A bell 206 B111 in annual inspection was found to have a control rod in excess of 4800 hours over li...

Attributes
ACN	469041
Time
Date	200004
Day	Sat
Local Time Of Day	0601 To 1200
Place
Locale Reference	airport : zzz.airport
State Reference	US
Altitude	agl single value : 0
Environment
Light	Daylight
Aircraft 1
Operator	common carrier : air carrier
Make Model Name	Jet Ranger/Kiowa/206
Operating Under FAR Part	Part 135
Flight Phase	ground : parked ground : maintenance
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	instruction : instructor maintenance : inspector
Qualification	technician : powerplant technician : inspection authority technician : airframe
Experience	maintenance technician : 35
ASRS Report	469041
Person 2
Affiliation	company : air carrier
Function	instruction : trainee maintenance : technician
Qualification	technician : airframe technician : powerplant
Events
Anomaly	aircraft equipment problem : critical maintenance problem : improper documentation maintenance problem : improper maintenance non adherence : far non adherence : published procedure
Independent Detector	other other : person 1
Resolutory Action	none taken : detected after the fact
Consequence	other other
Factors
Maintenance	performance deficiency : scheduled maintenance performance deficiency : non compliance with legal requirements performance deficiency : logbook entry performance deficiency : inspection
Supplementary
Problem Areas	Chart Or Publication Maintenance Human Performance Aircraft
Primary Problem	Maintenance Human Performance

Narrative:

During annual inspection checking life limited parts and overhaul limited parts, I found a flight control tube from servos to bell crank past life limit of 4800 hours. Time ran out after last annual before this one. A historical card with times entered and part number/serial number, but block, remove at XXXX, was not filled in. Before I spotted this, I was instructing mechanic to make sure these blocks were all to be filled for this very reason, it is easy to miss when the part should be changed. A computer run-out sheet was also kept, but removal time was skipped on this also. I believe this was an honest mistake the cost of the part is only $575.00 and lasts for 4800 hours to retire, .12 cents an hour. It was not paying enough attention to paperwork even if they kept a component computer run-out sheet. I was already lecturing and retraining the mechanic on record keeping when I spotted this error which brought the point home even stronger.

Original NASA ASRS Text

Title: A BELL 206 B111 IN ANNUAL INSPECTION WAS FOUND TO HAVE A CTL ROD IN EXCESS OF 4800 HRS OVER LIFE LIMIT.

Narrative: DURING ANNUAL INSPECTION CHKING LIFE LIMITED PARTS AND OVERHAUL LIMITED PARTS, I FOUND A FLT CTL TUBE FROM SERVOS TO BELL CRANK PAST LIFE LIMIT OF 4800 HRS. TIME RAN OUT AFTER LAST ANNUAL BEFORE THIS ONE. A HISTORICAL CARD WITH TIMES ENTERED AND PART NUMBER/SERIAL NUMBER, BUT BLOCK, REMOVE AT XXXX, WAS NOT FILLED IN. BEFORE I SPOTTED THIS, I WAS INSTRUCTING MECH TO MAKE SURE THESE BLOCKS WERE ALL TO BE FILLED FOR THIS VERY REASON, IT IS EASY TO MISS WHEN THE PART SHOULD BE CHANGED. A COMPUTER RUN-OUT SHEET WAS ALSO KEPT, BUT REMOVAL TIME WAS SKIPPED ON THIS ALSO. I BELIEVE THIS WAS AN HONEST MISTAKE THE COST OF THE PART IS ONLY $575.00 AND LASTS FOR 4800 HRS TO RETIRE, .12 CENTS AN HR. IT WAS NOT PAYING ENOUGH ATTN TO PAPERWORK EVEN IF THEY KEPT A COMPONENT COMPUTER RUN-OUT SHEET. I WAS ALREADY LECTURING AND RETRAINING THE MECH ON RECORD KEEPING WHEN I SPOTTED THIS ERROR WHICH BROUGHT THE POINT HOME EVEN STRONGER.

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 bell 206 B111 in annual inspection was found to have a control rod in excess of 4800 hours over life limit.