A mechanic reports composite repairs being made to DH8-100 aircraft not accomplished per the manufac...

Attributes
ACN	395238
Time
Date	199802
Day	Tue
Local Time Of Day	1801 To 2400
Place
Locale Reference	airport : zzz
State Reference	US
Altitude	agl bound lower : 0 agl bound upper : 0
Environment
Light	Night
Aircraft 1
Controlling Facilities	tower : dfw
Operator	common carrier : air carrier
Make Model Name	Dash 8-100
Operating Under FAR Part	Part 121
Flight Phase	other
Flight Plan	None
Person 1
Affiliation	company : air carrier
Function	other personnel other
Qualification	other other : other
ASRS Report	395238
Person 2
Affiliation	company : air carrier
Function	other personnel other
Qualification	other other : other
ASRS Report	394876
Events
Anomaly	aircraft equipment problem : critical non adherence : published procedure non adherence : far other anomaly other
Independent Detector	other other : unspecified
Resolutory Action	none taken : detected after the fact
Consequence	faa : investigated Other
Supplementary
Primary Problem	Aircraft
Air Traffic Incident	other

Narrative:

During FAA inspection, inspectors found insufficient training in the composite shop of dehavilland -8. FAA inspectors found that repair procedures may have deviated from the correct procedures. During the time that I have spent in the composite shop that I may not have complied with repaired procedures completely due to lack of composite training. The company was made aware that it had not provided training in composite repair to specific aircraft type. Callback conversation with reporter revealed the following information: the reporter stated that prior to the FAA shop inspection very few people were trained on the repair and buildup of composite structural components. The reporter said that some of the work done by untrained mechanics was not per the manufacturer's structural repair manual and was never inspected. The reporter stated that after the FAA shop inspection the company started a training program and now maintains training records of mechanic qualification. Callback conversation with reporter acn #394876 revealed the following information: the reporter said the shop operated with production as the primary goal with repairs not being done per the structural repair manual which cut job time and increased production. The reporter stated there never was a training department and no training records were maintained. The reporter said a lot of unapproved repairs went out of this shop and were never inspected.

Original NASA ASRS Text

Title: A MECH RPTS COMPOSITE REPAIRS BEING MADE TO DH8-100 ACFT NOT ACCOMPLISHED PER THE MANUFACTURER'S SPECS DUE TO LACK OF TRAINING POLICY.

Narrative: DURING FAA INSPECTION, INSPECTORS FOUND INSUFFICIENT TRAINING IN THE COMPOSITE SHOP OF DEHAVILLAND -8. FAA INSPECTORS FOUND THAT REPAIR PROCS MAY HAVE DEVIATED FROM THE CORRECT PROCS. DURING THE TIME THAT I HAVE SPENT IN THE COMPOSITE SHOP THAT I MAY NOT HAVE COMPLIED WITH REPAIRED PROCS COMPLETELY DUE TO LACK OF COMPOSITE TRAINING. THE COMPANY WAS MADE AWARE THAT IT HAD NOT PROVIDED TRAINING IN COMPOSITE REPAIR TO SPECIFIC ACFT TYPE. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED THAT PRIOR TO THE FAA SHOP INSPECTION VERY FEW PEOPLE WERE TRAINED ON THE REPAIR AND BUILDUP OF COMPOSITE STRUCTURAL COMPONENTS. THE RPTR SAID THAT SOME OF THE WORK DONE BY UNTRAINED MECHS WAS NOT PER THE MANUFACTURER'S STRUCTURAL REPAIR MANUAL AND WAS NEVER INSPECTED. THE RPTR STATED THAT AFTER THE FAA SHOP INSPECTION THE COMPANY STARTED A TRAINING PROGRAM AND NOW MAINTAINS TRAINING RECORDS OF MECH QUALIFICATION. CALLBACK CONVERSATION WITH RPTR ACN #394876 REVEALED THE FOLLOWING INFO: THE RPTR SAID THE SHOP OPERATED WITH PRODUCTION AS THE PRIMARY GOAL WITH REPAIRS NOT BEING DONE PER THE STRUCTURAL REPAIR MANUAL WHICH CUT JOB TIME AND INCREASED PRODUCTION. THE RPTR STATED THERE NEVER WAS A TRAINING DEPT AND NO TRAINING RECORDS WERE MAINTAINED. THE RPTR SAID A LOT OF UNAPPROVED REPAIRS WENT OUT OF THIS SHOP AND WERE NEVER INSPECTED.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.

A mechanic reports composite repairs being made to DH8-100 aircraft not accomplished per the manufacturer's specifications due to lack of training policy.