Key Responsibilities and Required Skills for Jet Aircraft Test Operator

🎯 Role Definition

A Jet Aircraft Test Operator is responsible for executing, documenting, and validating ground and flight test activities for jet-powered aircraft. This role encompasses pre-test inspections, engine and systems run-ups, instrumentation setup, data capture and analysis, troubleshooting, and safety enforcement to ensure aircraft meet performance, airworthiness, and regulatory requirements. The operator works cross-functionally with engineering, maintenance, quality, and flight crews to support certification, production acceptance, and in-service testing programs.

📈 Career Progression

Typical Career Path

Entry Point From:

Aircraft Maintenance Technician (A&P), Avionics Technician, or Test Technician
Engine Test Cell Operator or Ground Support Equipment Technician
Military Aircraft Crew Chief or Flightline Technician

Advancement To:

Lead Test Operator / Test Cell Supervisor
Flight Test Engineer or Test Program Manager
Quality Assurance Manager or Maintenance Manager
Certification Engineer or Production Test Lead

Lateral Moves:

Production Assembly Technician (final assembly/final outfitting)
Maintenance Planner / Technical Records Specialist
Avionics Integration or Systems Validation Specialist

Core Responsibilities

Primary Functions

Conduct comprehensive pre-test inspections and configuration checks of jet aircraft, including airframe, engine mounts, fuel and oil systems, hydraulics, landing gear, avionics, and environmental control systems to verify readiness for engine run-ups, taxi tests, and flight tests.
Execute engine start, warm-up, and controlled run-up procedures for turbofan/turbojet engines in both ground and test-cell environments, strictly following manufacturer procedures, company SOPs, and safety checklists to prevent damage and ensure personnel safety.
Set up, calibrate and operate data acquisition and instrumentation systems (DAQ), including strain gauges, pressure transducers, thermocouples, accelerometers, and digital avionics logging, and verify signal integrity prior to each test sequence.
Perform taxi checks, brake and steering function tests, and low/high-power ground runs to validate propulsion performance, nacelle/ducting integrity, anti-ice and bleed systems, and aircraft handling characteristics during ground test phases.
Execute functional checks of avionics, flight controls, autopilot, flight management systems (FMS), navigation radios, transponders, and communication systems as part of pre-flight and post-modification verification activities.
Capture, monitor, and analyze live test data during engine and flight tests using industry-standard software and tools; produce preliminary trend reports, annotated time-synced data plots, and summary findings for engineering review.
Follow and enforce all safety protocols for hot refueling, engine run-ups, APU operation, and high-energy system tests; establish and control exclusion zones and communicate safety status with the test team and ramp control.
Coordinate and brief multi-disciplinary test teams including test pilots, maintenance crews, engineers, quality inspectors, and GSE operators on test objectives, step-by-step procedures, risk mitigations, and abort criteria.
Document test activities meticulously in digital and paper logs — including detailed discrepancies, maintenance actions, serial numbers, configuration states, and sign-offs — to support traceability for certification or production acceptance.
Troubleshoot and diagnose system anomalies discovered during testing by performing methodical fault isolation, leveraging wiring diagrams, schematics, onboard fault indicators, borescope inspections, and engine test cell logs, then recommend corrective actions.
Participate in test program planning: review test plans, contribute to risk assessments and safety cases, estimate resource needs (fuel, oil, GSE, instrumentation), and sequence test points to maximize efficiency and data value.
Support certification and compliance activities by executing verification tests per FAA/EASA/TC methods, producing evidence packages, and liaising with regulatory representatives during witness testing.
Operate ground support equipment (GSE) and specialized test stands: power carts, hydraulic test rigs, environmental control units, jacking systems, load banks, and engine test cells while ensuring equipment inspection and readiness.
Perform post-test inspections and teardown checks to identify signs of wear, leaks, loose fasteners, or damage; validate post-test maintenance actions and update aircraft maintenance records.
Maintain and perform routine calibration checks on portable instrumentation and gauges; keep calibration records and schedule recertification to maintain measurement traceability.
Implement and document configuration control actions when temporary instrumentation or flight test modifications are installed, ensuring all changes are reversible and recorded in technical logs.
Contribute to root cause analysis and corrective action tracking by compiling test evidence, supporting engineering failure analysis, and participating in corrective/preventive action (CAPA) follow-ups.
Execute acceptance and delivery test runs for newly manufactured or modified aircraft, validating performance criteria and providing final sign-off documentation to production or customer representatives.
Train and mentor junior test operators and maintenance personnel on safe engine run procedures, test instrumentation setup, DAQ software basics, and test documentation best practices to build bench strength on the test team.
Participate in continuous improvement initiatives to refine test procedures, shorten test cycle times, reduce rework, enhance data quality, and improve safety — including updating SOPs and contributing to lessons-learned reviews.
Manage fuel/oil inventory and flow for test operations: ensure correct fuel grades, sample and analyze fuels if required, check for contamination, and document consumption for accounting and environmental compliance.
Liaise with suppliers and avionics/engine OEMs for specialized test support, test software updates, hardware builds, and troubleshooting support during complex certification or in-service investigations.
Ensure environmental and hazardous materials handling compliance during tests (fuel, hydraulic fluids, batteries, oil), including proper spill response readiness, MSDS access, and disposal protocols.
Maintain readiness to support off-site field tests, ferry operations, or rapid-response troubleshooting events, ensuring portable instrumentation kits, procedures, and trained personnel are deployment-ready.

Secondary Functions

Assist engineering teams with ad-hoc instrumentation requests and exploratory data collection for prototype validation.
Contribute to the organization’s test strategy and roadmap by providing operational feedback on repeatability, safety, and resource constraints.
Collaborate with maintenance planners and supply chain to ensure availability of parts and consumables needed for scheduled test campaigns.
Participate in safety stand-downs, incident investigations, and implementation of engineering change orders (ECOs) related to test findings.
Help maintain and organize test hangar/shop areas, inventory of test jigs, harnesses, and instrumentation to reduce test setup time.
Provide input to technical publications and maintenance manuals by documenting common test discrepancies and repair methods.
Support training program development by creating practical exercises, checklists, and competency assessments for new test operators.

Required Skills & Competencies

Hard Skills (Technical)

Deep working knowledge of jet engine systems (turbofan, turbojet), including start sequences, fuel schedules, bleed systems, and thrust control.
FAA Airframe & Powerplant (A&P) certification or equivalent civil/military maintenance certification (strongly preferred).
Experience with aircraft instrumentation and data acquisition systems (e.g., AeroVironment, Flight Data Recorders, NI LabVIEW, HAL Systems, or company-specific DAQ tools).
Proficiency in setting up, calibrating and troubleshooting transducers, thermocouples, pressure sensors, and accelerometers.
Ability to read and interpret aircraft maintenance manuals, wiring diagrams, system schematics, structural drawings, and engineering change documents.
Hands-on experience operating engine test cells, ground run stands, APUs, and supporting GSE such as GPU, hydraulic carts, jacks, and towbarless tugs.
Familiarity with avionics and flight control verification procedures (FMS, EFIS, autopilot, radios), including in-flight functional checks.
Proficient with MS Office suite for test documentation and reporting; experience with data analysis tools (MATLAB, Python pandas, Excel advanced functions) is a plus.
Practical knowledge of regulatory frameworks (FAA/EASA/TC) and production/test acceptance standards including Part 145/Part 21 processes.
Skilled in troubleshooting electrical, hydraulic, and pneumatic systems using multimeters, oscilloscopes, and hand-tools to isolate and resolve faults.
Experience maintaining calibration records and following ISO/IEC 17025-like processes for measurement traceability.
Proven ability to generate clear, concise test reports, discrepancies, and technical write-ups suitable for engineering and regulatory audiences.

Soft Skills

Strong attention to detail with a safety-first mindset, consistently enforcing test safety boundaries and procedures.
Excellent verbal and written communication skills for cross-functional briefings, test coordination, and report generation.
Analytical problem-solving capability and methodical fault-isolation mindset under time constraints.
Team player who can collaborate with engineers, pilots, quality, and supply chain while maintaining clear responsibility for test outcomes.
Ability to prioritize tasks and manage multiple concurrent test activities in a high-tempo production or certification environment.
Adaptability to operate in dynamic field conditions and to learn new avionics/engine platforms quickly.
Teaching and mentoring ability to develop less-experienced technicians and sustain team competency.
Strong organizational skills to manage test documentation, calibration schedules, and configuration control.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with technical certifications (A&P preferred) and significant hands-on aircraft maintenance/test experience.

Preferred Education:

Associate's or Bachelor's degree in Aviation Maintenance Technology, Aerospace Engineering Technology, Aeronautical Engineering, or a related technical discipline.

Relevant Fields of Study:

Aircraft Maintenance Technology
Avionics / Electronics
Aerospace or Aeronautical Engineering
Mechanical or Electrical Engineering Technology

Experience Requirements

Typical Experience Range: 3–8 years of progressive experience in aircraft maintenance, engine test operations, or flight/ground test roles.

Preferred:

5+ years experience performing jet engine run-ups, aircraft ground tests, and data acquisition for production acceptance or certification programs.
Demonstrated history of working with turbine engines and complex avionics suites in a production, MRO, or military environment.
Prior involvement in FAA/EASA witness tests, certification campaigns, or structured production flight test activities.