt.nz
Richard Lane – Maintenance, South Island
027 269 5796
richard.lane@caa.govt.nz
Pete Gordon – Operations, North Island
027 839 0708
peter.gordon@caa.govt.nz
John Keyzer – Maintenance, North Island
027 213 0507
john.keyzer@caa.govt.nz
More information
Use our occurrence reporting form to report a defect to us(external link)