This quote is also from my addendum (supplement) to my first report:
This item is closely allied with item 46 above, "OK to Install" and "OK to Close" inspections, and owes to our corrupted QA Planning department that is more concerned than Manufacturing about the efficient flow of work through PSD without inspections to slow it down. It is the complete lack of "OK to Seal" inspections at PSD. If I remember right in Everett, they had such inspections to ensure that QA had inspected the fastener installations and part installations before the Seal Shop cap sealed and fillet sealed over everything, making such inspections impossible. At PSD, all inspections are optional, per (my QA supervisor) and the actions of our QA Planning department, so you will not find such inspections. If you find evidence that such an inspection ever existed at PSD in its twenty-one year period, I’d be extremely surprised. Consequently, some part inspections and fastener installations, however critical they are to the safety of the airplane, have never been inspected at PSD in our over twenty year history. The shop could be saving the Company money by installing cheap substitute fasteners from (hardware store chain name), for all us inspectors know. Many of these installations, knowing how often I find loose parts during inspections, have delivered to customers and are flying around now with loose parts under the sealant, as shop has these parts and fasteners encased in cap and fillet seals by the time we have our first look at them. Hopefully that sealant will hold those parts together in service. A specific example is job (I.D. number) (model number) (line number), which does the (part number) chine installation on the fan cowls. The thirty-six fasteners holding the chine to the fan cowl are cap or aero sealed on both sides per operation 170 before we inspect the chine installation. There is a torque buyoff on the job prior to the covering of the fasteners, but it is just that--a torque inspection, and no inspection of the fastener installation is done at all during the inspection. Please make us fix this problem. If we had an ethical QA Planning department, this problem would never have existed, but we don’t.
The Last Inspector