This quote is also from my addendum (supplement) to my first report. Sadly, the thirty minutes noted in the below quote is overly generous. I timed at least two seperate rollerstamping inspectors and they both could "inspect the Engine Build-Up per plan, drawing, and specifications" in about seven minutes flat, including breaking from the "inspection" during that time multiple times to shoot the breeze with mechanics in the area (this is a huge, complex assembly, mind you, roughly the size of a car, except picture a car with complex networks of tubes, wiring, valves, ducts, and other miscellaneous equipment covering it). Note that this seven minutes of "inspection" for the fourteen or so complex jobs did not include any of the required rollerstamping of those jobs off as inspected per plan, spec, and drawing when they obviously weren't inspected even remotely to that required detail:
I got the opportunity to work the 737NG EBU line yesterday (2/25/02) and I gathered some info while I was there. I was in the area from about 9:30 AM to 1:40 PM. On the engine I was assigned to, shop put up no jobs for final inspection during that time, even during the approximately one hour or so I missed of the start of that engine build. I looked at the panel, and there was one greenline, one blueline, two O&IRs in C/C 218 of the panel, and fourteen jobs in C/C 581 of the panel. Eighteen jobs total. Shop was having some problems working with the plans, as they had been changed on only the prior unit to finally incorporate witnessing of drawing torque buyoffs to the plans. They were having to read them to figure out which torques they had to have us witness, and they were not used to reading their plans, as is typical of most BCAG mechanics. The plans had the usual messed up nature that comes with no oversight of M.E. by QA planning. Anyway, if the plans had been alright, I would venture to say that shop would only have sold the two jobs in C/C 218 during the time I was there. I talked to (name), line inspector, who I told you about in this item in my original letter, and pumped him for information for this report. I asked him how the inspection of the jobs flowed in the area. He said that shop put all the jobs (which would be fourteen O&IRs, plus the greenline and blueline (which shop usually never even look at until final inspection/shakedown time), up for inspection for him about 10:30 AM, if the build was on schedule, and that he had from thirty minutes to an hour to do the shakedown and buy them off. This surprised me. I had thought that "final inspection during shakedown" had ended long ago, when I forced the issue when I was in 747 struts, and I told shop that I wouldn’t final inspect the wire bundle job during shakedown, as was customary at PSD (some inspectors would do any number of "final inspections" shop wanted during the shakedown back then). I did that not only because it was the way it was supposed to be done per procedure (all jobs workable final inspected before the shakedown), but because shop would time us during shakedowns, and if they thought that time would interfere with their delivery schedule, no matter what amount of time it was, they would try to sic "their" supervisor, our QA Supervisor, on us. What (name) said disturbed me. It was still going on full bore--Just do a cursory shakedown inspection on the EBU and roller stamp all the jobs based on that "guten tight" (as the germans, like me, partially, say), "don’t let the big parts fall off and hit somebody on the ground" inspection--screw inspection for conformity to the plan, specs, and drawing. I don’t believe any one of those jobs could be inspected per those three items in the thirty minutes the inspector has to do them all, especially since none of these jobs has ever really been fully inspected that way before, and a raft of NCRs on planning, manufacturing, or drawing errors would probably have to be written on each job. I think this information makes my idea to have an ASI see if he can inspect the 737NG EBU jobs in the allotted time to prove it can’t be done unnecessary, unless you think they can inspect that many jobs in thirty minutes. Please put a stop to this before some planeload of people gets killed.
The Last Inspector