This quote is also from my addendum (supplement) to my first report.
References for 6-15-07 reference to lack of required "OK to Install" inspections:
This just in (it is 4/21/02 now): I have had the opportunity to do the two witness torques on this job for the (part number) spinner installation in the past week or so when I was assigned to take the place of (name) when he was absent. The inspector (me) stands on the 777 EBU FME (Floor Mounted Equipment) platform some eight feet away while the mechanic does the torques on the spinner from a scissor lift. Who knows what fasteners shop uses to install the spinner. From my viewpoint some eight feet away they appeared to be twelve point headed bolts of aircraft quality with some kind of spacer or washer underneath. But they could have been from Home Depot for all I could see from that distance (I was doing this torque witness the way the mechanic indicated it was always done (while the inspector stood on the FME). It was a good thing that I was just inspecting the torque and that I was not responsible for inspecting the fastener installation for being per drawing and spec. I could not do that at this distance. If I had my way I would be on the lift with the mechanic watching the torque, but I didn’t want to make waves by doing something that different. I did do something different that other inspectors did not do, judging from the reaction of the mechanic to my request, however. The mechanic was torquing the spinner per the newfangled (the way we should always have done it) method of torquing opposite bolts all around the spinner and not torquing it the old way of torquing all bolts consecutively in a circular pattern (the way it was done in the past until a few weeks ago).
He was marking the bolts with tape as he went, but I couldn’t see if the pretorqued bolts were moving as he torqued them when he did the bolts on the opposite side of the spinner, so I turned the fan after each torque so I could see what he was doing. When he finished torquing the spinner bolts, I asked if that was it. He asked me to hold on. He grabbed the (part number) spinner fairing that he had in the lift with him and slapped it over the uninspected installation of the spinner attachment fasteners and started to install the bolts for the fairing. I waited for several minutes while he got the fasteners ran down enough for me to witness the torque. When I was done witnessing the torque, we both went to the job panel and did our stamping after the process was completed, as shop has been somewhat consistently doing in preparation for the ACSEP audit. Of course, the day after the ACSEP, us inspectors and the shop will be back pre-stamping the whole jobs again.
Anyway, this torque witness of mine illustrates more part and fastener installations that have never been inspected at PSD due to our AWOL QA Planning department that "does not do their processes to meet the delivery schedule." Please hit us up for each of these missing inspections. There should be an "OK to Install" inspection for the (part number) spinner fairing so the fasteners and spinner installation are inspected prior to the fairing being installed.
Also, the (installation number) installation of the two (part number) clevis brackets C/T the inlet attach flange that are done on this job should be inspected prior to the (job I.D.) inlet installation job being done so QA can inspect the fastener installation C/T the two brackets before the fastener heads are covered up by the inlet installation. There are probably other similar fasteners we install on the inlet attach flange of the fancase that have never been inspected because of similar planning omissions. I believe shop inspects the two noted brackets before installing the inlet on the (job I.D.) job. They also, I think, are supposed to inspect to be sure certain jobs are complete prior to installing the inlet on the same job. Whether the listed jobs...have all the things covered by the inlet installation on them I do not know. Probably not, knowing our planning.
The Last Inspector