Position SummaryThe Flight Test Safety Program Manager is the functional owner of flight test operational safety and the Flight Test Safety Management System (FT-SMS). The role manages the flight test hazard and risk process, maintains the Flight Test Emergency Response Plan, leads investigations, and drives a proactive safety culture across all test activities. The Flight Test Safety Program Manager has clear authority to challenge and stop unsafe test activity and serves as a key interface between Flight Test, Flight Safety, Archer Air (for commercial alignment), Certification, and site EHS on safety-of-test issues.
Key ResponsibilitiesHazard Identification and Risk Management- Actively identify potential hazards across all flight test operations (aircraft, ground, airport environment, airspace, and support equipment) and maintain a structured Flight Test Hazard Log.
- Lead Safety Risk Management (SRM) for flight test activities, including documented risk assessments for new test cards, envelope expansion, new configurations, routes, and changes to test areas.
- Participate in flight test planning, safety-of-test reviews, and test readiness reviews to ensure hazards, mitigations, and risk acceptance are explicitly captured and agreed before execution.
- Conduct routine inspections and safety observations across hangars, flight lines, control rooms, and support areas, engaging personnel at all levels to surface latent and emerging hazards.
Flight Test SMS and Safety Governance- Develop, implement, and maintain the Flight Test Safety Management System (FT-SMS) in alignment with Archer's enterprise SMS and relevant regulatory guidance.
- Define and track flight test safety performance indicators and leading metrics (e.g., event rates, exceedances, high-potential near misses, deviations from procedures) and routinely present trends to leadership.
- Lead a periodic Flight Test Safety Review/board to review hazards, SRM outcomes, incidents, risk acceptances, and corrective actions with Flight Test, Flight Safety, Engineering, Operations, and EHS.
- Manage flight test safety reporting channels (occurrence reports, hazard reports, safety concerns), ensuring reports are captured, evaluated, prioritized, and tracked through closure.
Emergency Preparedness and Response- Own and maintain the Flight Test Emergency Response Plan (ERP) annex, including procedures, notification chains, and coordination with airport authorities, ARFF, and local agencies.
- Plan, schedule, and conduct flight-test-focused emergency drills and exercises (tabletop and functional), document findings, and drive timely closure of identified gaps.
- Support pre-mishap planning and notification procedures and act as a key safety lead during flight test emergencies or significant events, including participation in post-event reviews and debriefs.
Investigations, Assurance, and Reporting- Lead or co-lead investigations of flight test incidents, occurrences, and high-potential near misses using recognized investigation and root cause analysis methods.
- Produce clear, technically sound investigation reports identifying root causes and contributing factors, and define corrective and preventive actions; ensure actions are tracked to closure and lessons learned feed back into procedures, training, and SRM.
- Conduct targeted flight test safety audits/assessments of operations, procedures, and manuals to verify compliance with Archer standards, SMS requirements, and applicable regulations, using established flight test SMS audit concepts as a guide.
- Prepare concise, data-driven safety reports and presentations for Flight Test leadership, the Sr Director Flight Safety & Chief Test Pilot, and senior management, highlighting trends, emerging risks, and key action status.
Culture, Training, and Engagement- Foster a strong safety culture within flight testing by being visibly present in day-to-day operations, engaging with pilots, test personnel, engineers, technicians, and operations staff.
- Facilitate regular safety discussions (briefings, debriefings, toolbox talks) focused on current hazards, recent events, and upcoming test risk.
- Partner with Training, Flight Safety, and EHS to develop and maintain flight test-specific safety training, including SMS awareness, human factors, safety-of-test expectations, and emergency response roles.
- Promote open reporting and just-culture principles in how hazards, incidents, and errors are raised, investigated, and discussed.
Program Management and Cross-Functional Interface- Act as the program manager for Flight Test Safety, maintaining a clear roadmap, prioritized action register, and status tracking for safety initiatives and corrective actions.
- Integrate safety requirements into test plans, route/procedure development for proving activities, management of change, and test readiness processes affecting flight test operations.
- Collaborate closely with the Sr Director Flight Safety & Chief Test Pilot, Flight Test leadership, Archer Air safety/operations (for commercial alignment), Certification, Engineering, and site EHS to align on risk tolerances and safety-of-test decisions.
- Coordinate with engineering and certification teams on safety-of-test aspects of new designs and modifications, while leaving formal certification findings to DER/ODA or other delegated authorities.
Required Qualifications- Bachelor's degree.
- Minimum 5 years of aviation safety experience or formal aviation safety training (e.g., airline, rotorcraft, business aviation, military, UAS/eVTOL, or flight test environment).
- Demonstrated knowledge of safety investigation techniques, root cause analysis, and technical report writing.
- Strong understanding of risk assessment and mitigation strategies, safety audits, and continuous improvement processes.
- Knowledge of human factors in aviation and its application to flight and ground test operations.
- Ability to analyze safety data and trends, anticipate potential risks, and recommend targeted mitigation strategies.
- Proven ability to communicate complex safety issues clearly and effectively, both verbally and in writing, to technical and non-technical audiences.
- Demonstrated ability to uphold high standards of integrity and ethical behavior, maintaining safety as the top priority even when in tension with schedule or other business pressures.
- Exceptional written and verbal communication skills.
Desired Qualifications- Pilot certifications (e.g., private, commercial) or other relevant operational experience in flight operations or flight test.
- Experience implementing or working within a formal Safety Management System (SMS), preferably in flight test, Part 135, or Part 121 environments.
- Direct experience with manned flight test safety, proving runs, route/procedure validation, or test conduct in fixed-wing, rotorcraft, or eVTOL programs.
- Familiarity with commercial airline or air taxi operations and the interfaces between test programs and entry-into-service.
- Professional safety or aviation certifications (e.g., CSP, CFIOSH, ASQ, or equivalent).
- Experience collaborating with FAA or other aviation authorities on safety or operational matters. Knowledgeable with FAA Order 4040.26C
