Enterprise AI Analysis
Research on the Pre-Production Configuration Control Strategy for Civil Aircraft Prior to Type Certification: Utilizing a Multi-Dimensional Risk Assessment Model
Author(s): Jun He, Hongyang Sun, Binbin Wu, Hongfei Zhan, and Xin Guo
Publication Date: 2025-12-12
Executive Impact
This research addresses configuration management challenges in pre-production civil aircraft by proposing a multi-dimensional risk assessment model. It quantifies risks using a structured Risk Index (RI) that combines impact and probability metrics, implements a tiered decision-making mechanism, establishes a closed-loop control process linking design and production baselines, and integrates with PLM for intelligent risk assessment. The model, validated by case studies, enhances decision efficiency, reliability, and traceability, guiding manufacturers to balance market demand, production schedules, and airworthiness safety.
4
Risk Impact Dimensions
4
Risk Probability/Maturity Dimensions
70%
Decision Cycle Reduction
Deep Analysis & Enterprise Applications
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Configuration Control
9.56
Calculated Risk Index (RI) for Critical System Control Unit
Enterprise Process Flow
Present specific production requirements
→
Establish the design baseline
→
Risk assessment
→
Hierarchical decision-making in configuration management organizations
→
Establish a production baseline
→
Execution and Monitoring
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Configuration Change
| Feature | Traditional Empirical Risk Assessment | Multi-Dimensional Risk Assessment Model |
|---|---|---|
| Comprehensiveness & Objectivity | Relies on singular dimensions (e.g., cost or schedule). |
|
| Decision Efficiency | All decisions require top-level approval, causing delays. |
|
| Risk Control | Reactive; overlooks latent chain effects. |
|
| Traceability & Improvement | Unstructured data hinders iteration. |
|
Critical System Control Unit Pre-Production Risk Assessment
A specific aircraft type required pre-production of a critical system control unit (DAL-A, cost ~0.9M$, lead time 4 months). Its failure could lead to flight cancellations. Tests were 65% complete, safety analysis nearly done with minor compliance issues, TRR passed with 6 open problems, no recent engineering changes.
Key Findings:
- Calculated Impact (I): 4.25 (High safety, operational impact)
- Calculated Probability/Maturity (P): 2.25 (Some verification remaining, open TRR problems)
- Calculated Risk Index (RI): 9.56 (Medium Risk, Yellow Zone)
- Recommendation: Produce with caution, require mitigation plan (limit to 2 units, resolve TRR issues, agree on safety analysis, progress flight tests).
Calculate Your Potential ROI
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Estimated Annual Savings
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Hours Reclaimed Annually
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