This quote is also from my addendum (supplement) to my first report, but it is from a different section of the addendum where I asked the FAA to investigate these serious composite repair noncompliances at Boeing. I skipped ahead to quote this section because it expands upon the last quoted section and contains further proof of wrongdoing at Boeing. Starting here, The next several day's paragraphs can be read sequentially, as I wrote them. It should give pause to anyone thinking about the integrity of composite repairs done by Boeing, and bodes ill for the 787 program, where composite repairs will obviously be more frequent than on past aircraft, as much more composite surface area will be exposed to damage. This is one area of my report the corrupt personnel in the FAA's TAD chose not to investigate, probably due to the seriousness and obvious extent of the problem. Now it is up to the DOT OIG to get the required reforms in the inspections of these critical structural composite repairs before they possibly jeopardize the 787 program and current programs with structural composite parts:
Another 737NG T/R was reworked at PSD in the last few weeks by (name),...EMF Composites composite repair technician. You probably recognize his name, as it is in the table above. The lay-up repair on the NCR that did the repair, (NCR number), was also done with the wrong material, BMS 8-212, and had only one thermocouple monitored on the printout during the repair, just as all of his prior repairs to 737 T/Rs had. There was one major difference between this most recent repair and all of the prior repairs in which he used the wrong material without the required engineering or stress approval---this one was done after (NCR number), in which I wrote his repair up for using the wrong material and not having enough data to inspect the cure, and after which he went and got (my QA Lead) to roller stamp his work off. When I told him he had used the wrong material on (NCR number), (and) had to write a revision to the tag to get it approved, that, at that point, was simply an error, I might believe. But what do you call it when a person intentionally does something wrong to an airplane again, as was done by him on (NCR number), after he was warned it was wrong previously, as he was on (NCR number)? Right--sabotage. (Another QA Lead) bought the (NCR number) tag on 1/31/02.
This just in: More sabotage: Another 737NG T/R was reworked at PSD last week by (the same composite repair technician) (it is 3/11/02 when I am writing this), and the wrong material was used again without required Engineering and Stress approvals. Reference (NCR number) on the (P/N and S/N) T/R.
The Last Inspector