This quote is also from my addendum (supplement) to my first report.
With the roller stamping and lack of process buyoffs on NCOs (Non-Conformance Orders) that occurs at PSD, even a good C/T (Close Tolerance) hole QOI probably wouldn’t change the level of C/T hole inspection at PSD, unless those things are also changed. You might want to check out NCR (number), which reamed a hole that did meet our current definition of a close tolerance hole. Ask the inspector who bought it what he used to check the hole. As I don’t think we have any intramicrometers in our current limited stash of tools in MRSA, they probably did the usual thing--putting a bolt in the hole and wiggling it to see how loose the hole was. I think the tag had to do with a hole that was too small for insertion of a bolt, so that is probably what happened. Ask the inspector to show you the tools he used. If he acts like he doesn’t know where he is going to go to show you, you’ll have your answer. I think the inspector that bought it was (name), who is a pretty good inspector. I don’t want to get him into trouble, as he is only doing what his management expects him to do at PSD. I’m just trying to illustrate the problem for you by this example.
Business Process Issues Management issue (number) covers the lack of uniformity among sites that build BCAG products in the definitions of close tolerance holes in their QA Manuals, and the resulting bad consequences it could have on the conformity of the entire airplane once put together (some C/T holes would have been inspected, while others with the same tolerances would not have been, like those drilled at PSD). This issue has been sitting on the web for almost a year with no action noted. Who knows when it was first identified. It is being "worked" by the same group (under (name)) that is sitting on my safety device RDR (item 42) so fixing it does not cost the Company money. The issue lists FAA findings as a possible risk in not fixing the problem. They have not fixed the problem and are dragging their feet purposely. Their time is up. Make their prediction of consequences for letting this slide come true--please hit us with a finding on it.
The Last Inspector