Heard Similar Reports Before
But none as detailed as what FLY ON WALL provided this evening:
It's crunch time in production!
It is end of August and not even close to one a day. Aircraft stacking up with out wings to install, mandatory long work days, local 12 week trainee's pouring in with backgrounds in JR-High teaching, Grocery tellers, auto mechanics,... Management believes you can snap an aircraft together just as you would a automobile. The few that are left with real aviation backgrounds are being ignored while EX-Ford and Intel engineers try to stumble through it all.
The line is a mess, they have moved tooling around to create two production lines, but the Techs are crawling all over one another trying to complete jobs and fix NCR's from up the line.
Aircraft do not simply bolt together. As with all aircraft there is always craftsmanship involved. Parts need trimming and things get laid out by hand. Each of the thousands of fastener holes are precision drilled and reamed and this takes skill. The tooling is some what substandard in many of the cells. This leads to out of contour fuselages and other parts having to be tweeked to fit.
The work force on the floor has become very discouraged with the constant change in work schedules, disorganization, and leadership changes. Many leads have stepped down and the turn over rate of quality mechanics is high. Throwing 12 week wonders on the line will only make matters worse as NCR's litter the aircraft from poor workmanship of unskilled mechanics.
Well I am sorry to say that management and some engineers do not want to hear from Aviation experts on how to build the plane. There are people in the company that can help but all they get is how Ford would do it.
I have never seen an aircraft facility so cluttered with parts laying around stacked unprotected on shelves, FOD littering the floor, tables, and inside of aircraft. Tool control is out of control. The beautiful orange snap-on tool boxes are a mess with tools missing and empty drawers. The company has spent thousands on tools and just sat back and watch as they walk out the doors and get left in aircraft.
Ok here is the scoop on NCR's. Techs and inspectors point out problems on the aircraft at times using a sharpie. Then go back and write up the items creating either NCR's or squawks. Many times the marks are left if no one wipes them off , like under the floors. But these items are being fixed and re inspected.
They are not building one a day. Not even every other day. Go take a tour of the place and see. The line is not even completely full.
Fly, thanks for coming forward, it is not a pretty picture.