Sofema Online (SOL) considers key aspects of HF Design Considerations related to EWIS

Introduction

To ensure the effective integration of human factors into Electrical Wiring Interconnection Systems (EWIS) design, it is essential to focus on accessibility, simplicity, and error-proofing.

• The design should enable easy access for maintenance while minimizing complexity and the potential for incorrect assembly or connection.

• Ergonomic considerations play a vital role in reducing human error by ensuring that components are positioned and handled comfortably, even in challenging working environments.

• Human factors-based safety assessments, including Failure Mode and Effects Analysis (FMEA), should be conducted to identify and mitigate risks associated with human interaction with the design.

• Additionally, providing comprehensive training and establishing feedback mechanisms will help to capture real-world challenges and continuously improve the design process, ensuring that human performance limitations are effectively addressed.

Accessibility and Maintainability

• Design should consider the ease of access for maintenance personnel to perform inspections, repairs, and replacements without introducing damage or human error.

• Example: Routing of wiring should avoid confined spaces where access may require the removal of other components or awkward positioning.

Ergonomics

• Consider the physical limitations and strengths of maintenance staff when designing EWIS installations.

• Example: Ensure that connectors and wiring bundles are positioned to allow ergonomic handling without strain.

 Installation Complexity

• Minimize complexity in wiring routing to reduce the risk of errors during installation and maintenance.

• Example: Reducing excessive wiring lengths or crossover points reduces the likelihood of misrouting.

Environmental and Operational Factors

• Design should consider environmental stressors such as vibration, temperature changes, and humidity, which may degrade wiring over time.

• Example: Use appropriate shielding, insulation, and strain relief to protect wiring from environmental and mechanical stressors.

Human Error Potential

• Reduce the risk of human error during assembly, inspection, and maintenance.

• Example: Implement keyed connectors to prevent incorrect assembly.

• Example: Design harnesses and connectors that are easy to identify and differentiate.

Design Strategies to Embed Human Factors in EWIS Design - Human-Centered Design Approach

• Engage maintenance and operational personnel during the design process to gather feedback on installation and inspection challenges.

• Conduct design reviews with a focus on human interaction and limitations.

Design for Inspection and Maintenance

• Design EWIS in a way that minimizes disruption during maintenance.

• Provide accessible and visible test points.

• Ensure that critical wiring runs are accessible for borescope inspection without dismantling other systems.

Error-Tolerant Design

• Use physical design features to prevent incorrect assembly or connection (e.g., different-sized connectors).

• Introduce design features that make incorrect installations physically impossible.

Use of Advanced Materials

• Select materials resistant to chafing, corrosion, and environmental stress to reduce the need for frequent maintenance.

• Use lightweight materials to reduce the load on connectors and reduce the chance of breakage.

Training and Documentation - Comprehensive Training for Design Staff

• Provide training on human factors and their influence on EWIS design and maintenance.

• Focus on the risks of improper handling and stress on connectors and harnesses.

Technical Documentation and Procedures

• Clear and complete documentation to support maintenance and troubleshooting.

• Include standardized wiring diagrams and fault isolation manuals.

• Provide QR codes linked to digital manuals for quick access during maintenance.

Compliance and Human Factors Integration Process - Human Factors Assessment – Include human factors evaluation as part of the design review process.

• Failure Mode and Effects Analysis (FMEA) – Assess the impact of human error in EWIS design and maintenance.

• Certification Planning – Develop a Human Factors Certification Plan (HFCP) as part of the overall compliance plan.

• Safety Risk Assessment – Conduct human performance-based risk assessments during design and operational phases.

Next Steps

Sofema Aviation Services and Sofema Online provide classroom, webinar and online training covering all aspects of EWIS. Please see the websites or email team@sassofia.com.