5-17-2007 Daily Eastman Report to the FAA Quote

This quote is also from my addendum (supplement) to my first report.

Audit of our D6-1979-3 QA Manual: Many of our IDGs, generators, and hydraulic pumps installed on the APUs and engines are attached with a QAD ring, and the fasteners attaching the QAD to the gearbox are not visible after the installation of the IDG, generator, or hydraulic pump.

Some of these items have "OK to Install" inspections and some do not. They should all have them, as inspection cannot view these areas after the IDG, generator, or hydraulic pump is installed. You may want to go farther, and require an "OK to Install" on all IDGs, generators, and hydraulic pumps, even those without QADs, to inspect the splines, o-ring installation, and areas of the IDG, generator, hydraulic pump and/or gearbox that will be covered when the item is installed, as that part of the gearbox is covered when the engine is received.

​I don’t know how specific your "items must be inspected at stages of assembly where valid conformity decisions can be made" FAR is intended to be. Please educate us, and make sure FAA requirements are included in our, now missing, Closure Inspection QOI. See the attached Exhibit P Closure Inspection QOI that I turned into my QA supervisor Tom Nakamichi to correct this problem, which he has apparently round-filed because it does not fit in with his BCAG QA Supervisor’s "we’re here to train mechanics, not inspect" philosophy.