In This Issue
Our Sponsors
Accountability is a wonderful thing
AS&D News
AS&D Events
Do you know what's in your product material?
FAA 8130-3 Update
FAA NPRM on Light-Sport Aircraft
 
Featured Article
 
Accountability is a wonderful thing
 
By: M. Dreikorn
 
 
Our Sponsors
 
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The IPL Group focuses on bringing sustainable cultural change to AS&D organizations.  Support areas include:
 
Back to the basics
Leadership development
Integrated process teams
Knowledge management
Supplier development
Supplier oversite
Lean/Six-Sigma
Quality management
Regulatory support
Auditing processes
Level III NDT
Operations
Project management
Training
Urgent response
Due diligence
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Visit The IPL Group at www.TheIPLGroup.com
 
 
 
 
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The Aerospace and Defense Learning Institute (ADLI) is a 501(c)(3), not-for-profit organization which is dedicated to the sustainable knowledge base of the AS&D industry.
 
Sponsors are needed.  If your organization is interested in supporting this urgent industry-wide project, ADLI urgently needs financial support to make the BoK happen faster.
 
Click the above logo to find out more about the ADLI its important project - the development of the AS&D body of knowledge.
 
 
 
 
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The TrainingNow.org
website is presently undergoing a complete make-over.  When it re-emerges in mid-June it will offer a complete Learning Management System (LMS) to clients of any size.  Clients will be able to effectively manage its organizational training needs through our internet-based solutions.
 
TrainingNow.org offers AS&D relevant training, in-house, public, or over the internet.  New courses are being added, so check the website for updates.
 
New look and content is on its way!!!
 
 
TrainingNow.org is the Training practice of The IPL Group, LLC.
 
 
 
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Did you receive this newsletter from a friend and would like to ensure you are on the mailing list.  Click the above button to stay informed on what's going on in the AS&D industry.
 
 
 
A "Back-to-the-Basics" Workshop
mdreikorn
Visit Our Sponsor
 
May 23, 2007
Anaheim, California
 
This one-day public workshop is perfect as either an introduction or refresher to root cause and corrective action.  Participants will learn:
 
Purpose and urgency for RCCA
Understanding of root cause
How to select a root cause tool
Using 5 Whys
Tree diagrams
Understanding corrective action
What is closed-loop
Using mistakeproofing
Applying preventative action
 
The price for
his workshop is $495USD.
 
Michael Dreikorn is the instructor for this value-added learning event.
 
Call 239.283.2839 to reserve your spot today.  Space is limited!
 
 
If your organization continuously deals with the same problems, again and again... then this is the workshop for you!
 
This workshop can also be delivered at your location.  Best when delivered with an IPT and other workgroups.
 
 
 
Did You Know?
 
There is more than just aircraft traffic to be concerned with while flying...
 
Last week, an Indonesian jet carrying hundreds of passengers was forced to turn around over Indian airspace after a nuclear-capable ballistic missile streaked across the sky.
 
 
 
 
Synergy of One Book
Visit Our Sponsor
 
 
By using the concepts of Integrated Performance Leadership (IPL), as described in The Synergy of One, organizational leaders will discover how to more effectively implement change by remaining aware of the big picture and how it affects the entire organization.
 
This book, published by the American Society for Quality (ASQ) presents the modern day challenges of organization and a recognition that there is no one remedy to fix the system.  Systemic improvement requires systemic action!
 
The IPL Group offers implementation support!
 
QUOTE

"We have investigated several accidents and incidents that have highlighted the safety implications resulting from aircraft aging and these accidents repeatedly demonstrate the importance of effective airworthiness programs throughout the service life of  aircraft,..." ... "With the proper maintenance program, these accidents involving aging aircraft could have been prevented."

NTSB Commisioner Rosenker stated at the 2007 Aging Aircraft Conference.
 
 
AS9100B Workshop
in St. Petersburg, FL.
 
16 May 2007
 
Airline 1
 
The aim of the workshop is to provide participants with a general understanding of the content and requirements of AS9100B, the Quality System Requirements for Aerospace organizations.  Participants will be guided through the AS9100B standard with rich discussion along the way. 
 
Space is limited, so reserve your spot today!
 
Call 239.283.2839
 
The price for this workshop is $495USD. Includes workshop, course guide, and refreshments.
 
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The IPL Group, LLC
 
 
 
In need of expert witness services?

 
Dreikorn & Associates 2
Michael Dreikorn and Associates have a demonstrated track record of supporting AS&D litigation needs.  Within the AS&D industry, we are experts in:
 
Quality
Regulatory compliance
Supplier controls
Manufacturing
Maintenance
Log book entries
Product investigation
Contract compliance
 

We can also show you how to avoid litigious situations by being proactive.  Contact us today to find out how we can help you save your reputation.
 
 
Visit
www.MichaelDreikorn.com 
or call 239.283.2839.
 

Dreikorn & Associates 1
 
 
 
Did You Know?

If your supplier management system uses Nadcap certification as part of your supplier managment process, you will not be automatically notified if your supplier loses their certification.

It is your (company) responsibility to control the quality of your suppliers, which includes maintaining a means of certification status oversight.  And, don't forget the ISO/AS registration certificates too.
 
 
Aircraft Maintenance Pic
 
 
 
Only available in the resale market.  This text is a great primer for those who are trying to make sense of quality in the aviation industry.
 

Avn Industry Quality Systems Book 
 
 
Did You Know?

Overflight Fees

Fees in U.S.-Controlled Airspace

The FAA charges overflight fees to operators of aircraft that fly in U.S.-controlled airspace, but neither take off nor land in the United States. There are two types of fees:

  • Enroute - $33.72 per 100 nautical miles (nm), Great Circle Distance (GCD), from point of entry into to point of exit from U.S.-controlled airspace
  • Oceanic - $15.94 per 100 nm, GCD
 
FAA Fees Map
Source: FAA.gov
 
 
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For indepenent analysis of issues relating to the aviation, space and defense industry, consider the Aerospace and Defense Learning Institute's "Think Tank" services.
 
As a not-for-profit organization, we assemble the right talent for the issue.
 
239.283. 2647
 
 
 
 
STS 117 Crew
 
 
Next Space Shuttle Launch
 
Due to the amount of tank repair work remaining, the rollout of Atlantis to the launch pad is now scheduled for May 12. This six-day change is not expected to affect the June 8 target launch date.
 
STS 117 Patch
 
 
 
In Memory
Spaceport America
Upham, New Mexico
 
UP Aerospace launched a Spaceloft XL rocket. Payload included the remains of actor James Doohan (Scotty) and astronaut L. Gordon Cooper as well as educational experiments. 
 
 
 
Questions or comments, please feel free to call, fax, or email us at:
 
(P) 1.239.283.2839
(F) 1.239.283.2197
 
 
 
 
AS&D Header 1

01 May 2007
AS&D Quality, Safety and Regulatory
 Newsletter

 
Your source for professional connection
 
ASD Header 2
 

The objective of this newsletter is to provide perspective to the Aviation, Space, and Defense (AS&D) industry on current and relevant quality, safety, and regulatory matters in our industry.
 
 
 
Accountability is a wonderful thing
 

Historically, quality management systems have been designed to control the operational business processes of organizations and install mechanisms to prevent nonconformances from reaching customers.  When we take a look at most of the systems in place today, we rarely find mechanisms for determining true responsibility, nor do we find processes for assuring proper accountability.  In most cases, organizations are doing their best to keep up with the pace of delivery requirements and are frequently challenged with their own internal cultural hurdles.

 

Organizations need to start thinking more in terms of increasing the accuracy of their problem analysis processes and ensuring accountable parties are taking responsibility for the problems they own.  If not, then problems will continue to cycle again-and-again.  Here are a few suggestions for eliminating performance issues and developing a quality-focused culture.

 

  • Ensure leadership believes in the importance of killing problems and behaves in a consistent manner to support a quality culture.
  • Ensure organizational policies and procedures are aligned to ensure process owners are held accountable for all aspects of their performance.
  • Ensure process owners have the resources needed to perform their responsibilities as expected.
  • Ensure organizational members have the intellectual understanding to perform the processes for which they are responsible.
  • Plan and fund to eliminate problems quickly.
  • Ensure there are effective communication processes throughout the organization.
  • All the above also apply to your supplier-base.
  • Hold suppliers financially responsible for performance.

In review of the above recommendations, it is obvious that there is no silver bullet that will fix all the ills of an organization.  To sustain performance a quality culture must exist.

 

Once established, a quality culture is very fragile.  The integrity of a desired organizational culture is dependent on the leadership actions - never compromise the promises made.  Meaning, the organization's policies and procedures are promises made to the organization, its suppliers, partners, and customers, and any intentional deviation is considered a lie.  Trust will be rapidly eroded and process integrity greatly compromised.  If we expect performance to be sustained, we must hold everyone accountable for their own actions, behavior and performance... Especially ourselves.

   
Written by: M.J. Dreikorn
 
 
AS&D News
Afgan 747The following are news links relevant to quality, safety, and regulatory matters in the AS&D industry.  These are only events which have been reported in the past two weeks.  If you would like to see something else or more, please let us know.
 
 
Pilot error has been identified as the primary reason for the Lockhart River air tragedy, according to the Australian Transport Safety Bureau (ATSB) final report released.
 
Safety Records a Click Away (USA)
 
African airlines have fatal accidents nine times more often than North American ones, and Asian and Latin American carriers are roughly six times deadlier than North American carriers. What can a traveler do to judge the safety of third world carriers?
 
 
"There were several times when routine checks of landing gear and flaps were ignored. In fact, I know of several pilots who were forced to take off even though routine checks were not conducted. I could no longer justify it to my conscience. I had to quit."
 
 
International Civil Aviation Organisation (ICAO) yesterday urged air navigation officials to cut costs.
 
 
Russia and members of the Commonwealth of Independent States (CIS) had the highest rate of airplane accidents in the world in 2006.

FAA bans disputed landing procedure (USA)

The Federal Aviation Administration has ordered a halt to a controversial practice in Memphis that allowed arriving aircraft to fly directly over planes on another runway.

No rush to settle for some Comair crash victims' families (USA)

Despite quick settlements between Comair and two families whose loved ones were killed in a plane crash last summer, other plaintiffs said Tuesday they still need more answers from the airline about the accident that claimed 49 lives.
 
 
A new published report on aviation safety by the National Transportation Safety Board (NTSB) concludes that fatigue among air traffic controllers contributed to one fatal accident last year and at least four other close calls.
Dubai Quality Group (DQG), a non-profit organization dedicated to raising the performance level of the local business environment, has announced that it has received the support of high-profile sponsors for the second edition of the Ideas.
 
 
A trio of US companies has launched a flight data monitoring (FDM) package for piston-engined general aviation aircraft based on the flight operations quality assurance (FOQA) model used by commercial airlines to share data and improve safety.
 
 
Flight Options, LLC, a provider of fractional shares in business aircraft, announced that the company has signed a Memorandum of Understanding with the Federal Aviation Administration (FAA) to extend its existing Aviation Safety Action Program (ASAP) to its maintenance personnel.
 
 
The merger of two private airlines has hogged more limelight than the malfunctioning of two aircraft of the national carriers in quick succession resulting in a narrow shave for some 300 passengers. The unrelated events bring into focus two important aspects of the aviation scene in the country--and also how it has remained neglected for long.
 
 
A Memorandum of Understanding between Qatar General Organisation for standards and Meteorology (QS) and EADS-Qatar competence Centre (EADS-CCQ) has been signed.
 
 
Centre for Asia Pacific Aviation (CAPA) predicts a round of airline consolidation in India in the medium term, as a solution to widening losses and rampant capacity growth, in its new Outlook 2007 report, released recently.
 
 
The race to send tourists into space is heating up with billionaires from Richard Branson to Amazon.com Inc. founder Jeff Bezos funding their own companies to build and launch spaceships for nonastronauts.
 
Travellers who took to the skies during 2006 were safer than fliers from any other year.
 
 
Do not be surprised if, on your next domestic Qantas flight, an attendant announces it is safe to switch on your mobile phone.
 
 
Australia's safety investigator will not pursue the prosecution of a Brisbane-based airline responsible for one of the nation's worst air disasters.
 
 
Winners of four awards honoring
excellence in the aviation industry were announced during Aviation Week's annual MRO Conference & Exhibition in Atlanta, GA.
 
 
Michael Cooney revealed his concern over the crash worthiness of fuel tanks and con-rod failures in the  2004 crash that claimed the life of Tauranga cameraman Peter Harris, 48.
 
 
The number of Queen's Awards for Enterprise granted this year fell sharply after hitting an 11-year high in 2006.
 
 
Vertical guidance by means of signals from the sky: this is what EGNOS, the first European satellite navigation service, will offer pilots during approach and landing.
 
State firms outperform market (USA)
 
According to PCE Indexes LLC, the year-to-date return from the Florida companies it tracks on its PCE Florida Index is more than 10 percent so far this year. Over the last five years, the rate of return is 155 percent.
 
 
The North Carolina Department of Labor has fined two Wilson companies after two construction workers died of carbon monoxide poisoning in February.
 
Aerospace Outsourcing Can Turn Shops Into High Flyers (USA)
 
The aerospace market has taken a major upturn and is expected to be strong for several years to come, and more than ever before, prime aerospace contractors are outsourcing almost all of their regular machining and are actively looking for qualified shops to do that work.
 
 
Indonesia will establish cooperation with the U.S. Federal Aviation Administration (FAA) to improve the aviation safety standards and regain international confidence in the country's air transport recently marred by major disasters.
 
 
The Irish Aviation Authority (IAA) today announced that it had recorded another strong performance in 2006.
 
 
The U.S. government wants Boeing Co. to demonstrate that composite fuel tanks and wings on its 787 Dreamliner resist fire long enough to let passengers escape in an emergency.
 
 
NASA is shuffling target dates for five future launches to accommodate the recent decision to delay the next shuttle mission's liftoff to no sooner than June 8.
 
USAF Work Force Cuts May Pose Next Problems for Space Programs (USA)
 
Now that the U.S. Air Force Space Command has a plan to head off technical and financial problems, it may be the human side of acquisition that could continue to cause problems for its major programs, according to a report from the Government Accountability Office (GAO).
 
FAA Has Some Unhappy Controllers (USA)
 
Concern about employee attitudes developed early this year after FAA officials analyzed the results of a workforce survey conducted in August and September.
 
Asteroid Sample Mission Facing Uncertainty (Japan)
 
The Japanese Aerospace Exploration Agency's (JAXA) Hayabusa asteroid sample return mission will officially begin its return to Earth April 25, but it faces an uncertain journey with only one of four ion engines working properly.
 
Skyguide braced for fresh challenges (Swiss)
 
Switzerland's air traffic control agency Skyguide faces new hurdles this year, including a trial next month of eight employees implicated in a major air crash.
 
India aviation sector set for take off, says FAA's Marion Blakey (India)
 
Federal Aviation Administrator (FAA) Marion C Blakey has expressed optimism about the Indian carrier and aviation business, observing that it was very focused, and due to hit a period of high growth after an initial period of heavy losses.
 
Government air safety changes draw fire (Canada)
 
Transport Minister Lawrence Cannon said Monday the federal government will consider backing away from some controversial changes to air safety regulations that've come under fire from critics who say they'll reduce government oversight and allow the industry to police itself.
 
 
"General Aviation has a high priority for the European Aviation Safety Agency. Some 75 percent of Type-Certificates we have delivered are in the GA sector," said Patrick Goudou, the Agency's Executive Director at the opening session of the 16th International Trade Exhibition.
 
 
In a report adopted on 25 April, MEPs backed several amendments to council's position on a new regulation laying down common rules for air safety including banned items and air marshalls.
 
 
Transport Ministry said that ISASI membership will enable Bulgaria get access to the newest technology and procedures related to aviation safety.
 
 
 
Do YOU Know What's in YOUR Product Material? 
Gears
 
Just because you have material certifications for your raw material, which attest conformity, it does not mean that your product material is free of contamination.
 
Manufacturing and repair processes can easily introduce contaminates into a product.  Processes such as grinding, milling, polishing, and shot peeing can cross-contaminate a product if proper assurances are not taken.  How do you know what's in your product?  There's only one way... You must walk the processes and truly understand what's going on in your own processes and those in the supplier-base.
 
Here are a few tips....
  • Look for process cells that process more than one type of alloy.  Chances are cross-contamination is occurring.
  • Grind wheels need to be alloy specific.
  • Shot media needs to be controlled by type of media and alloy application.
  • If separate wheels and media controls can not be installed, then consider the adequacy of cleaning prior to further processing.
  • Integrate these reviews into your internal and external audits.
 
So what happens if there is cross-contamination?  In most cases not much.  But that depends on product design and application.  However, if the product operates in extreme environments or must perform while transferring high levels of dynamic energy, they can fail.  In such cases, the failure mode starts with a dissimilar metal corrosion pit, which leads to a crack, which can very quickly lead to catastrophic failure.
 
Our advice:  Review your processes, especially those in your supplier-base.  And, if your organization does not posses the technical capability to understand the processes, go get the right people to help.
 
FAA 8130-3 Update 

Be advised that change 1 to FAA Order 8130.21E has been signed by AIR-200. The scope of the change is as follows:

a. Paragraph 205 was changed to allow manufacturing designated airworthiness representatives (DAR) and maintenance DARs, when authorized, to issue Form 8130 3 for domestic airworthiness approval purposes at certificated air agencies and air carriers.

b. Paragraph 305k was revised allowing serial/batch number information in Block 11 of Form 8130-3 for return-to-service items.

c. Paragraph 305m(1) was deleted, which required the term "approval for return to service" to be entered in Block 13 when the right side of the form is completed. Paragraphs were re-numbered and sample forms and references were revised as necessary.