Importance of Complete Inspection Records in Aerospace Manufacturing

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Fuggles996

#1
As a QE in an aerospace manufacturing facility which is AS9100 registered, I use inspection data to determine where improvements need to be made. Inspection results are entered into a database which is easily sorted to find what is pertinent to my area. Unfortunately, 20% of the inspection records have important information missing, such as date inspected, inspector name, part number, lot number. In addition, there are obvious errors such as the number of parts being accepted being greater than the total number in the lot. I fear I am missing some opportunities for improvement due to these errors.

I issued a corrective action to the inspection supervisor for this. I offered to assist in solving this problem (it would take no more than a week or two of auditing the database and finding out why the information was missing - most of the time inspector error) but they are not concerned that this is a big issue. The Quality Manager of the area does not think it is a big concern, saying that they have bigger fish to fry, and the Director of Quality is not concerned with it either. I have talked with the CEO and they told me it was up to my department to take care of it. This has been going on for quite a while (months since the CAR was issued, and I looked at data from before I started there, there is 4 years worth with the same problem).

Am I being overly picky in thinking that inspection records should be complete and accurate? The only ones concerned are me and my supervisor. As an auditor, if I discovered this at a supplier, it would be a major finding, and any inspection data would be questioned; if the records are not accurate, how accurate are the actual inspections? I can't say the name of this company but they are a major supplier of turbine engine components for military and commercial aircraft.
 
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ARTEMIS

#2
You are definetly not being overly picky. I am surprised that uppper management does not view your findings as important. Inaccurate or missing data from an inspection record is a serious finding from the auditor point of view.

By the way I am an ASQ CQA. Since your firm is certified to AS9100 these types of issues are not acceptable. I would start with a meeting with all QC inspectors that are guilty of the data ommisions and explain to the importance and possible consequences associated with this type of behavior.

By reviewing the inspection data you are showing your committment to Kaizen and for whatever reason upper management does not see this, who knows? When you have errors such as the number of parts being accepted being greater than the total number in the lot. You need to question the competence of your inspection team.

I recommend you document your findings and submit these to upper management, this way you have shown them that an issue exists. If they choose to ignore your concerns then you have you email and attached documents as evidence that a problem exists. Kind of the "I told you so" theory.

Let me know if you need further help, I am open to helping you.
 
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Fuggles996

#3
Thank you, I have met with the inspectors numerous times but unfortunately they do not report to me, and their supervisor is one of the ones that does not think this is important so my words fall on deaf ears. I have documented my findings and emailed them to the entire quality department as well as upper management several times with no response other than "it's not really that important". There has to be more to the story than this, I will do some digging and find out why management does not care.
 
J

Jeff Frost

#5
Has this been an issue with your customers or registrar requiring corrective action in the past? If your register has identified a problem related to incomplete records of inspection then, your company may be heading to a Major finding of nonconformity per AS9101. The registers, under the audit requirement AS9101D, are now required to write a Major finding of nonconformity when two successive audits identify the same nonconformity. All Major nonconformity findings require a special audit by the register to close the finding and if you have not corrected the nonconformity your registration is suspended.
 
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Fuggles996

#6
Hi Jeff, I'm not sure if they got "caught" in any registrar audits, I don't think so but I've not been here long.

I did uncover some disturbing information, apparently my predecessor had a corrective action issued for this same exact issue, and the quality director forged his signature indicating that he had closed it, then he was fired. Not the quality director, the engineer who's signature was forged!! I met and talked to this guy in person, he is still friends with many people here and what a story, he had a lawsuit against the company and several people in upper management lied under oath to cover themselves. I saw the actual court documentation and my jaw dropped. That would explain the look of fear when I bring this subject up. Needless to say my job search starts immediately. I cannot believe the parent company knew of this and did nothing.

Has anybody had experience with anonymously getting the FAA involved with this situation? I believe if I contact any customers or the registrar I will be "let go" regardless what their Ethics and Business Code of Conduct states.
 
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