This quote is also from my addendum (supplement) to my first report.
This section documents the lack of concern by Key Engineers about safety device issues and the fact that budget matters trump safety at Boeing, even in the most obvious safety related areas, such as safety device integrity. I believe this safety device specification issue was partially fixed just months before my termination, some six years after I formally brought it to the attention of the approriate engineering department. This was well after Boeing corporate management and the FAA had refused to fix it on the multiple occasions I notified them of it.
I believe the change that partially fixed this critical problem that allowed untold numbers of defective (insufficient strength) critical safety devices to deliver to BCA customers with the full knowledge of Boeing and the FAA occurred when a new Key Engineer was assigned to the spec. Of course, the hundreds if not many thousands of defective safety devices allowed to deliver on airplanes because of this problem and the rollerstamping quality system in place at Boeing are still flying around, uncorrected. As this is a long section, I am quoting the section sequentially over several days:
Anyway, I digress. I almost lost control of my bowels due to the fact that the obviously incompetent engineer, the "key engineer" of the safety device specification, BAC5018, at Boeing, was just going to change the spec to say the minimum required crimp length would be what I said was the average crimp length I had guessed I had seen, while inspecting the .020" diameter safety cable installations at PSD, on my RDR. I had even noted on my RDR that the exact minimum ferrule crimp length would have to be determined by MR&D or Engineering, inferring that some research and testing needed to be done to determine the length, as I had no idea what it should be, only what I seemed to remember. I couldn’t believe he was going to simply take my word for such a critical spec requirement. I called (him) and told him that he shouldn’t do the change that way, as I was no expert, only a lowly line inspector, and he should do some testing first before he determined the minimum acceptable length and added it to the spec. He reluctantly agreed. I didn’t hear back from him, so I contacted him a few months ago. I asked him what the status of my RDR was. He said it was not a priority as they didn’t have the budget for the testing required. I couldn’t believe it. I asked for his supervisor’s name. I called her. She gave me the same answer. I called back (him) and asked what would make it a priority, as I thought it was essential, as product with discrepant safety devices was shipping from Boeing to customers everyday. He didn’t know. I asked him, if I wrote a tag on an installation for it, if that would make it a priority. He said yes. I never wrote a tag, as I work in fitcheck, where we don’t install much of anything, much less safety cable. Plus I wouldn’t have written it up anyway, as I didn’t much like the thought of standing on that highway off-ramp, holding my unoriginal sign up for small change and braving the disparaging looks from people who think I should just get a shower and go get a job.
The Last Inspector