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The Duncan Download Blog: Business Aviation Advice & Observations

The Interior Shop Helped Duncan Aviation Transition From Sales To Service

Posted by Kate Dolan on Tue, Jan 26, 2016 @ 12:42 PM

1982 had barely flipped a calendar page when Duncan Aviation opened its brand spankin’ new Interior shop, and 19-year-old Matt Spain was one of the shop’s first five employees.

1982MattSpain-employee-ID_SM.jpgHe’d been working for a company that refurbished aircraft interiors in 1981 when his good friend Chip Mosley encouraged him to take a look at Duncan Aviation.

Matt liked what he saw, was hired by Bob McCammon. Matt began his career here on June 22, 1981 in the Paint shop, and he moved to the new Interior shop a few months later when it opened.

“On the day the new Interior shop opened its garage door, I was there,” says Matt. “We didn’t yet have a Design Center or a Cabinet shop, and we mostly did soft good replacement and Interior repairs. We fixed broken seats, hinges and armrests and installed carpet, headliners and side ledges. And we sewed. We all knew how to sew, or we learned on the job.”

Matt, who will celebrate his 34th anniversary with Duncan Aviation in June, is the only one of the original Interior shop employees who’s still at Duncan Aviation. Housed in a garage in one of the old hangars, Matt worked with Ray Butkus, Arnold Goodlett, Dennis Hansen and Mike Harris, and Mike Winters supervised the small staff.

“Ray and Arnold wereMatt-Spain_sm.jpg the upholstery specialists, Mike could do a little of everything, and I focused on completions and modifications,” says Matt.

During those early years, the guys in the Interior shop worked on primarily 25 and 30 series Learjets, Jetstars and Sabreliners. The biggest aircraft they touched was a GII.

“In addition to the fact that I got to work on an airplane, I loved working with my hands and seeing the difference between before and after,” says Matt. “It is so rewarding to see the look on owners’ faces when they pick up their aircraft and say ‘Wow! You guys are really good at what you do!’”

Cabinet work was outsourced to Dwight Moody’s cabinet shop in the Haymarket. In 1983, Duncan Aviation bought that cabinet shop and many of its employees became Duncan Aviation employees. Gerry Hilde, who retired in October 2015 after 32 years, was one of the original Cabinet shop employees who transitioned to Duncan Aviation after the acquisition.

Around that time, the Interior shop and the newly acquired Cabinet shop moved from the garage to the backside of the LAI hangar (now Hangar C). Duncan Aviation also hired Interior Master Finish Specialist Steve Reznick as its first finish guy. 

“Before Steve, we did whatever we could to get by,” says Matt. “He knew and taught us materials, products and methods that we just didn’t know. Steve showed us how to match stains and fix damaged areas, he introduced a whole new interior painting system and he taught us about faux finishing, too. He knew clear coats and materials that worked on wood. With his knowledge and experience, Steve took the shop to a whole new level.”

In 1985, Matt transitioned to the Interior shop Team Leader, and he says he was a man on a mission.

“As a brand new Team Leader I was a hard driver focused on getting aircraft finished and delivered on time,” says Matt. “I was learning how to be a manager and how to conduct business in a professional manner, but I had high expectations. I worked right alongside my team, but if we were told something had to be done by Friday, I’d make sure it was done by Friday no matter how many hours we had to work.”

As Duncan Aviation’s reputation grew in the industry and the Interior shop grew (by roughly 18% each year), Matt grew professionally. He was managing the Interior shop, was married and had two children, and Skip Madsen and John Slieter encouraged Matt to go to college. With tuition assistance from Duncan Aviation, Matt went to Doane College and graduated with a degree in Business Administration, with an emphasis in management.

“It was an interesting time, but my education was timely and extremely valuable,” says Matt. “I was insanely busy, but I’d go to school at night and apply the principles I had learned the next day on the floor.”

Matt began managing the Interior shop in 1991, and he oversaw the growth of the production team from 35 people to more than 200, with 28 team leaders. As business picked up and aircraft transitioned from small to mid-sized cabins, the Interior shop outgrew its space.

Members of the Interior shop, including Matt, were called upon to submit their ideas to Tectonic Management Group who asked for our input on the design and layout of the new shop. In 2001, on the day President George W. Bush was inaugurated, the Interior shop opened in its current location in Hangar D.

In 2007, Matt left the Interior shop to work with our NetJets Program.  He transitioned to Project Manager in 2009 and then on to Paint and Interior sales in 2010. He spent nearly 30 years on the production side, managing and building teams.  When Mike Minchow, then Manager of NetJets and Sales, asked him to join the sales team, Matt jumped at the opportunity.

“I often thought sales would be a good next step for me” says Matt, and he credits Senior Sales Representative in Completions and Modifications Service Sales Tracey Boesch for teaching him the art of selling interiors for Embraer and Bombardier aircraft, even though she specializes in sales for Dassault Falcons and Learjets.

“I love sales, and it’s been a welcome change from managing people,” says Matt. “The experience of working on the floor and managing people has given me an advantage in sales, though. I know what we’re capable of, and I know what questions to ask. From a customer’s perspective, the whole process should be seamless from proposal to production. In order to offer that kind of experience, it’s important that we sales people ask the production folks a lot of questions. Learn from them; let them help you when you’re writing a quote. Go and ask them questions.”

During Matt’s tenure with Duncan Aviation, the Interior shops’ capabilities grew from the original handful of airframes to dozens, including Falcon, Gulfstream, Global, Challenger, Hawker, Citation, Learjet, Embraer, Hawker, King Air, Astra/Westwinds, and more.

The Interior Mods/Completions shop is in Manager Jared Stauffer’s capable hands now, and in partnership with the Duncan Aviation Design Center, offers custom designs by professional designers, quality products and meticulous attention to detail. Over the years, the Interior shop has evolved from its humble beginnings to a production crew that’s capable of refurbishing headliners, building custom cabinets, upholstering chairs and divans, constructing executive tables, and much more.

Tags: Interior Refurbishment, 60th Anniversary

Aircraft Sales and the Art of Listening

Posted by Diane Heiserman on Thu, Jan 21, 2016 @ 04:35 PM

Peter Burwell’s experience with aircraft consignments have not all been positive experiences. “I have had several brokers feed me a line of garbage, telling me what they think I should do in order to achieve their objectives, not mine.”

While Burwell Enterprises’ 39th aircraft, a Falcon 900EX, was in prebuy at Duncan Aviation in Battle Creek, Michigan, Peter, president & CEO, sought recommendations on whom to work with in order to sell number 36, a Challenger 601. It took no time at all before he was handed the name of Doug Roth, one of Duncan Aviation’s Aircraft Sales and Acquisition team members.

Burwell Enterprises has operated and flown so many aircraft over so many years that when it comes time to add to or upgrade their fleet, Peter puts his trust in the experience of his flight department to research and find the right replacement aircraft while at the same time working with a broker to handle the previous aircraft’s consignment.

Although because of previous encounters, he was skeptical when he picked up the phone to call Doug Roth.

DRoth_SM.jpgDoug Roth, Duncan Aviation Aircraft Sales

Doug has been selling aircraft for customers for more than 36 years. During that time, he has learned that no two transactions are alike. What works for one customer will not necessarily work for the next. So the first thing he does when he talks with a client is LISTEN.

Within a few minutes of speaking with Doug on the phone, Peter knew this experience would be different. “Doug was honest and upfront. He provided me with the facts without the fluff. He shot me straight and I believed him,” said Peter. “I feel I can trust him.”

After meeting with Peter and examining the Challenger, Doug tapped into the technical resources at Duncan Aviation. Armed with the knowledge of airframe, engine, avionics and interior experts and his personal knowledge of and experience with the preowned aircraft market, Doug told Peter exactly what he would do to best represent him and the aircraft. Then, he followed through and did what he said he would.

“Whether buying or selling, I work for my client every time, keeping their objectives in mind. ” says Doug. “I listen to them and create a plan that leverages all the resources I have at Duncan Aviation combined with my knowledge of aviation and the aircraft sales aftermarket.”

It may be several years down the road, but Peter says he will absolutely return to Doug to sell number 39.


Read more from the Fall 2015 Duncan Debrief Magazine

The Duncan Debrief free publication is available for aviation enthusiasts around the world through mail and online. To receive the magazine, subscribe here. Have an iPad? Access the magazine through the Duncan Debrief app. Search for Duncan Debrief in Apple’s App Store and download it. Once downloaded, you can receive push notifications each time a new Duncan Debrief magazine is published. 

Tags: Aircraft Sales

Duncan Aviation Line Services: Decades of Quick Turn Service—And More

Posted by Lori Johnson on Tue, Jan 19, 2016 @ 08:00 AM

Duncan Aviation began providing aircraft fuel services in 1963, when the company opened a state-of-the-art facility at the then-new general aviation side of the Lincoln Municipal Airport in Nebraska. Aircraft at the time couldn’t make coast-to-coast trips without stopping to refuel and customers expressed to Duncan Aviation team members that they wanted fast service that would allow them to get back in the air quickly. Duncan Aviation soon became well-known for the Duncan Quick Turn, which promised a fuel stop in 10 minutes or less.

bob_mccammon.jpgBob McCammon, now an Aircraft Sales Representative, has been with Duncan Aviation since 1968. He spent several years in the early 1970s as the Line Service Manager. He remembers the early Duncan Quick Turns well.

“We had 10 to 20, sometimes as many as 30 aircraft a day visiting Duncan Aviation for Quick Turn fuel,” Bob says. The company offered pilots unique ways to better meet their fuel service. A Falcon pit was constructed that gave Falcon 20 pilots a lower point for their nose gear, tipping the fuel tanks and allowing the aircraft to take on more fuel. And the company would have three fuel trucks available with two hoses each to more quickly service the six-tank Jetstar, he says. “We also provided maintenance help and troubleshooting if the operator had any issues. This really helped expose future customers to our small FBO in the Great Plains.”

Line-Photos_004.jpg

Duncan Aviation still offers Quick Turn fuel service at all of its main FBO locations (Battle Creek, Michigan; Kalamazoo, Michigan; and Lincoln) along with many other amenities and access to nose-to-tail support services. Our line crews are known for quick and convenient line service and our front desk personnel are known for hospitality. Repeat customers are greeted by name and new visitors are welcomed and shown the services they can expect: office space, conference rooms, pilot lounges, advanced weather planning, and café service, to name just a few. See a full list of FBO amenities here.

If you are attending the NBAA Schedulers and Dispatchers show January 19-22 in Tampa, Florida, this week, stop by Booth #1219 to talk with our Line Service team members to hear about how we have met needed FBO Services for customers for decades.


2016 is a special year. It is Duncan Aviation’s 60th year of helping business aircraft operators be safe, efficient and productive. For six decades, customers have asked us for solutions and services. We are celebrating our 60 years by telling the stories about the people of Duncan Aviation who listened and took action.

Celebrate with us by subscribing to the Duncan Download blog, following us on Facebook and Twitter (@DuncanAviation) and visiting our anniversary website at www.DuncanAviation.aero/60.

Lori Johnson has been the Marketing Communications Manager for Duncan Aviation for more than 20 years. She enjoys working with the smart and passionate aviation experts at Duncan Aviation, helping them connect with and educate customers about important industry topics.  

Tags: 60th Anniversary, FBO Services

Duncan Aviation : Aircraft Turbine Engine Services From the Beginning

Posted by Diane Heiserman on Fri, Jan 15, 2016 @ 01:45 PM

IMG_1979.gifIn The Beginning...

In 1973, Leo Sawatzki stepped off the Navy ship U.S.S. Constellation and signed on with Duncan Aviation in Lincoln, Nebraska, as a jet engine mechanic. He was prepared to service GE CJ610 and Pratt & Whitney PT6 engines. However, it wasn’t long after he arrived that Airesearch introduced a new engine, the TFE731. This engine showed lots of promise. Leo and six other Duncan Aviation turbine engine mechanics, with only a four-section wooden box filled with plugs, caps and hardware, were eager to discover and learn all they could.

Early on, as with many first-generation technologies, this new engine had some growing pains. Our engine technicians were called upon many times to provide Aircraft on Ground (AOG) services. Just by the sheer volume of hands-on, field-repair work, they discovered first-hand how the engines operated and what was needed to fix them.

Seeing an unmet need, it didn’t take long before we invested in the necessary tooling and equipment to dispatch a team to any location whenever the calls came in. And the calls did come. On a weekly basis, mechanics were sent as far away as Iceland, Argentina or Canada... or to the hangar just down the road. Their quick responses made them the go-to guys for TFE731 on-the-road engine services.

This Duncan Aviation team was the original AOG engine road crew before such crews became popular. This practice of being ready to travel at a moment’s notice is the genesis of Duncan Aviation’s Engine Rapid Response Teams (RRT). Today, our RRTs are strategically located all across the United States, able to reach an operator’s location in as little as 24 hours.

The Authorizations

We had become a reliable resource for TFE731 operators flying all over the world, proving that even a small shop from the middle of America had a worldwide impact. In 1981, we hit two milestones and received major level authorization to work on the Airesearch TPE331 and TFE731engines. These authorizations allowed all who previously relied upon us to come to their rescue during times of need to entrust their engines to us for high-level, expert Major Periodic Inspection (MPI) service.

In those early years, the Duncan Aviation engine team disassembled the engines and sent them out for repair, relying on the abilities and time schedule of others. The culture at Duncan Aviation has always been to deliver only the best, on time and at budget. Unfortunately, not every company has the same level of customer commitment. "We knew we could provide these same services better, faster and cheaper," says Leo. With that, the decision was made to invest in the research, tooling and training to bring those capabilities in-house.

Engine Services Today

Engine-Line_002.gifToday, Airesearch is now Honeywell and Duncan Aviation Engine Services has grown to include 73 licensed factory-trained turbine engine technicians working two shifts to provide line maintenance, MPIs, AOG road services and technical expertise, in support of Honeywell, Pratt & Whitney, Rolls Royce and Williams International aircraft turbine engines.

The "four-room" wooden box is now a modern 20,000-square-foot facility with 12 separate engine bays.  In 2014, we added a 4,050-square-foot engine line maintenance shop to support in-house aircraft maintenance events. This makes Duncan Aviation truly a one-stop shop for all turbine engine maintenance events.

Obtaining the maximum performance out of your engines is an art mastered by the Duncan Aviation turbine engine professionals. Generations of experience combined with investment in all Original Equipment Manufacturer (OEM)-authorized repair methods bring the most reliable and proven techniques to ensure performance and reliability of your engines.

Leo, now the Engine Acquisitions and Sales Manager, has seen first-hand the changes the TFE731 has gone through over the last 38 years. One thing has remained constant—Duncan Aviation has remained Duncan Aviation. The company has never changed its name, its ownership or its commitment to delivering only the best.

Years To Come

In 2015, we reached another milestone with the designation as a Honeywell AS907 (HTF 7000) Series Minor Maintenance facility.

Duncan Aviation is the only U.S.-run, family-owned company with this length of historical and technical experience on the TFE731. We are still Duncan Aviation. We have been there since the beginning. And we’ll be here for generations to come.

Tags: Engine Maintenance

At Duncan Aviation, Standing Still is Not An Option

Posted by Duncan Download Blog on Fri, Jan 08, 2016 @ 09:28 AM

At Duncan Aviation, we don’t wait for others. We lead while others follow.

It is in the very fabric of our culture with every team member to stay at the front of business aviation, providing innovative, responsive and revolutionary customer service.

We listen. We act. Our customers are loyal.

Listen as our team members talk about what excites them about the future of Duncan Aviation

 


60-theme.jpg2016 is a special year. It is Duncan Aviation’s 60th year of helping business aircraft operators be safe, efficient and productive. For six decades, customers have asked us for solutions and services. We are celebrating our 60 years by telling the stories about the people of Duncan Aviation who listened and took action.

Celebrate with us by subscribing to the Duncan Download blog, following us on Facebook and Twitter (@DuncanAviation) and visiting our anniversary website at www.DuncanAviation.aero/60.

Tags: 60th Anniversary

VIDEO Falcon 900: Everything and the Galley Sink

Posted by Duncan Download Blog on Tue, Jan 05, 2016 @ 09:48 AM

N183WW0347_blog.gifRead the Fall 2015 Duncan Debrief to see more gallery photos and details of this project.

The best laid plans often go awry. Business aviation maintenance is no exception. Most maintenance directors will tell you it’s almost impossible to plan for everything that might pop up during a large inspection that is coupled with a variety of updates and upgrades.

So how can Duncan Aviation guarantee turntimes? The answer is really pretty simple but often overlooked by those who don’t have the right people and the right processes.“We plan ahead and work hard,” says Finish Team Leader Tony Houk. “We still encounter hurdles, but we work together as a team to overcome them.”

Business jets are incredible assets. When they’re in our hangars for months, we recognize the owners are missing a valuable resource, so we do our best to meet turntimes and set efficient schedules to get customers in, out and safely on their way.

When an 18-year-old Falcon 900 was added to the schedule at Duncan Aviation’s Lincoln, Nebraska, location, promising a finite out date seemed far-fetched—because it was. A laundry list of inspections, avionics, interior upgrades and new paint packed the to-do list.

During the inspection, a handful of corrosion squawks required extra hours, making serious teamwork mandatory in order to adhere to a tight schedule. With some teams needing access to the same areas at the same times, schedules were changed to second or third shifts so progressing could be maintained at the same rate.

Everyone realized they needed to make it happen, even if that meant working in hourly blocks, or changing shifts and working weekends.

And all that teamwork paid off. The aircraft delivered, the customers were ecstatic and Duncan Aviation was able to add another success story to the books.

Watch this video and witness firsthand, how all the teams (airframe, paint, interior and avionics install) accommodated each another to do what was right for our customer.

 

Tags: Videos, Falcon

Duncan Aviation Team Members Resolve To Be Better For You in 2016

Posted by Diane Heiserman on Thu, Dec 31, 2015 @ 01:31 PM

2016Jan_Newyear.jpgWe all know the drill. As soon as the ball drops we make promises to ourselves to improve life in the coming year. The most common resolutions are to improve fitness, stop vices or change a behavior.

But this is also a time to make and renew commitments to improve our work for the benefit of our customers.

A group of Duncan Aviation team members from all levels and across the country were asked ‘What is your Duncan Aviation New Year’s Resolution?’

Here’s what a few of them had to say.

Todd Duncan Aviation Duncan Aviation Chairman

For me personally, I want to fly more. I’m not in the aviation business just for the benefits of the transaction, I’m in it because I love to fly and I want to spend more time in my personal aircraft.   

On a business level, I am going to celebrate all year the fact my family has been in this business for sixty years and have remained family-owned. In an industry where everyone is for sale, I am committed to remaining independent. For sixty years, we have built our brand around our team members, their families and the American craftsman. We are up for sixty more.

Michael Hill Manager, Engineering Services, BTL

Continue to educate myself and others on Duncan Aviation’s Certification and Engineering processes so we can all understand why we do what we do.

Chris Gress, Manager Duncan Aviation Parts and Rotables Sales, LNK

My goal for 2016 is to get more of our Parts & Rotables Sales Team out to meet Duncan Aviation customers at industry events throughout the year.

Jeff Schipper, Project Manager, PVU

During the coming year, we will continue to seek new offerings and capabilities for our customers at our Provo, UT, location, as well as improve responsiveness to AOG events.

Steve Gade, Vice President of Marketing and Business Development, LNK                                    

Do a better job of asking our customers the right questions and listen carefully to their responses so that I may better understand exactly how we can better serve them so they can better serve their customers.

Andrew Arcuri Assistant Manager, Engine Rapid Response Teams

Duncan Aviation Rapid Response Team has grown significantly in 2015, adding seven new technicians alone to the east coast. No matter how carefully we select the technicians for the Rapid Response Team or how thoroughly we prepare them with product knowledge training, there is no substitute for reinforcing customer service communication skills. For my 2016 resolution, I look to better communicate with our customers regarding aircraft/engine workscope, aircraft return-to-service time and an accurate cost of service. I look forward to a great 2016 and thank you to all our customers that make working for Duncan Aviation a great personal experience.    

Melissa Raddatz Avionics Sales Representative, BTL

To continue be a person of integrity, to provide high quality customer service and to seek excellence in all I do.

Joe Tulowitzki Turbine Engine Service Sales Representative

For the coming year I am committed to working closely with my team to say what we are going to do and then deliver exactly what we say, leaving no surprises for the customers in the end.

A Culture Unchanged 

From the beginning, Donald Duncan, Duncan Aviation’s Founder, believed that if you take care of employees, employees will take personal pride to improve and then care for customers. 

To this day, this belief is unchanged. During 2016 as we celebrate our 60th anniversary, we resolve to take personal accountability towards improvement so that we are better able to serve you, our customer.

Celebrate with us by subscribing to the Duncan Download blog, following us on Facebook and Twitter (@DuncanAviation) and visiting our anniversary website at www.DuncanAviation.aero/60.

 

Tags: Announcements, 60th Anniversary

Duncan Aviation: Being The Voice of Clarity in an Acronym-Happy Industry

Posted by Lori Johnson on Tue, Dec 29, 2015 @ 08:00 AM

The business aviation industry is highly technical, highly regulated, extremely dynamic and full of acronyms. If you are like many in the industry you don’t have the luxury of time or resources to do proper research and fact-finding on the most important issues facing your flight operations.

That’s why we do it for you. It’s free of charge and yours for the taking.

Todd Duncan was recently asked why, in this highly competitive industry, the company gives away such robust technical resources to operators. Here is what he had to say.

“This is not a new concept by any means. Duncan Aviation has been educating customers for decades. Aviation is highly regulated and mandates can be confusing to those who don’t live and breathe them every day. Ultimately, our goal is to guide operators to make the most of their assets and be able to use them efficiently and effectively. The best way to do this is to ensure they are able to make informed decisions for their aircraft and their flight department. Doing so ensures that they will continue to operate their aircraft, and we will be able to continue providing them with meaningful and valued services. If operators really understand the work they need and want to have completed on their aircraft, they are able to make decisions that allow them to maximize their downtime and, in turn, make more efficient use of their asset.”

That’s why we do it. Now here’s how.

Straight Talk Books

Straigh_Talk_covers.jpgThe first Duncan Aviation Straight Talk book was written in the early 1990s by our avionics experts when the mandates for Traffic Alert & Collision Avoidance Systems (TCAS) in business aircraft were being discussed and implemented.

Since then many Straight Talk books have been published to address complicated avionics mandates and other industry initiatives, such as NextGen, FANS, ADS-B and RVSM. The same Duncan Aviation technical experts who author these informative books are available to operators by phone anytime they wish for clarification or more information.  

Download Straight Talk books here: http://www.duncanaviation.aero/resources/straight-talk/

Duncan Intelligence newsletters

DI-thumb.gifTwenty years ago, we started a quarterly technical newsletter with airframe-specific information that was faxed to operators. Our goal was to share technical tips and information that operators could use to better maintain and care for their aircraft.

Our goal has remained the same, but now the Duncan Intelligence is a monthly e-mail subscription for business aircraft operators around the world. All articles are written by our team of airframe-specific technical representatives.

Subscribe to the Duncan Intelligence here: http://www.duncanaviation.aero/intelligence/

Presentations and Seminars

In keeping with our goal of educating aircraft operators, we have held a variety of seminars and educational courses over the years, from two-day-long conferences at our facilities to hour-long presentations at major industry tradeshows and events.

In 2016, we will continue this tradition. Those events will include our popular ADS-B and NextGen seminars.

Check out all future Duncan Aviation events here: http://archive.da.aero/events/


2016 is a special year. It is Duncan Aviation’s 60th year of helping business aircraft operators be safe, efficient and productive. For six decades, customers have asked us for solutions and services. We are celebrating our 60 years by telling the stories about the people of Duncan Aviation who listened and took action.

Celebrate with us by subscribing to the Duncan Download blog, following us on Facebook and Twitter (@DuncanAviation) and visiting our anniversary website at www.DuncanAviation.aero/60.

Tags: 60th Anniversary

Duncan Aviation Sends You...

Posted by Duncan Download Blog on Thu, Dec 24, 2015 @ 08:00 AM

A World of Good Wishes. 

HappyHolidays.jpgOne of the real joys this holiday season is the opportunity to say thank you for your business and wish you the very best throughout 2016!

Tags: Announcements

Duncan Aviation's R&D Has Had a Ripple Effect Throughout the Industry

Posted by Diane Heiserman on Tue, Dec 22, 2015 @ 04:24 PM

With only $30,000 and 90 days, Ed Gilmore, then Duncan Aviation Avionics Bench Tech was challenged to design and develop a working prototype to replace the Collins 980L autopilot test set.

He did it. That was 1981 and only the beginning.

1994Don-Reeves_RichTeel_Ed-Gilmore.gifOriginal R&D Team circa 1984 

With the help of a local community college instructor and another former Duncan Aviation team member, Ed designed and built the DATE 1 (Duncan Aviation Test Equipment).

It was probably the first-ever computer controlled test set in General Aviation. It used an Apple II-E computer with whopping 64K of memory. It was functional and remained in service for many years.

This test set laid the innovative foundation for what would eventually become Duncan Aviation’s Research and Development (R&D) team. Established in 1984, the R&D department was initially created to support Duncan Aviation’s Avionics Satellite network.

The initial Avionics Satellite shops opened up across the country with the first generation DA test equipment that consisted of large panels taking up a lot of space. In order to grow, the equipment needed to shrink. R&D’s task was to develop test equipment that integrated the current equipment into smaller boxes with increased testing capabilities. But another important requirement was for the equipment to look high-tech and “cool”.

softset.gif
Photo of an original Softset developed by the Duncan Aviation R&D department. 

By 1985 the team began the development of equipment that used software rather than hardware called SoftSet. SoftSet was able to test 80 percent of the avionics units that arrived at Duncan Aviation for repair or overhaul.

By 1990 DATE 1 was upgraded to DATE 1A, converted to run on a Macintosh computer and included the addition of Artificial Intelligence (AI). AI assisted in troubleshooting units and offered solutions based on repair history. The equipment got smarter with each test and became more accurate with repair recommendations.

By the mid-90s, both SoftSet and DATE 1 were advanced further with the ability to handle an advanced number of capabilities with a significantly smaller footprint…and they looked “cool”.

DATE 1B became fully automated in 1996 significantly reducing test times. For example the 4.5 hour test of a 562A-5M5 Collins A/P was reduced to 50 minutes and the eigh hour test of the CA-200 Sperry A/P was able to produce results in only three hours. This freed the technicians to do other things and get the units returned to customers quicker.

For the last 30 years, Duncan Aviation’s R&D has provided far more than just support for the Avionics Satellites. The lion share of their projects are smaller dedicated circuits, mockups, test boxes, modules, and mechanical jigs for the rest of the company.

These projects have helped facilitate Duncan Aviation to hold and grow in the avionics repair market, by providing quality test equipment, support documentation and assistance with certification.

Chris Hogg, R&D Tech, says that this innovation is a partnership between R&D and the technician on the floor. “When the technician sees an opportunity to make how they do their job better, faster or more efficient, they get us involved. We work together to provide services that bring the idea to reality, which is very gratifying. We have had more than a thousand such projects, each a story unto itself.

Other R&D Designed Projects

The Falcon Flight Control Force Tool measures the force required by the pilot to move the control wheel and rudder pedals on Falcon 2000, 900 and 50 series aircraft. It has been recently granted ‘tool equivalency’ status by the FAA after an extensive comparison to the original factory tool.

The R&D also crafted Tail Stand Alarms that notify the mechanics prior to the aircraft making contact with the tail stands.

R&D utilizes 3D printing technology to reduce fabrication time and project costs. It has also been used to provide mockups of in-house developed antenna mounts for aircraft.

DATE 1C upgrade is in development and will replace the current Mac computers used in the Duncan Automated autopilot/flight director Test Equipment with PCs.


The development of this software and equipment is one of the many examples demonstrating how Duncan Aviation employees strive to stay at the front of business aviation, providing innovative, responsive and revolutionary customer service.

Innovative technology has a ripple effect that doesn’t end when a project is over. Today’s fresh new ideas become the foundation and infrastructure for tomorrow’s next big thing. This natural evolution allows those who are willing, the ability to think creatively and find the next step.

Tags: Avionics & Instruments, 60th Anniversary

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