This quote is also from my addendum (supplement) to my first report.
Please investigate I&R inspections, or the lack thereof, at PSD. Please audit our plans for lack of the required I&R caution notes per (procedure I.D.). I think you’ll find many I&R parts without the required notes. Please interview (name), manager of the PSD phase I and phase II I&R committees. (Name) chairs and administers the I&R committees.
Also please check into the use of "calibrated eyeballs" by our PSD inspectors to inspect the fit and fair of the engine inlets and exhaust sleeves and plugs, rather than calibrated tools.
Please see item 54 below for a definition of what a "calibrated eyeball" inspection really is---I won’t bore you with a repeat of it here. I believe most of our I&R inspection plans have been canceled, probably due to the fact that we never write I&R tags any more due to the inaccuracy of our "calibrated eyeball" inspection method to detect discrepant fits and fairs.
We used to have to fill out a fitcheck document page on the gaps and fairs of the engine inlets and exhaust sleeves and plugs when we inspected the jobs that installed those parts.
Actually, we never filled them out, shop took the measurements, manipulated them if they wanted to, and then presented the page to us for inspection of that data. We had no idea if those measurements were correct or not, as we didn’t take them.
After a time of doing this, the requirement to fill out the page was deleted from the job, probably due to no rejections being initiated from them. I have no idea if this bogus data is what resulted in the cancellation of some of our I&R plans, or not, but it is quite likely it was.
I know some of the jobs that install the noted I&R items currently still have fit and fair buyoffs on them (the inlet job on the engine I inspected the weekend of 1/12/02 had one), but inspectors don’t even use the gap gages and misfair gages shop might have used when they used to do the measurements for us, we just use the "calibrated eyeball inspection method."
Please check into this. Make sure all jobs at PSD that install I&R parts have the required I&R notes against them. Ask inspectors to show you what tools they use to inspect these fit and fair in-process inspections.
Don’t be surprised when you get that "deer in the headlights" look in response. When you see that look, don’t "brake;" "gas your car" instead, and hit us with write-ups. Make sure we have fit and fair buyoffs on all I&R parts jobs. Some access panel jobs in the strut area may require I&R notes and fit and fair buyoffs also.
Review our I&R inspection plans, or lack thereof, to see if they were validly canceled with accurate data, and see if we are complying with those plans that have not been killed without cause yet.
Please audit all PSD bought off I&R installations still in BCAG inventory with accurate inspection devices to see if any discrepant products were delivered due to some of our inspector’s eyeballs being out of calibration, even after our 2/4/02 eye test.
Please nail us if we do not comply with the as-written processes, or any discrepant engines or struts are found.
The Last Inspector