FAA/Boeing has just published a joint report on 787 certification issues
http://www.faa.gov/about/plans_repor...port_Final.pdf It's soothing in its conclusions but reveals seriously deficient processes. Examples that should cause concern include:
“3.2.3. INSPECTION DELEGATION
........ many of Boeing’s suppliers have unique inspection delegation processes, some of which do not meet minimum industry standards....”
“3.2.4. FAA REGULATORY OVERSIGHT
....... several FAA orders do not align with current practices. Specifically, the FAA orders do not—
• Encourage surveillance at critical subtier suppliers and require risk management models to allow assigning risk and surveillance requirements at integrator tier suppliers.
• Recognize the differing levels of complexity of aircraft manufacturing systems and technologies (small, relatively simple aircraft manufacturers versus large-scale, complex aircraft manufacturers with extended supply chains.)”
“A.2.1.SELECTION PROCESS SUMMARY
Even though Boeing requirements existed, verification/validation of the requirements did not always occur between Boeing and/or subtier suppliers.....
With multiple suppliers involved......the lack of a defined owner resulted in a requirement not being adequately communicated and/or verified....
There were cases where a tier 1 supplier did not correctly flow down specific Boeing requirements to a subtier supplier(s). In these cases, it was expected that industry standard design practices would be followed. Because there was no specific requirement, the supplier considered that aspect of the specification to be optional and made an inappropriate design decision....”
“A.4.3.CONCLUSION
Boeing addressed the shimming issues identified in fuselage sections 46, 47, and 48 through corrective actions implemented before delivery. However, five airplanes were delivered with potentially discrepant shims in section 48.....”
There’s much more and it all helps to explain how the 787 entered service with batteries that did not meet certification requirements.
The report has been released while the aviation industry is distracted by MH370 and I wonder if this is deliberate media management. Call me cynical but I was not born that way; it’s the result of a lifetime in aviation!