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Boeing 737 Max: Key Learning for Boards & Executives with Dr Andrew Hopkins

Boeing 737 Max: Key Learning for Boards & Executives with Dr Andrew Hopkins

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In this distinctive episode of The Safety Guru, renowned safety expert Dr Andrew Hopkins joins us to explore the critical lessons from the Boeing 737 MAX. Drawing from his latest book, Andrew unpacks a comprehensive analysis of its troubled history, uncovering flawed system design, organizational blind spots, and safety decisions that led to devastating consequences. He shares key learnings for boards and executives, emphasizing safety as a core responsibility and underscoring the importance of understanding and managing risk at the highest levels, while addressing how long-term safety performance is essential to sustainable business success. This information-rich episode delivers valuable takeaways on strengthening the role of safety governance, enhancing risk oversight, improving leadership accountability, and building safer systems for the future. Listen now!

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Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe, yet productive operations. For those companies, safety is an investment, not a cost for the C-suite. It’s a real topic of daily focus. This is the Safety Guru with your host, Eric Michrowskiy, a globally recognized ops and safety guru, public speaker and author. Are you ready to leave a safety legacy? Your legacy success story begins now.

Hi, and welcome to the Safety Guru. Today, I’m very excited to have with me Dr Andrew Hopkins. He’s Professor Emeritus at the Australian National University in Canberra. He’s written multiple books. So, Andrew, welcome to the show. Very excited to have you with me.

Well, thank you, Eric. It’s actually a pleasure to be talking to this particular audience, people who are either in the C-suite or sensitive to what goes on in the C-suite. That’s very much my concern as well. I thought I’d just say something about how I came to write this most recent book; The book is called Boeing: The 737 Max Crisis and Aviation Safety: The Perils of Profit-driven Engineering. The Perils of Profit-driven Engineering. That last subtitle really sums up what the book is about. So, the question is, how did I come to write it? Well, I’m a sociologist, and sociologists are interested in many things. I’m particularly interested in the sociologist community of organizations and how they operate, how they fail, and why they fail, and what leads them to behave in negative kinds of ways, in indeed negligent kinds of ways. That’s one of the drivers behind this book, is that professional concern. But there is another one, of course, that motivates me in all of much of what I do, because reading these accounts of accidents, of major accidents, such as the, well, this one, the Boeing accidents, and for the BP’s Deepwater Horizon, oil well blowout in the Gulf of Mexico in 2010.

All these accidents are characterized by big companies who are behaving in truly negligent ways, and they are pursuing profit above all else, and certainly above safety. They’re very careless with respect to safety, especially major accident risks, which rarely result in a major accident. But when they do, it’s major. It really is often life-threatening. They often are very focused on lost time injuries or other injury rate data because it is good data, and they can look at that and seek to drive that down. But they don’t pay attention to the really the major risks because for most companies, they seem rather theoretical and far off and distant. But the net result is when these accidents happen, one is overwhelmed by, I should say, I am overwhelmed by a sense of outrage that they were indeed so careless. That outrage is one of the drivers. It’s not a useful emotion in terms of creating a sensible analysis, an analysis which highlights what needs to be done, but I have to acknowledge it’s one of the drivers there in the background. Okay, so these books then that I write are all aimed at identifying lessons, particularly lessons that boards can learn from these accidents and this one, this accident is particularly useful from that point of view because there’s a lot that I can say and will say about the failures of the board.

But let me start with the story. Sure. We have these two crashes of the new Boeing 737 MAX aircraft in 2018 and 2019. The first one, in 2018, the aircraft had just taken off from an airport in Jakarta, actually. It’s irrelevant where they were because the location plays no part in this. Just taken off from the airport, and it was climbing away from the airport when suddenly the nose of the aircraft dropped, suddenly dropped, and it headed for the ocean below, steep descent in towards the ocean. Of course, the pilots didn’t understand what was happening, and they were terrified, and they worked hard to pull back on the to pull the aircraft back on course, back onto its normal rate of ascent, and they managed to pull the nose back up. One can imagine the sense of relief they felt, but straight away, the nose dropped again suddenly. It’s as if the aircraft had a mind of its own. They must have been totally bewildered by what was happening. Again, they fought to bring the nose back up, but again and again, the nose dropped, and it was like a It must have been like they were on a bucking bronco trying to control this aircraft.

It seemed set on diving into the sea. Finally, the aircraft went, and it dived at a very steep angle into the sea, killing everybody on board. Now, the same thing happened then, just four months later, another one of these aircraft, 737 maxes, taking off from a different airport. It was climbing away from the airport, and the same thing happened. The nose dropped, and a struggle ensued between the pilots and the aircraft to try and keep the nose up, and the pilots ultimately failed, and the aircraft drove itself into the ground, killing everybody on board. Now, of course, when two aircraft do this in quick succession, it’s clear there’s something very seriously wrong, and the regulators around the world grounded the 737 have MAX until further notice, and they remained grounded for two years until that problem was sorted out. What was the problem? There was a design failure. The MAX was just the latest model of the 737, each new model involves new design features, basically the same aircraft as first took to the skies in 1967, I think it was. It was the original model was… The original design was very old. It was a very good design.

It had served the Boeing and the traveling public well. But each time there was one of these one of these design modifications, it introduced the possibility of failure. There was a particular failure which was introduced in this most recent model in 2017, around that time, as this new aircraft was about to go into production. A new hazard was introduced. I won’t try and talk in detail about that hazard, except that it was a tendency to stall in certain circumstances. It was intended to stall. Sure. Stalling involves when the nose of the aircraft rises too sharply and the aircraft is trying to climb too steeply, it loses lift, and the aircraft will stall and fall out of the sky. This was a hazard which was introduced in the most recent design modifications. The engineers then in the design process, in the testing process prior to production, came up with a solution to how to deal with this. They introduced a piece of software. It’s always whenever you introduce These modifications like this, when you’re adding on something to increase the safety, these add-ons often introduce additional hazards of their own, and that’s what happened on this occasion.

This additional piece of software, it was designed so that it would automatically force the nose of the aircraft down if it detected that the nose was too far up and that the aircraft was about to stall. This would be totally automatic and be beyond the control and indeed beyond the knowledge of the pilots. The pilots were not told that the aircraft would behave in this way at all. But that’s the new piece of software which was sitting there in the background ready to swing into action. How is this software to be triggered? What would trigger it? Well, there’s a tiny sensor on the side of the aircraft fuselage that sensors what the angle of the aircraft is and whether it is approaching any dangerous angle. If it detects that that is the case, then it will send a message to the software and the nose of the aircraft automatically drops. It’s a very vulnerable little thing, very easily damaged. This is what happened in these two cases. In the first case, the aircraft, as it was taking off, hit a bird, and this damaged the sensor, and the sensor began to send through haywire kinds of commands to the software.

In the second case, I think there was a maintenance error on the ground just before the aircraft took off. Again, the sensor started sending through wildly inaccurate information to the software. That’s really the technical detail of what happened. But the point to notice about this was this whole thing dependent It depended on a highly vulnerable piece of equipment. It depended on a single point operating as it should. There is a principle in aircraft design that you should never be vulnerable to a single point failure. Yet this design, this design which they had introduced, was vulnerable to that single point failure. The question then is, why did the engineers allow this to happen? We’re now going to get into what I want to do look at the history of the company a little bit and talk about some of the forces that were at work on that company that led to this apparent carelessness by the engineers in this situation. Boeing had been a very successful company, and still is, of course. But in the early days, it started in 1916. It was started by engineers. It was owned by engineers. Engineering excellence was the absolute touch shown of everything they did.

They would never sacrifice engineering excellence to any other motivation. But around about the year 2000, there was a significant shift in Boeing’s approach to these matters, and they began to focus very much on shareholder return. That became the dominant criterion by which everything was assessed. What is the shareholder return? How are we maximizing shareholder return? In the process, engineering excellence gets downgraded. Engineering becomes how well we’re doing as engineers is a secondary consideration. That was a decision that was made quite consciously by the Boeing Board and the Boeing CEO. There was a bit of a problem, though, for them because the engineers were still in power, and the engineers were wielding too much power as far as the top management was concerned. Everyone was located in Seattle. The engineers, the top management of the company, all located in Seattle. The top management, the CEO, decided the only way to cope with this pressure from the engineers, because it was a conservative pressure. Safety always involves conservative decision making. Engineers were on the conservative side when it came to making a decision. The only way that the top management could deal with this was to move their location away from Seattle to Chicago.

To Chicago, right. So, the headquarters of Boeing moved. It then moved later, again, elsewhere. But this part of the story, they moved to Chicago where they were, I don’t know, it was a thousand kilometers away from Seattle. I don’t know exactly, but it’s a long way. In that way, they were cut off absolutely from any day-to-day contact with the engineers. Engineers didn’t have that direct access to the people at the top, which they previously had. The result was that the engineers ended up disempowered and unable to insist on engineering excellence. Their reporting lines changed. They reported to lower-level business managers, and their voice was muffled as a result of that. They were not heard at the top of the company. This was a very deliberate strategy. I think the CEO at the said, this has been a great engineering firm. We need to change it from being a great engineering firm to being a great business firm. That was the conscious state of mind of the top management. Now, Boeing was not alone in this, and we need to understand that other companies are doing the same thing. The other one that I’ve studied was BP and its blowout in the Gulf of Mexico, which I mentioned before, was attributable to the engineers being disempowered.

They had been disempowered. One of the lessons that BP learned was the need after that to re-empower them so that they would be heard and listened to. But the point is this was part of a more general change in the nature of capitalism. After World War II, capitalism developed in a way that took account of all quite a range of stakeholders, not just shareholders, but also passengers or customers. Customers, in this case, would be the airlines, workers. Government itself, government has an interest in the quality of what goes on because they draw taxation from these companies, and vendors, and lenders, all these people are stakeholders. The way capitalism developed and the way it was regulated was designed ensure that all these stakeholders’ voices were heard. But that attitude changed dramatically. It began to change with Ronald Reagan in the 1980s. The move was to move away from stakeholder capitalism to shareholder capitalism, where shareholders’ interests are paramount, everything else is secondary. That’s what happened. This is part of a much more general phenomenon. In many companies, and certainly in companies like Boeing, the way this was achieved was by setting in place a system of bonuses, very large bonuses, which the CEO and the very top managers received if they were entirely dependent on the share market stock price.

These were the so-called long-term bonuses. Long-term bonuses, they’re paid three years after they’re earned, depending on what the share price does. Sure. Of course, there are many other bonuses that operate in these companies, but it’s the ones at the very top that are critical because this drives the decision-making of the CEO and the top management. These long-term bonuses are very, very large. They’re worth 10 to 15 times the salaries of these individuals. There are massive bonuses which dwarf their salaries. They’re very effective keeping the attention of top management absolutely focused on maximizing return on investment. As I say, this has nothing to do with Boeing specifically, but it’s a universal phenomenon that was going on at the time. It leads to a loss. The top management absolutely lost their any focus on safety. In fact, many of them thought that safety was not their business. One of the interesting consequences of this is that it really places the regulator in a more difficult position. The regulator now becomes, if you like, almost the last line of defense against things going wrong in a catastrophic way. Regulators must be willing and able to exercise the power to ensure that these companies are not heading for disaster.

In this case, the regulator is the FAA, the Federal Aviation Administration. But FAA and regulators frequently, it was not adequately resourced. It was unable to carry out this new and more critical watchdog role that it had in this emerging form of capitalism. This was very relevant in the 737 MAX case because the FAA had to certify that this aircraft, this new version of the 737, was safe before it could go on sale, before it takes to the skies. How did it do this? Well, in the end, it had to rely on Boeing’s own engineers for the information which they would need to certify the aircraft as safe. Now, you can hardly imagine a more horrifying conflict of interest that these engineers are in. They’re under enormous pressure to speed things up so that the company can start selling these aircraft generating a stream of revenue. Enormous pressure to speed things up, on the one hand, from the company and on the other, the engineers who’d been appointed by FAA to act as that watchdog, they were under pressure from the FAA to ensure excellence was not being compromised. It’s an impossible conflict of interest. It’s unbelievably crazy.

That’s what was, I guess, one of the major factors which contributed to this accident. It meant that the FAA did not know anything about this single point failure when it certified the aircraft as safe. It certified the aircraft in ignorance of one of the most significant changes in the design at that point. Again, it’s a story. It’s not unique to Boeing, and it’s one from which we can all learn. Finally, then you might then ask, Well, what about the board? Does it have a role in ensuring safety? These boards are very far distant physically and in every respect from the day-to-day operations of a company like Boeing. But do they still have a role in relation to safety? Certainly, they do. The fact of the interesting thing is that this board, Boeing’s board, did not ever ask questions about the safety of the new aircraft. As far as it was concerned, safety was a responsibility of others, in particular, Boeing’s engineers, but also the FAA. The board was simply relying on the FAA certification to ensure that the aircraft was safe. As far as the board was concerned, the FAA was just another bureaucratic hurdle that had to be jumped.

They frequently ask, How’s the FAA going in relation to this certification? It’s an ongoing process that takes years, actually. How’s it going? But the only reason they were interested in what was happening with the FAA was that this was standing in the way of this stream of revenue which they were expecting as soon as that aircraft could take to the skies. That was their focus. It was not on, well, is the FAA discovering Is it covering any safety problems? Is it having difficulty with any aspect of the design? They were not thinking in those terms at all. Let’s ask the question, what should the board have been doing? What might the board have been doing? There’s some very important information that became available in this particular case, in the Boeing case, because of a particular legal action. The shareholders in Boeing sued the company on the ground that the board of directors had failed them. Now, this is a very unusual thing, and they sued them. This is a civil action for damages. The damages to the shareholders were that they lost share value.

Significant share value.

Yes, significant share value. Most of the actions that have come out of this crash, and others like it, are from people who were killed or their relatives, or their families who are demanding compensation for that damage. But this is about purely financial damages to the shareholders. They took this action, and they won. It was before a judge, and the judge came to the conclusion. The judgment says that the board had been entirely negligent with respect to safety. In some respects, dishonest, which is a very strong thing to be saying. This judgment actually went on beyond that to say, well, these are the things which it should have been doing and wasn’t doing. That’s why this judgment is so valuable, because it tells us it’s an authoritative statement about what boards should be doing.

There are several things that I want to talk about coming out of this judgment. The first important point that he made was that boards need to be skeptical. They need to be skeptical of the information which they’re being fed because as we all know, good news passes upwards in any organization quickly. The bad news follows way behind if it ever does. Boards need to understand that and must be willing to ask pointed questions and pursue those questions as far as they can. Skepticism was about the safety, about the certification process. That skepticism is a state of mind which boards need to aspire to and exercise. More generally, the attitude can be expressed as challenging the good news and embracing the bad news because the boards are constantly fed these reports which say that everything is okay, all our indicators are on track, etc. Boards who generally say, That’s great, good. What they should be doing is saying, well, tell us about these indicators. How reliable are they? Can we trust them? The moment you started asking questions about the reliability of the information, if they’d been asking, in this case, about FAA’s conclusion that the aircraft was safe, if they’d asked those more penetrating questions, they would have got to maybe had a glimmering of understanding of the incredible conflict of interest which Boeing’s engineers were placed in and how dangerous that was.

But they didn’t go anywhere near that. They didn’t challenge the good news and embrace the bad news. Now, embracing the bad news and looking for the bad news is a very important part of this state of mind because there are always warning signs before a major accident occurs. There are always warning signs, and I stress this is always the case, that things are not as they need to be. Things are not going well. Something’s wrong, and if something is not done about it, then a major accident is likely to ensue. The boards need to be on the lookout for this bad news. When they identify it, they need to explore it as far as possible, learn from it, and understand what needs to be done to deal with that situation. For example, they need to ask the CEO to pass through to them any information that he or she is getting from whistleblowers. They didn’t hear. There were lots of whistleblowers in Boeing, but the board never got to hear about them because the CEO and top management protected the board from that bad news. This is why this is such an important slogan.

It’s often put in metaphorical terms, the traffic light metaphor of green and red, of challenge the green and embrace the red. It’s a really simple idea, but powerful. It’s about state of mind the boards need to exercise. This board went nowhere near that. Some of the other things, the more detailed things that the board, that the judgment highlighted were that there was nobody on the board who had any aeronautical expertise, aeronautical engineering expertise. Nobody on the board who had any understanding of the fundament, the most serious risks, that safety risks, quality risks, risks that confronted Boeing in the manufacture of these aircraft. All boards need to have, said this judge, all boards need to have at least one specialist, someone who’s a specialist in the technology, in the risks, in the major hazards which confront the organization. This, by the way, these findings now by the judge actually echo a lot of conclusions that the authorities have come to elsewhere in other countries, particularly in the UK. These ideas have been understood for quite a while. So, boards need to have these kinds of specialists. Boards need to have subcommittees whose job it is to focus on these major accident risks which confront a major hazard company, a company which deals with major hazards, as this is the case with oil companies or aircraft companies or mining companies.

All these companies confront possibilities of catastrophic risks which can kill hundreds of people. Boards need to have subcommittees which specialize or focus on those kinds of questions and develop information about those which they can then pass on to other board members about how well those risks are being managed. It’s a way of directing at least part of the board to focus on these kinds of things. That’s another thing that the aspect that came out of the judgment, which is now being implemented. A lot of these things have been implemented in Boeing to some degree. Unfortunately, not completely, but to some degree.

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Another aspect of this accident, which is quite typical, is that when it happens, the companies try and blame the frontline operators for making mistakes. In this case, it’s the pilots. The concept of pilot error is the first resort of a company when it’s faced with this crisis. Indeed, the CEO of Boeing, after the first crash and questions were raised, the CEO was able to say, this was pilot error. There was nothing wrong with the aircraft. The aircraft is safe. If only the pilots had followed the correct procedure, this wouldn’t have happened. This is a very standard response that happens. What it betrays is a complete failure to understand the human factors that lie behind these accidents. Because it is true that the pilots were lost. They didn’t understand what was going on. There were some actions they might have taken which would have prevented that accident, but they didn’t understand what they were. They were so overwhelmed by what was happening to them that they weren’t thinking rationally.

It’s predictable that pilots in this people, human beings in these kinds of situations will not think rationally, will not stand back and say, well, what should we be doing? They won’t consult the manuals. They haven’t got time to consult the manuals. They will make mistakes which to the outsider seem irrational, and that’s certainly one of the things that happened here. But Boeing was actually very much at fault for the state of mind of the pilots because Here was this change that they’d introduced in the aircraft, this piece of software, which in certain circumstances would thrust the nose down. They’d introduced this, and they didn’t tell the pilots. In fact, they decided that the pilots ought not to know about this and shouldn’t know about this because it wasn’t necessary, they thought, Boeing thought. There was an economic reason for this. They said, if pilots don’t need to know about this. There’s nothing really new in this aircraft. They don’t need… Pilots will not need additional training. In particular, they won’t need to be trained on simulators, which is a standard form of pilot training these days, simulators on the ground. They won’t need that training.

Now, this was a major selling point to the airline industry because simulated training for pilots or retraining, as would have been required if this matter had been taken seriously, Simulator training is expensive. Because Boeing was able to promise the airlines that there would be no additional simulated training necessary, this was a big selling point, which when they announced that this new aircraft was going on the market was an important reason why they began to pick up orders. The result was that pilots were entirely unaware. They were entirely unaware of what was this new development. They had to go back, and they would have had to go back and try and work out, okay, in a crisis like this, this is what we do. We don’t know exactly what it’s all about, but this is what we should be doing. We should be canceling the automation on the flight and trying to fly the aircraft manually. Had they done all that, then maybe they would have avoided the accidents. But they weren’t thinking in those ways because they hadn’t been trained to, they weren’t aware. Boeing’s decision to keep the pilots in the dark and not to provide additional training to them was a key factor, I think, in why it was that the pilots made the errors that they did.

This is a human factor angle in all these accidents that you need to consider how will people react in these situations. If you had considered how will the pilots react in these crisis situations knowing nothing about it, it was quite predictable that they would and fail to do what they might have done had they been thinking about it in a simulator on the ground. Boeing had cut back on its human factor’s expertise. What it should have done in the design of this aircraft was ask itself seriously, how will pilots cope with this new situation? And run a series of experiments to see how will pilots cope with this new situation? They didn’t do that. And so that’s, I think one of the ways in which Boeing itself contributed to the pilot error.

The last thing I want to talk about here is the way of re-empowering the engineers, which is vital in this case and in all the other major accidents that I’ve studied. Ways need to be found to re-empower the engineers. It’s about organizational redesign. It’s about redesigning the structure of reporting, reporting lines so that engineers are not reporting to relatively low-level business managers. The reason why they mustn’t be reporting to low-level business managers is because the Those business managers, their primary concern is maximizing profit and production.

When they’re talking to their engineers, they will not be asking the question, Is this design good practice? Is this engineering good practice that you’re using in your design? But the question is, Is it good enough? Is it good enough? That’s a fundamentally different question because it’s inviting the engineers to cut as many corners as they possibly can, provided that what remains is good enough to ensure safety. That way of phrasing it, as you can understand, is going to over time corrupt the judgment of those engineers, especially as their bonuses are determined by these managers. These managers will be warding bonuses on the basis of how pliable and how compliant these engineers are with the needs of that business manager. Now, the only way around that is to stop, is to alter these lines of reporting and ensure that the working engineers don’t report in that way but report up to a more senior engineer who reports further up an engineering line, ultimately to a chief engineer who then reports to the CEO. Now, of course, engineers can’t operate entirely independently of commercial pressures. They have to be subordinated to the company at some point. If they’re subordinated at the point of the CEO, what that means is that their concerns will flow upwards freely to that very top of the company.

It’s the CEO who will be making those decisions and will be accountable for those decisions. As things stand, all those critical decisions are buried, and the CEO and top management never gets to hear the compromises that are being made. We have to find a way to ensure that the CEO, in a sense that his face, his or her face is rubbed in the facts of what is going on. They realize that the pressure on their engineers is to give them an answer that, okay, this is good enough. Once the responsibility is put on the shoulders of the CEO, you’re going to get a better outcome because they don’t want to be tolerating something which is not good enough. Sure. Yeah. Then, of course, the other feature of this is that that chief engineer also has a reporting line to the board, and that’s really important. The chief engineer will have dual reporting lines, one to the CEO, but he’s in a position to speak to the board independently of the CEO. If he or she thinks that the CEO is not passing on the relevant information to the board, then the chief engineer is in a position to do that.

These are some of the things that came out of that inquiry. This is one of the reasons I think that the Boeing case is such an important one to study because it dealt with these matters. It’s just something I think that boards operating in all major hazard industries need to be aware of the kinds of lessons which come out of this particular accident.

I think one of the pieces you bring up, you talk about the reporting lines of engineers. I would draw a parallel as well of reporting lines of safety functions in most organizations in that if it’s embedded inside the operational areas, you have a risk that the information remains there. They advise the same issues you talked about from an engineering standpoint may not percolate to the right levels of the organization. In the same way that you wouldn’t want audit to report to the lines of business.

Yes, that’s right. Auditors need to report to the top of the company. They need to find… It’s very interesting because audit firms are appointed by the company. If they provide a positive view of what the company is doing, they’re likely to be reappointed. That’s an unfortunate conflict of interest that they are often in. In far too many cases, auditors have failed to report things that are wrong because they’ve… Or at least the way they’ve expressed it has not raised alarm, and it’s deliberately designed not to raise alarm because they’re ultimately concerned about the next contract. That’s another conflict of interest. I think we have to be very aware of conflict of interest and design systems, design organizations, so that we don’t have those conflicts of interest. In the area of safety, that would mean that safety auditing auditors should not be appointed by the company. They should be appointed by… This is one possibility. They could be appointed by the regulator. You might have a pool of auditors available to the regulator, and the regulator would pull one of those out of the hat and say, okay, your job this year is to audit Boeing, if it has the relevant expertise.

That way, you’re removing that conflict because they have no more, no less chance of being appointed to Boeing next time around, regardless of the findings that they come up with. I think this is what I’ve seen in every single accident I’ve looked at, is that so many people are compromised in various ways. This is, I think, why boards need to be so alert to what can be going wrong, be asking questions all the time about what compromises is being made in the development of the information which we are seeing.

I think the same point I would make around when you talked about at Boeing, the need to have expertise specialists at the board level, in addition to a subcommittee, I would say it’s something as well, same in terms of operational expertise, expertise and safety. So, beyond the Boeing case study, it’s obviously around engineers and engineering safety. But in in a mining organization or in different other organizations, it may just be somebody who understands the context, the operational needs, and the safety elements and safety risks, some awareness of it, and potentially even value in having better awareness and training for board members around safety and what does it mean to have the right safety culture within an organization.

Yeah, I think this is right. I think each organization will be different. It’s a question of working out what is critical and then ensuring that you’ve got people on the board who understand the critical issues. They will be different. In health care, for example, this is another situation where these are in hospitals. This is another situation where It’s vital that people with expertise in what can go wrong are there in decision-making roles. I don’t know whether you know that there’s a very famous accident analyst by the name of Jim Reeson, and He’s done a lot of work on major accidents in the oil and gas sector. But in the last part of his life, he was working on the medical sector. Medical accidents, which involve accidents to patients who are in hospital for other reasons. Nevertheless, there are accidents which can cost the lives of these patients. The issues are very similar. It’s about identifying what’s going on, having people whose job it is to focus on what might be going wrong and learning from that.

One other thought that comes through is you talk a lot about shareholder value versus stakeholder value. The thing that strikes me, you mentioned BP as an example. We are obviously talking about Boeing. In both instances, short term shareholder value appears to be what was prioritized. But the long-term value of both BP and Boeing took an incredible dive following these incidents. Is there a need to really rethink what shareholder value means?

Yes. The story of share buybacks is a very important one here. You’re right that the rewards that go to the top company, the top managers in the company, are based upon annual performance. That means that everything is short term, and the long-term horizon disappears from their view for the most part. One of the, I suppose, most dramatic and most extraordinary examples of this is the phenomenon of the share buyback. This became popular, was made much easier than previously, and it became popular during the era of the Reagan residency in the 1980s. What share buybacks involved was… Well, you have to think of it in this way. Company makes a lot of money in one year. Big profit. What does it do with that big profit? Well, the new avenue which has opened up to them in the 1980s was to use that big pool of money for the company to buy shares, buy back shares on the stock market. Now, this is an extraordinary… It’s a puzzle, really, how this can happen. How can a company buy shares in itself? But that’s what’s going on. That’s what’s going on. The company uses a lot of this under the instruction of the board and the CEO, the company itself buys back a lot of shares in itself and then cancels them.

There are now fewer shares in this company. The total value of the company has remained unchanged, but there are fewer shareholders, which means that every share individually is worth more. After the share buyback process has been executed, the remaining shareholders are winners in this situation. Their share price, their share value has gone up, and therefore the top management, they’re winners. Their bonuses depend upon the share price going up, and this is what’s happened. And so, they’re reaping these massive rewards. And that’s fine for them. But what does it mean? It means that this money which had been earned by the company is being looted, as somebody said. It’s being looted by the shareholders, and it’s not being used in ways that will benefit the company itself. It’s not being used to do research and development. It’s not being used to develop new ideas, new aircraft in the case of Boeing. It means that the company can stagnate. This is what was happening to Boeing at the time. It was stagnating because it was resting on its laurels and redistributing all its profits in the way I’ve described. Now, the consequence of this was that Boeing was in a competition with Airbus, as everyone knows, and it was a very fierce competition.

At this time, around the year 2000, Airbus was marketing a new aircraft, which was a direct competitor with the 737, and it was recognized by many to be a much better deal than the existing 737, and Airbus was getting all the orders. Now, this was a crisis for Boeing, in fact, because I think it was American Airlines, which had previously bought only Boeing aircraft and a sense of loyalty to Boeing, placed a major order for Airbus aircraft. This was a crisis, as I say, for Boeing. It was a shock. They said, we need a new aircraft. It was too late at that point to be doing the R&D, the research and development for new aircraft. They said, well, we’ve got to do something. What we’ll do is simply put bigger and better engines on the existing design and go to market with those. Now, that was the design change which led to the 737 max. Because it was a shortcut and a spur of the moment decision to do this, they didn’t think through and didn’t have the time to think through what the consequences would be. This design change actually introduced this tendency to nose up that I spoke about before. But yeah, so Boeing was not in a position to develop a new aircraft which would compete effectively with Airbus. This really is one of the critical steps in the story as to why these defects went through to market.

Excellent. Andrew, thank you very much for joining me today. You’ve written numerous books on various events, the latest one published by CRC Press, Boeing: The 737 MAX Crisis and Aviation Safety. You talked about BP investigating multiple different at incidents, published multiple different articles, including some recent ones I was looking at on your LinkedIn profile, on risk matrices and so forth. What’s the best way for somebody to keep in touch, to learn more about some of your articles, your publications, and your books?

Well, I’m always available on email. My email is [email protected]. That stands for Australian National University, Au. Edu. Au. But I think the other thing is I’m also on LinkedIn, if you want to contact me on LinkedIn. The books are widely… If you know the name of the book that you want to access, it’s available in bookstores. Amazon has a lot of these books, and that’s a way to get in touch with me. But I do answer my emails, so please feel free to Contact me.

Excellent. Thank you so much.

Thank you for listening to The Safety Guru on C-suite Radio. Leave a legacy. Distinguish yourself from the past. Grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.

ABOUT THE GUEST

Andrew Hopkins is Emeritus Professor of Sociology at the Australian National University, Canberra. Andrew was a consultant to the US Chemical Safety Board in its investigation of the BP Texas City Refinery disaster of 2005, and also for its investigation into the BP Gulf of Mexico oil spill of 2010. He was an expert witness at the Royal Commission into the 1998 Exxon gas plant explosion near Melbourne. He has written books about these accidents as well as books on mining disasters. Over 100,000 copies sold.

He has been involved in reviews of Work Health and Safety regulation and regulators and has done consultancy work for major companies in the mining, petroleum, chemical, and electrical industries, as well as for Defence. He speaks regularly to audiences around the world about the human and organisational causes of major accidents.

  • BSc and MA (Sociology) from Australian Natl U, PhD (Sociology) from U of Connecticut.
  • Independent member of the Air Force Board of Inquiry into the poisoning of F111 maintenance workers. Author of the Board’s report.
  • Winner of the 2008 European Process Safety Centre safety award, the first time it was awarded to someone outside Europe.
  • Honorary fellow of the Institution of Chemical Engineers in recognition of his “outstanding contributions to process safety and to the analysis of process safety related incidents”
  • Life member of the Aust Institute of Health & Safety. Recipient of an award for “lifetime achievement”
  • Officer of the Order of Australia (AO) in recognition of his “distinguished service to industrial safety and accident analysis”
  • Former member of the advisory board of NOPSEMA – the Aust Nat Offshore Petroleum Safety and Environmental Management Authority
  • Member of an expert panel that drafted the Global Industry Standard on Tailings Management.

Books by Andrew Hopkins:

Making Safety Work (Allen & Unwin, 1995)

Managing Major Hazards: The Moura Mine Disaster (Allen & Unwin, 1999)

Lessons from Longford: The Esso Gas Plant Explosion (CCH, 2000)

Lessons from Longford: The Trial. (CCH, 2002)

Safety, Culture and Risk (CCH, 2005)

Lessons from Gretley: Mindful Leadership and the Law, (CCH, 2007)

Learning from High Reliability Organisations (CCH, 2009). Edited

Failure to Learn: the BP Texas City Refinery Disaster (CCH, 2008)

Disastrous Decisions: Human and Organisational Causes of the Gulf of Mexico Blowout (CCH 2012)

Nightmare Pipeline Failures: Fantasy planning, black swans and integrity management. (CCH 2014) with Jan Hayes

Risky Rewards: The Effect of Company Bonuses on Safety (Ashgate, London, 2015) with Sarah Maslen

Quiet Outrage: The Way of a Sociologist (CCH: Sydney, 2016)

Organising for Safety: How Structure Creates Culture. (CCH, 2019) Credibility Crisis: Brumadinho and the Politics of Mining Industry Reform (CCH, 2021), with D.Kemp Sacrificing Safety: Lessons for Chief Executives (CCH Sydney, 2022) Boeing, the 737 MAX Crisis and Aviation Safety: The Perils of Profit-Driven Engineering (CRC, UK, 2025)

For more information: https://sociology.cass.anu.edu.au/people/professor-andrew-hopkins

Contact: [email protected]

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Aviation Learnings and Human Factors: Turning Complex Challenges into Simple Solutions with Ian Hollingworth

Aviation Learnings and Human Factors: Turning Complex Challenges into Simple Solutions

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ABOUT THE EPISODE

Drawing from his extensive experience in high-performance aviation, Captain Ian Hollingworth joins The Safety Guru to share powerful insights on aviation learnings and human factors. In this engaging episode, Ian brings riveting real-world case studies to life and explores how key aviation principles can be applied to safety-critical industries. He also unpacks three essential elements of human factors that are vital to improving safety and performance. Whether you’re in aviation or another high-stakes field, Ian’s insights offer practical applications to elevate safety, decision-making, and problem-solving. Don’t miss this episode—you’ll walk away with valuable takeaways to help turn complex systems and challenges into simple, actionable solutions.

READ THE EPISODE

Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe, yet productive operations. For those companies, safety is an investment, not a cost for the C-suite. It’s a real topic of daily focus. This is the Safety Guru with your host, Eric Michrowski, a globally recognized ops and safety guru, public speaker and author. Are you ready to leave a safety legacy? Your legacy success story begins now.

Hi, and welcome to the Safety Guru. Today, I’m very excited to have with me Captain Ian Hollingworth. He’s a former fighter pilot as well as a commercial pilot with a lot of experience flying but also brings a lot of expertise in human factors. Ian, welcome to the show. Very excited to have you with me.

It’s great to be here. Thanks very much indeed. I’m looking forward to it as It should be a lot of fun.

Excellent. Let’s start with your background in aviation and safety. You’ve crossed analog last flight decks. We’ll get into all of that very soon. But tell me a little bit about your background and how you got into human factors.

Well, done. You’ve already introduced me as the former fighter pilot and commercial airline captain. Well, for over 40 years, Eric, it’s been a privilege to be involved in aviation as an instructor examiner on the airplane types themselves, which vary from 1980s times in the UK Royal Air Force, flying the lightning, which is akin to the F-104-star fires It’s that generation of airplane. I was firstly flying those as an instructor, very much during the Cold War in the 1980s, which turned out to be quite hot from time to time. It was not cold at all, really. Then Once I’d done that for 12 years or so, and in the meantime, moved on from being a single fellow to being married with kids, I did the hop, which is not unusual to commercial types. I then joined commercial aviation, initially flying the very early 747 model, 747 Jumbos, the one and 200 series, very early analog aeroplanes as well. That was quite comfortable for me, and I had introduction through flight engineers, et cetera, et cetera. Through to more modern types, you might say, through to the 737, where I attained my first command, more models of that, back onto the jumbo as a captain and as a trainer, and then more laterally as a trainer on the Boeing 777 and the 787.

Most of my time, almost all my time has been with Boeing as well as my time in the UK Air Force. How I got into the safety side of things? Well, right now, my business, Cassandra Flight Training in UK and Plainetalks.com, really consult to aviation and non-aviation industry, but principally safety critical organizations such as nuclear, health care, and fire and rescue services here in the UK. Sometimes I work through associate companies as well. It’s great to cross-pollinate and work with other teams. This takes me to all parts of the globe from time to time. More recently, it’s been Africa, the Indian subcontinent, and generally throughout Europe. I do what I’m not doing now. I don’t tend to do a lot of talking. I tend to do much more listening in this environment and facilitate and craft a discussion, generally using case studies, really to get inside the heads of those operators that had been involved in incidents and accidents to work out what was really so compelling and was right about what they were doing that led them to the accidents. That’s it. How I arrived here, to a certain extent, Eric, is still a bit of a mystery to me.

But I was a child of the ’60s and ’70s, and I very much was building those plastic models when I was a kid, throwing them out the window and following the likes of the Gemini and Apollo programs for NASA. I watched the development of Concord. I sat there, my I had at three o’clock in the morning with a black and white TV watching Neil Armstrong land on the moon. How could I not be inspired to go into aviation or other? It wasn’t with any great plan, Eric, at all. I got out of university, really, as the world’s worst physics graduate. But all I wanted to do was to do my best within aviation, which was to fly the most exciting airplanes available that signed to me in the Air Force, which is the Harrier and the Lightning. As far as the safety element of that question goes, I like to aviation, I’ve always been interested in the background as to what makes a complex system work so well. But it’s when safety becomes personal that your mindset develops as it does.

When I look back to the frequent accidents that occurred in and around me in my time on the lightning in particular, the second time I flew the airplane as a single-seat fighter, I had a catastrophic engine failure myself. Oh, my goodness.

No big deal because it had two big engines, and the other one was quite capable of getting me back on the ground again. It was a case of, pick up another airplane, go with it. But we had several accidents which involved the loss of airplane ejection, and also from time to time, the loss of the pilot as well, which really hurt, particularly when it’s your friend. In ’88, in particular, my very best friend at the time was killed in a Red Arrows accident. When we think of the red arrows as a team of excellence, really, akin to other great aviation teams. It was a massive shock to me. But the results of that accident inquiry, essentially, the word pilot error. But there was much, much more involved in that accident from a systemic that really concentrated my mind, I would say. The loss of a friend in the 1985 Manchester 737 accident, a commercial accident, Papa 2 8 Mike, was my wife’s best friend, in fact, my wife’s best friend, really does offer you more in terms of understanding aviation safety. And that’s it, really. But my first formal exposure to CRM, as such, on joining British Airways.

I think I’d always been involved in airmanship, as it was told. Sure. It was. But joining BA, and thereafter much more deeply and enjoyably working with a guy called nick Dahlstrom at Emirates Airlines, probably about 20 years ago now. So that’s me. That’s my general background in aviation and safety.

I’d love to explore in terms of how decision-making has shifted in the aviation world. You alluded to analog versus glass-flight decks and shifting from one to the other, from the older generations of 47, 100 as an example, to more modern to 787. Tell me a little bit more in terms of how decision-making has evolved over time.

Sure. You’re absolutely right. In my case, I’ve been exposed to a lot of analog type airplanes and those systems all the way through to really sophisticated airplanes, glass carpets, et cetera, and digital stuff. Also, operating with basically a single pilot, but within a team, if you like, all the way through to multi-cruise on big airplanes. It’s worth looking at what is still the same, if you like. We still work to a checklist. It’s a checklist environment. We still adhere to standard operating procedures, either in the military or outside. The decisions that we make as a human being are still essentially the quick ones, the experiential ones, the recognition prime ones. If I go back to my engine failure on my second flight on the light, it went bang. I knew what it was. You could instantly recognize that and had to deal with it through a checklist which you practiced, all the way through to the more considered or rule or procedural bound decisions that we run to in more complex systems. So, type one, type two, fast and slow. But the big difference now is the complexity of circumstance. It’s sifting through the large amount of data that’s available to to the operator or to the pilot, and to be able to prioritize exactly what you’re going to do and how you move forward.

Sometimes, I try to offer an analogy to that with the teams that I’m working with. It’s like if you’ve got a deck of cards and the 52 cards in the pack, and each card offers a solution or a part solution or a way forward. Sometimes those cards can be in a pack in your hand, all folded up. Or you can have the same 52 cards all spread out on the table, and you can have a whole group of people having a big discussion about which card you pick up first and why and how it’s going to work. It all depends upon the time that you’ve got. And quite often in aviation, time is limited, or the perception of time is limited. So, you can pick cards up in your hand and you can pick a card up, that doesn’t work. Pick another one up, that doesn’t work. Pick a third card up. That keeps me safe and that allows me time to make another decision. And that’s a way of thinking about decision making. But within this, we’re still the same human being, and the system will become much more complicated and much more complex.

But we’re the same. We haven’t evolved particularly well. We have to manage our time. We’re still subject to the same time constraints, and it is crucial to understand how much time is perceived to be available in order to get these decisions made. So, one of my struck lines, Eric, is trying to simplify solutions to complex problems. And when you have a complex problem, a complex non-normal, let’s say, on an airplane, begin with just starting the clock. Always, always start the clock because the time will run away with you otherwise. Then quite quickly, I think it’s like going back to Apollo 13 and missions that can quickly go so badly wrong. You have to ascertain your bottom lines very quickly. What are the non-negotiables? And work on from there. Once you’ve got the clock running, once you understand how much time you got, once your bottom line’s ascertained, then you can work simply from there. One of the great things that’s worked in the evolution of CRM is the evolution of decision-making models. You may have heard the acronyms FWDEC, DODAR, T DODAR, grade, they’re all doing the same things. They all offer you a framework to build a decision.

So DODAR, for instance, which is well used within aviation, first off, once the time is sorted out, then you spend time in diagnosis of a problem, and the time is rarely wasted diagnosing a problem. Coming up with options, so D and then O, options and risk, how we’re going to categorize risk, decide what you’re going to do, assign the tasks, and then review. So, you’re going through a well-founded circular pattern to go back into your original diagnosis to make sure that what you thought was the problem was actually the problem and that you’re not trying to offer a solution to a problem that isn’t there. In a way, how has decision making shifted? It’s become more sophisticated, and it’s cognizant to the fact that the human being has to be able to break down that complexity of circumstance into a simplified form. Within that, then we can learn how to brief a circumstance and debrief a circumstance and learn from that effectively.

Sometimes you’ve got very short periods of time. We’ll talk about some of the lessons from aviation. Air frost comes to mind in one of those cases to diagnose a problem when autopilot kicks Tell me a little bit about some of the key takeaways in terms of what are really the key essence of human factors and maybe bring some stories and some examples from aviation.

Well, the problem-solving decision making that you’ve just talked about is central to the 9 or 10, let’s say, assessment markers that we use for pilot competencies nowadays in a era. Those pilot competencies are way beyond just the technical ones that that were experiential for me in the 1970s and ’80s, where it was stick and rudder and you were learning to fly the airplane, hand-eye coordination. Really, it now evolves much more into the social skills of leadership, communication, teamwork, et cetera. But the stuff that I work around with is the cognitive factors, the thinking things of the problem solving and how that manifestness itself in terms your workload management, your situational awareness, and your threat and error management understanding. So, the essentials of human factors, as you say, spin out from that. And I’m not going to list them all, but the few that are important to me here, if you like, and some of the others are available. As I’ve said, effective communication really is a skill set that runs through everything that we do in terms of normal and normal operations. Effective communication is much more than what it just says on the 10, if you like.

To have a true understanding, you need to be able to obviously convey information clearly accurately and timely within aviation. But as a crew, you need to be both concise and interactive, and that’s quite difficult to achieve sometimes. Normal communication, generally from one person to the next involves talking effectively to pair of eyes and using body language, which sometimes is mitigated, again, on the flight deck. But it’s, again, the use of the spoken word, again, which is high upon the list of communication within aviation in a way that you’re using both open and closed questions and limiting those questions appropriate to a circumstance. So, Communication runs through everything in human factors. But if I just pick out some other bits and pieces from that. Let’s look at assertiveness, for instance, which in the West of the world, UK in particular, we’re very good at not being very clear. We use mitigating speech the whole time. We playthings down when really in a safety critical environment, you have to be, at all times, clear and concise and well-paced in your delivery and understand that your delivery is only appropriate to the receiver. Can the receiver take that information and understand it?

The package needs to be delivered clearly, objectively, and non-aggressively. So, all those things come up. We see a lot of case studies, a lot of accidents and incidents, whereby people knew what was going on, but they just didn’t communicate that clearly enough to be understood.

Great.

If I might just bring in three other elements that are essential to me. Five things, if you like, that are essential to me in terms of human factors. First of all is threat and error management, which is part of the latest iteration, if you like, of human factors CRM. It’s understanding what the threats in your business, both obvious and not so obvious, the later ones, and how to manage those, and spending most of your time avoiding situations. The anecdote, the one that I learned when I was a kid learning to fly was that superior pilots should avoid situations that might require the use of their superior skills. So, you’re spending your time avoiding threats and managing them rather than working hard to obviate the results or to mitigate the issues. The other two that I build in are absolutely essential, and all these things dovetail. Situational awareness, and I think awareness is a bit of a misnomer. Situational awareness means the perception of a circumstance, your comprehension or understanding of it, and then projection of that understanding into the future. So, you can really work out what you think is going to happen next, five minutes down the line, 30 minutes down the line.

Clearly, if you’re operating transatlantic on a big airplane, what happens? Do they get sick? Where do I divert to? What is the weather, et cetera? That’s your situational awareness. And then is resilience, because there are so many times when you get hit by a problem, and then another, and then another, and then another, that those things for me, communication, assertiveness, threats, and management of your circumstance and the resilience are really important. What I would say is, how does it go wrong? More often than not, we talk about loss of situational awareness rather than trying to regain situational awareness. I had an issue. Well, very early on, I was quite a competent fighter pilot, so mid-1960s in the Cold War, and I was scrambling for what’s called a QRA sortie, which is quick to reaction alert. You’re fully armed. Basically, you’re the policeman of the skies, in my case, around the United Kingdom. I was scrambling at night in the most awful conditions and scrambling from slumber, from bed. But if I take that flight forward about three or four hours, I was fulfilling mission, which was to interrogate the outside of an airplane, which was a Russian airplane, a Russian four-engine bomber, a bear foxtrot, way out over northern Scotland, going out into the Atlantic.

I was taking photographs for intelligence purposes, obviously. But I was very quickly way beyond the capabilities of where the airplane should be. I was flying in an airplane that never carried enough fuel. It burnt whatever fuel it had very, very quickly indeed. You needed air tanker support to get the job done. I stuck myself on a limb and I wanted to get this job done. It was very much a can-do scenario. I had a cockpit fire. I was underneath this airplane, pretty close to this Russian guy, taking photographs of aerials and stuff like that. In those days, you flew the airplane with the control column between your knees because you had a handheld camera. There I am in a squashed-up airplane. That was away from anywhere. Those airplanes were rudimentary. There’s no GPS. There was no initial navigation system, no nothing. It was all to do with mental dead reckoning, how far you’ve been traveling for how long at what speed in what direction. You work out where you would go. When I was on my own, I’d left the tanker a long, long, long way back in order to intercept these guys. So, when I had the cockpit fire, all of a sudden, my mindset turned from a QRA, operational intelligence gathering scenario to, one, a survival Am I going to burn?

Am I going to fire the canopy off and freeze to death? Or am I eventually going to have to eject from this airplane into a sea and never be seen again? And my mindset turned completely. So, how did it go wrong in terms of human factors? And where did it start? I’ve asked myself those questions so many times because I clearly did not think through positively enough about what could happen, how things could possibly go wrong. And at that time, because you’re then in a circumstance with a radar that basically was on fire. It was only about half a meter away from my face. Do I have the cognitive capacity to update myself under those circumstances particularly well? Had I thought this through? No, I hadn’t. And I was in a right old mess, a right old pickle. And I was quite fine, Eric. I really was. But then I had to disengage from that operation and find my tanker, again, just using mental maths. We’re at four o’clock in the morning in a hazy early morning sky north of Scotland in May, trying to find some contrail of what I hope was a tanker and to be able to have him intercept me because I was very short of fuel to grab to get home.

I needed to get the fuel in order to make some landfall back in the UK, maybe more fuel, keep the fire down to be able to land back at pace. It was one thing after another. But I really messed up that day. But It was a great case study for me to reflect on how I got it completely wrong and how fortunate I was in the end to be able to bring the airplane back, along with some pictures for intelligence reasons. And there we go. That’s one of a number of personal studies, and I kidnaped Eric. There are lightning pilots out there that’ve got much better stories than that and many more of them because that was the nature of the operation.

This episode of the Safety Guru podcast is brought to you by Propulo Consulting, the leading safety and safety culture advisory firm. Whether you are looking to assess your safety culture, develop strategies to level up your safety performance, introduce human performance capabilities, re-energize your BBS program, enhance supervisory safety capabilities, or introduce unique safety leadership training and talent solutions, Propulo has you covered. Visit us at propulo.com.

It gets to what you were mentioning before around making it personal as well, that safety is personal in a circumstance like this from a learning standpoint.

I was a complete rookie. I didn’t think I was. I was a second tourist. Most accidents and incidents happened to people that were the most experienced guys on the squadron. They were tasked with the more difficult scenarios. Sometimes it was the can-do attitude. You were good enough. You were fully operational. You could do all these things, but sometimes you stuck your neck out far too far. That’s what I did on this occasion. But it got me thinking about myself, my self-awareness in terms of my capabilities or lack of in this case. Then as I went into commercial aviation a little later on, you’ve asked me about things like Tenerife and Air France 447. What are those things bringing? Clearly, anybody that knows about this this circumstance and have analyzed those accidents in considerable detail. But I try to look at accidents with colleagues through different eyes, really, and go beyond the accident report. For instance, if you look at the Tenerife accident and essentially, the KLM captain, Jacob van Zante, was a very senior training captain within- Very senior. Yeah. That accident was caused by a whole bunch of circumstances. The American side doesn’t quite agree with the KLM side, the Dutch side.

But essentially, the captain’s mindset was very much can do on that day. You have to try to work out why was that? Is that just his personality, or can we shift that behavior? Okay, he was very, very clear about what he wanted to do. And we had perhaps a less than assertive crew copilot within there. But the mindset of that captain was probably driven as much as anything else by the fact you spend a lot of time in the simulator. When you’re training in the simulator, Eric, you can utilize the four hours that’s in there as best you possibly can as a trainer. We don’t spend a lot of time, as you would do in real-time circumstances, taxiing around as they were in Tener Reef, you can reposition the simulator instantly to another point, debrief, even brief for another approach. You If you can reposition the airplane in the sky or on the ground. But if you’re minded like that, that you can do stuff and circumvent time to a certain extent, I can understand where Captain Van Zante just wanted to get this this airplane, airborne as quickly as to get to these destination within time, within the flight time limitations for the rest of the crew and so on and so forth and make that commercial viable.

There’s a lot of things that go in there. Into the mix that are not just the obvious. Sure. And there we go. So poor outcomes from that. Similarly, the Air France 447, 20 years later, June 2009, we come up with now a very sophisticated airplane of Petro Cube icing, which compromises a highly complex system, not necessarily easily recognized by the crew. Then if they’re not trained in dealing with that in this circumstance, then what’s the outcome going to be? It’s generally going to be less than ideal. Finding those positive outcomes, the great stories, there’s less outcome. But clearly, in ’89, for those people that want to research this is a really interesting one is United 2: 32 that landed at Sioux City, which the headline is, Eric. It was survivability from a non-survivable accident. How did that happen? By to have great communication and quality CRM in action from the very early days of a formal CRM being taught, a superb Al Haynes-led incident from which we learn a huge amount from as well. There we go. I’ve rambled on for a bit, haven’t I? Essentially, human factors.

Human factors, yes.

It’s the case studies that are important. It’s not somebody like we’re talking about. Absolutely. It’s the case studies that always surprise, and it’s the case studies that are really interesting.

You mentioned the word CRM. For anybody in aviation, that’s a very common word. Tell me a little bit more in terms of for somebody who may be outside of the aviation industry, what is CRM and how has it really evolved? Because it’s a very key component to a lot of the progress that’s been made in safety in aviation.

Perfect. Well, put indeed. I mean, the definition is out there, and it’s what it says, really. It’s utilizing all resources, human and others, other human beings, the technical side of stuff, in order to get the best and the safest outcome from any circumstance that you might find yourself in. That is essentially it. How has it evolved within aviation? Aviation has obviously been the background to CRM. My first understanding of CRM which is crew resource management, was actually cockpit resource management. Let’s say the late 1980s, evolving from NASA studies and high-profile accidents all the way from late ’60s, ’70s, it became cockpit resource management, meaning captain resource management, to start off with, understanding how the captain led a team and stuff. Then recognizing that it was more than just one man or one lady. It was to do with a crew and a team and all those elements that go into a safe operation. It then started to evolve, and there are a number of iterations of which we’re now looking at the sixth and generating the seventh. But it involves understanding the fact that error is a human issue. Error is out there. We’re never going to change the fact that the human being creates errors all the time.

So, it was trying to mitigate errors and then understanding that errors actually are generally systemic, understanding that they’re part of a system and a procedure. Right now, we’ve got evolution of CRM with the sixth iteration, which is threat and error management right at its core. But it’s also evolving along with the technology. It’s evolving along with the training systems. And now we’re into We’re learning systems that mirror exactly what the needs of the system are. It’s competency-based training, not learning to do just one thing, deal with an engine failure on takeoff. But it’s enhancing all the skills are softer skills, that allow us to take those skills in a translational way into any circumstance. The evolution considers the early analog structures, the training systems that reflected the fact that machines initially were unreliable and could be regarded as dangerous, through to So the more modern stuff, which innovations, GPS, performance tools, digitalization, super reliability. But constantly, we’re trying to align human capability with a level of the tech system that’s there at the time and what we do best. So, producing super reliability probably reduces human resilience because we’re not exposed to the same stuff as we were, thankfully, 30, 40 years ago.

It’s trying to make sure that we, as human beings, still do the stuff that we’re best at, which is decision making and allowing the system to do what it does best, which with highly complex systems is generally monitoring the systems themselves and data analysis. It’s constantly on the move. We need to perceive the erosion, if you like, of traditional pilot skills. We still need to have manual handling skills. We still need to have this situational awareness. It’s marrying all those things together. We now have a very complex understanding of training systems and how we manage training systems within the sphere of CRM, which leads to things like evolving cultures and just cultures, where we can really learn, and business can learn from aviation.

I think that’s a good segue in terms of how do these principles we talked about from human factors to CRM, to some of the elements around decision making, more complex systems, how can this translate into other industries? A lot of the work you mentioned that you do now is in other industries that are also high risk or require high reliability in bringing some of these principles from aviation to them.

That’s a fantastic question. The learnings for industry are so many. We just talked about just culture, and I don’t know whether an understanding of a true just culture needs to be probably defined first. Trust, which is a proactive and generative culture. Trust and transparency need to be there and accountability. It promotes learning from mistakes, effectively, to understand that we’re distinguishing between the good behaviors and the bad behaviors, aiming to create the ideal environment to support a good organization. In terms of particularly industry, which industry is the safety critical stuff? First, you have to ask from a high level whether that particular business has the moral courage and vision to move forward with this and have the passion for a possible reset of an organization if things are not going quite so well. That is a big buy-in to start off with, courage and vision. But because you’re going to be looking at organizational performance from the top down, from the philosophies driven by management all the way through to the procedures and practices, in my case. Sure. There are some big questions to be asked first before you embark on this, but the consequences, the positives are myriad and absolutely fantastic, if you can embrace it.

When I work with, for instance, work with nuclear power for the first time, and I was working predominantly with nuclear reactor control room staff and how they were assessed in role. Basically, in the UK, at the time, there were eight nuclear power stations. All of them were different because there were all sorts of prototypes. The systems were different, and the people involved in running the control systems had been in place for 20, 25 years, so lots of legacy items going on. How do we learn from aviation in terms of managing this and keeping the system safe? Well, first of all, it doesn’t start with the sharp and the interactive control room staff. You have to pay close attention to effectively the organizational blunt end of your operation and understand that within your system, error is the human precondition to start off with. But if you got frequent error in any of those systems or any of the way in which people work, it It’s really a system of a less ideal circumstance within the system. And then understanding. The third thing I would say is understanding the levels of accountability and trust that are placed within those people within your team, those safety critical members.

Once you’ve done that, so you analyze what you’re doing, then you can find, and this is the crucial bit, you need to find the stuff within your system that is latent, is unsafe, that nobody knows about, because that’s the stuff that’s going to cause harm in the end. It’s not the accidents and the incidents that we that we analyze. It’s the stuff that’s been in there for years and years. It’s built into the system. You can do that by, again, using your people. You need to embrace a dynamic and facilitative series of discussion and learn how to brief and debrief efficiently and giving people the opportunity to do that by setting up, for instance, human factors CRM sessions in a company, let’s say, a nuclear or an aviation or a maritime company that involves initial CRM. Everybody gets to know the culture of the company. Then you revisit that on an annual basis or semi-annual basis and refresh it all the time by having these discussions. And within that, you can then explore and analyze your industry case studies or your personal case studies within the business and encourage people to be imaginative and creative in their thought.

And this is quite fun, actually. It does cost a little bit of money, but it’s a great exercise to get people actively involved in understanding the culture of their business. From there, stuff drops out. People begin to find those latent threats and make them less latent, more observable. You can then start to properly explore strategies that develop the resilience in your business, both individual and systemic, to continue, to obviously make you a safer and more effective entity. You’re going well beyond regulatory compliance or a need to know this, and you need to have serious, from a business perspective, outcome-based conversation, what you want out of this rather than how much is it going to cost.

Right. In How do you surface, you touched a little bit on it in terms of some of those lean conditions, because that’s a key element in terms of really addressing some of the system factors.

You talked about some training, but there’s also workshops conversations. Tell me a little bit more in terms of what that looks like, if you can. The workshops that I run generally work from an organizational perspective. If you got, let’s say, between 6 and 12 people in a room, and it’s a classroom environment. This is not something that’s technically difficult to achieve. It is a real privilege to be involved in these circumstances where you are utterly comfortable in saying what you need to say and feel without feeling of compromise or of blame. This is who doesn’t just culture. And generally, within a simple environment, cup of coffee, classroom, whiteboards, flip charts, not doing everybody’s death with PowerPoint, a management video, but straightforward, having an understanding, find Fred, the guy who is really critical to your organization. It might not be the CEO in the business that’s most critical to your organization and the way in which it works. It’s somebody further down the peaking order. So, this is a bottom-up circumstance where everybody is getting to understand the culture of the business. And from time to time, you were involved in a circumstance happened a couple of weeks ago where I was in a classroom week with some guys from Air Baltic, from Latvia, smart airlines, smart people, seven or eight training captains.

We talked for a week about how we can improve various circumstances within the business, training systems in particular. It was a complete joy. Once everybody got to know one another, we’d introduce one another and each other’s background. We then get into the anecdotes, the case studies. Those are the things that people learn from area. It’s the personal stuff, and it has to be entirely relevant to what they’re doing and how they see themselves. Quite often, it’s a journey of self-knowledge, to be quite honest, understanding where you fit in the system, but being assertive enough and comfortable enough within the system to be able to deliver whatever material it is that feeds back into the system. And feedback is absolutely critical. And that’s all that we’re trying to do. And I facilitate that as best I can. I don’t talk through it. I allow people to talk and spend a lot of time listening and try to work out cognitively, sometimes paraphrase what people have said, but try to work out cognitively what this actually means within the business. James Reason, and you may have heard of Professor James Reason, sadly, he passed away earlier on this month.

He was one of the greatest giants of human factors. I don’t know whether you know he passed away. I didn’t. No. He was so instrumental in the way in which human factors work, both in aviation and outside aviation. He’s famous for the Swiss cheese model. Yeah? Yeah. Great. Yeah. He’s in recognition for the Swiss cheese model. Most people know about Swiss cheese. I won’t go into that. But He said that the operator in accidents is operating but adding the final garnish to a lethal stew whose ingredients have already been. Right. With that, a phrase that sticks with me at the end of every day and before I go to work is having, as he said, a sense of chronic unease about what you do. If you can teach your staff in a safety critical environment that. When I mean chronic unease, it’s not being scared about what’s happening. It’s just knowing about what ifs are going to happen today, how my day is going to finish. Everybody that’s crashed an airplane that’s had a problem at sea didn’t think that the day was going to end up with their demand. It’s always thinking about the what ifs in the future.

Chronic on ease will keep you safe within your system, if you can say that your system is about safety and more, and it’s about what we do, and that is a strapped line that works, then it’s good enough for me. It’s The lesson is learned.

That’s it. There we go. That’s it. I think that’s a key piece, this element of chronic unease. It’s almost a healthy form of paranoia of being prepared for what could happen, as opposed to what I often see in key industries is an overconfidence of, I know my craft, I know what I’m doing.

You’re absolutely right. You have to take into fact that the skill of the craft, if you’re a director control room team supervisor, is essentially what it’s all about. But I really enjoy the cross-pollination of taking circumstance from aviation into, let’s say, nuclear industry. To have these open discussions, it’s a really healthy place to be. Similarly with the healthcare scenarios, nobody knows everything. The more I’m around, the less I feel that I know. That’s a very good analogy.

So, Ian, thank you very much for joining me today and for sharing some of the key elements around human factors, CRM, but also the applicability in other industries. If somebody wants to get in touch with you, what’s the best way to do that? In many ways.

You can find me on LinkedIn, on YouTube. My Gmail address, which is simple, [email protected] It will almost get me there. I’m quite happy to pick up anything at any time, and I’ll always respond. That’s it. Excellent. Well, thank you so much for joining me today.

It’s been a great pleasure, Eric.

Thanks a lot for the invitation.

I appreciate it. Absolutely. Thank you.

Thank you for listening to The Safety Guru on C-suite Radio. Leave a legacy. Distinguish yourself from the past. Grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.

ABOUT THE GUEST

Having been an integral member of some of the world’s most respected high-performance aviation organizations, Ian Hollingworth is able to share unique insights into truly world-class standards, behaviors, and cultures and how they are both built and maintained. 

Drawing upon his unique experiences flying military fast jets and within commercial aviation, Ian will engage your audience with anecdotes and tips on how to build winning teams, inspire great leadership, and overcome adversity whilst maintaining focus in challenging and pressurized scenarios. 

Ian is extremely passionate about people reaching their full potential and setting big goals; for the past 20 years has worked with some of the world’s most respected businesses in order to develop the talent of tomorrow. 

For more information: https://www.planetalks.com

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