In the aeronautic industry, the performance demonstration of Non-Destructive Testing (NDT) procedures relies on Probability Of Detection (POD) analyses. This statistical approach measures the ability of the procedure to detect a flaw with regard to one of its characteristic dimensions. The inspection chain is evaluated as a whole, including equipment configuration, probe effciency but also operator manipulations. Traditionally, a POD study requires an expensive campaign during which several operators apply the procedure on a large set of representative samples. Recently, new perspectives for the POD estimation have been introduced using NDT simulation to generate data. However, these approaches do not offer straightforward solutions to take the operator into account. The simulation of human factors, including cognitive aspects, often raises questions. To address these diffculties, we propose a concept of operational NDT simulator [1]. This work presents the first steps in the implementation of such simulator for ultrasound phased array inspection of composite parts containing Flat Bottom Holes (FBHs). The final system will look like a classical ultrasound testing equipment with a single exception: the displayed signals will be synthesized. Our hardware (ultrasound acquisition card, 3D position tracker) and software (position analysis, inspection scenario, synchronization, simulations) environments are developed as a bench to test the meta-modeling techniques able to provide fast-simulated realistic ultra-sound signals. The results presented here are obtained by on-the-fly merging of real and simulated signals. They confirm the feasibility of our approach: the replacement of real signals by purely simulated ones has been unnoticed by operators. We believe this simulator is a great prospect for POD evaluation including human factors, and may also find applications for training or procedure set-up.