AN EMB135LR (ERJ135LR) PILOT BELIEVES MAINT COVERED-UP GROSS NEGLIGENCE AND UNSAFE MAINT PRACTICES BY UNNECESSARILY CHANGING BOTH NOSE TIRES WHEN MECHANIC'S SCREWDRIVER FOUND FWD OF CAPT'S PEDALS.

Date: 2008-01

Anomalies: aircraft-equipment-problem-critical|deviation-discrepancy-procedural-published-material-policy|deviation-discrepancy-procedural-maintenance|deviation-discrepancy-procedural-far

Synopsis

AN EMB135LR (ERJ135LR) PILOT BELIEVES MAINT COVERED-UP GROSS NEGLIGENCE AND UNSAFE MAINT PRACTICES BY UNNECESSARILY CHANGING BOTH NOSE TIRES WHEN MECHANIC'S SCREWDRIVER FOUND FWD OF CAPT'S PEDALS.

Narrative

WHEN WE LANDED WE HAD MAINT FIX THE STALL PROTECTION PANEL. IT WAS NOT FULLY SECURE BECAUSE THE FASTENER WAS BROKEN. THE MECH CAME OUT WITH 2 OTHER MECHS. THE LEAD MECH SAT IN THE FO SEAT WHILE I WAS IN THE CAPT SEAT. I SAT AND WATCHED THE MECH BRING IN THE COCKPIT A YELLOW DEWALT DRILL WITH A SMALL BIT; A RIVET TOOL; A PERSONAL LEATHERMAN; A SCREWDRIVER WITH A BLACK HANDLE; A FLASHLIGHT; AND A SMALL ZIPLOCK BAG WITH NEW BACKING PLATES AND RIVETS IN IT. HE PLACED ALL OF THESE ITEMS ON THE CTR PEDESTAL AND STARTED WORKING ON THE PANEL BY DRILLING OUT THE OLD BACKING PLATES. AFTER A WHILE I LEFT THE COCKPIT AND THE LEAD MECH DOING ALL THE WORK SAID IT WILL BE DONE WHEN YOU GET BACK. I CAME BACK APPROX 30 MINS LATER AND I REVIEWED THE LOGBOOK AND WE DEPARTED ON TIME FOR ZZZ. WHILE TAXIING OUT TO RWY 13 WE HEARD A CLUNKING SOUND COMING FROM THE RUDDER PEDAL AREA EVERY TIME WE MADE A TURN. WE GOT TO THE RWY AND ASKED TO RETURN TO THE GATE. WHEN WE GOT BACK TO THE GATE I DEBRIEFED THE MECH IN DETAIL AND WROTE IT UP IN THE MAINT LOG. WE SAT AND WAITED APPROX 15-20 MINS AND THEY DECIDED TO SWAP THE ACFT. WE DEPLANED AND AFTER EVERYONE GOT OFF AND WHILE WE WERE PACKING OUR KIT BAGS I GOT A FLASHLIGHT TO CHK AND MAKE SURE WE REMOVED EVERYTHING AND ALSO TAKE A QUICK LOOK AT THE RUDDER PEDAL AREA BECAUSE I NOTICED NONE OF THE MECHS NEVER EVEN LOOKED IN THAT AREA WHILE THEY WERE TROUBLESHOOTING. THEN I NOTICED A SHINY OBJECT IN BACK OF THE CAPT'S R RUDDER PEDAL AND WHEN I LOOKED CLOSER; IT WAS THE SCREWDRIVER THAT THE MECH WAS USING TO FIX THE STALL PANEL THAT HE PUT ON THE CTR PEDESTAL. I HAD OPS SEND OUT THE MAINT SUPVR TO SHOW HIM WHAT I HAD FOUND. MY WHOLE CREW ALSO SAW THIS BLACK HANDLE SCREWDRIVER. THE MAINT SUPVR ALONG WITH THE 2 MECHS WHO WERE TROUBLESHOOTING ACFT X SAW THE SCREWDRIVER. THE MAINT SUPVR SAID HE WOULD GET TO THE BOTTOM OF IT AND APOLOGIZED. THE NEXT DAY WE WERE ASSIGNED THE SAME ACFT. WHILE I WAS REVIEWING THE LOGBOOK AS PER COMPANY POLICY I NOTICED WHAT WAS WRITTEN IN THE CORRECTIVE ACTION BOX OF MY WRITE-UP AND IT FLOORED ME. MAINT REPLACED BOTH NOSE LNDG GEAR TIRES. MAINT MADE NO ENTRY AS TO THE SOUND WAS CAUSED BY FOD IN THE COCKPIT BECAUSE OF A MECH'S SCREWDRIVER THAT WAS LEFT BEHIND MISTAKENLY. THEY WASTED THOUSANDS OF DOLLARS OF COMPANY RESOURCES TO COVER UP A MECH'S GROSS NEGLIGENCE AND UNSAFE MAINT PRACTICES THAT COULD HAVE RESULTED IN A FLT CTL JAM AND CAUSED THE ACFT TO BE UNCONTROLLABLE AND CRASH. I WAS VERY CLR WITH MAINT WITH WHAT I DESCRIBED TO THEM ABOUT THE CLUNKING SOUND. I DID NOT STATE THAT I HAD VIBRATION COMING FROM THE NOSE LNDG GEAR. I DID NOT STATE THAT I HEARD A CLUNKING SOUND COMING FROM THE STRUT OR NOSE LNDG GEAR AREA. I TOLD THE PAX WHEN WE GOT TO THE NEXT ACFT EXACTLY WHAT HAPPENED BECAUSE THEY WERE VERY UPSET AT THE DELAY AND WANTED TO KNOW WHAT THE PROB WAS. UNSATISFACTORY MAINT PRACTICES CAUSED BY NEGLIGENCE AND UNETHICAL BEHAVIOR. ALSO; A VERY POOR MAINT TOOL INVENTORY PROGRAM OR A NON EXISTENT ONE. MANDATE THAT ACR MAINT START A TOOL INVENTORY PROGRAM THAT HAS A TOOL CRIB MONITOR WITH CHITS FOR ALL MECHS LIKE THE MIL LINE MAINT ORGANIZATIONS DO. ALSO OUTLAW ALL PERSONAL TOOLS LIKE LEATHERMANS ETC. MANDATE THAT AFTER ANY WORK IS DONE ALL TOOLS MUST BE TURNED BACK IN TO THE TOOL CRIB FOR INVENTORY AND IF ANYTHING IS MISSING THEN THE ACFT THAT THE MECH WAS WORKING ON IS GROUNDED UNTIL THE TOOL IS FOUND AND ACCOUNTED FOR.

Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.