US Air Force restricts KC-46 from carrying cargo and passengers

[rangerrebew]

 
US Air Force restricts KC-46 from carrying cargo and passengers
By: Valerie Insinna   

WASHINGTON — In a move that could have major impacts on the already-delayed tanker program, the U.S. Air Force has indefinitely barred the KC-46 from carrying cargo and passengers, Defense News has learned.

The decision was made after an incident occurred where the cargo locks on the bottom of the floor of the aircraft became unlocked during a recent flight, creating concerns that airmen could potentially be hurt or even killed by heavy equipment that suddenly bursts free during a flight.

“As a result of this discovery, the Air Force has submitted a Category 1 deficiency report and is working with Boeing to identify a solution,” Air Force Mobility Command spokesman Col. Damien Pickart said in a statement. The service uses the term Category 1 to describe serious technical issues that could endanger the aircrew and aircraft or have other major effects.

https://www.defensenews.com/breaking-news/2019/09/11/air-force-restricts-kc-46-from-carrying-cargo-and-personnel/

[rangerrebew]

It would seem the aircraft's reliability is in question!

[PeteS in CA]

But deliveries were interrupted earlier this year by the discovery of foreign object debris in multiple planes. The Air Force suspended KC-46 flights at Boeing’s production line in Everett, Wash., this February after finding debris. Then it paused all tanker deliveries in March as the service investigated the extent of the problem. The service began accepting tankers again later that month, only for deliveries to stop — and restart — in April due to similar problems.

Will Roper, the service’s acquisition executive, told reporters at the Paris Air Show this July that the service expects to find foreign object debris in KC-46s moving through the line, and it may be months before planes are reliably clean.

“As those airplanes flow forward down the line, we think it’s going to take some time for the new quality assurance inspection processes to start early enough so that airplanes will flow that are FOD-free,” he said, according to Defense One. “It’s not the way we want to get airplanes into the Air Force, but it’s what we’re going to have to do in the meantime.”

I remember this, earlier this year. "FOD" = "Foreign Object Debris". Frequently it means a tool left inside ... a wing, and engine cowling ... . For some reason, Boeing is unable to train its workers to return their tools to the tools' designated places in toolboxes at the end of a shift (typically, foam with cut-outs for each tool, so that the absence of a tool can be spotted quickly). Having had to live with this shtick at a defense electronics company for 5+ years, I suspect sabotage rather than lack of training. Especially since Boeing is unionized.

[SZonian]

The type of FOD you will typically find in manufacturing mainly consists of metal shavings, metal chips, pieces of wire, string tie, safety wire, misc. small parts such as washers, rivets, nuts, etc.  It's just poor housekeeping practices by the mechanics and QA, plain and simple.  It is not a new concept by any means.

Tools can be a part of that equation though if there are poor tool control policies/enforcement.  I believe the mechanics at Boeing use their own tools and are entrusted to properly inventory their tools prior to and after work to ensure all are accounted for.

We had the same problem years ago with Lockheed, but ultimately convinced them to move to company owned CTK's (Composite Tool Kits) which had a lot more control.  2 people inventory before and after work.  The amount of tool related FOD fell dramatically.