The paper develops a set membership detection methodology which is applied to the detection of abnormal positions of aircraft control surfaces. Robust and early detection of such abnormal positions is an important issue for early system reconfiguration and overall optimisation of aircraft design. In order to improve fault sensitivity while ensuring a high level of robustness, the method combines a data-driven characterisation of noise and a model-driven approach based on interval prediction. The efficiency of the proposed methodology is illustrated through simulation results obtained based on data recorded in several flight scenarios of a highly representative aircraft benchmark.