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A B767-300 captain reports a contract maintenance organization's failure to correctly modify the trailing edge flaps. Many reports of 'flap disagree' caution.
| Attributes | |
| ACN | 605224 |
| Time | |
| Date | 200401 |
| Day | Mon |
| Local Time Of Day | 1801 To 2400 |
| Place | |
| Locale Reference | airport : zzz.airport |
| State Reference | US |
| Altitude | agl single value : 0 |
| Environment | |
| Flight Conditions | VMC |
| Aircraft 1 | |
| Operator | common carrier : air carrier |
| Make Model Name | B767-300 and 300 ER |
| Operating Under FAR Part | Part 121 |
| Flight Phase | ground : takeoff roll ground : maintenance |
| Flight Plan | IFR |
| Person 1 | |
| Affiliation | company : air carrier |
| Function | flight crew : captain oversight : pic |
| Qualification | pilot : atp |
| Experience | flight time last 90 days : 250 flight time total : 13000 flight time type : 3000 |
| ASRS Report | 605224 |
| Person 2 | |
| Affiliation | company : air carrier |
| Function | flight crew : first officer |
| Events | |
| Anomaly | aircraft equipment problem : critical maintenance problem : improper documentation maintenance problem : improper maintenance non adherence : published procedure non adherence : far |
| Independent Detector | aircraft equipment other aircraft equipment : flap disagree warning other flight crewa other flight crewb |
| Resolutory Action | flight crew : overcame equipment problem flight crew : executed go around |
| Consequence | other other |
| Factors | |
| Maintenance | contributing factor : schedule pressure performance deficiency : unqualified personnel performance deficiency : scheduled maintenance performance deficiency : repair performance deficiency : non compliance with legal requirements performance deficiency : fault isolation |
| Supplementary | |
| Problem Areas | Maintenance Human Performance Aircraft Company |
| Primary Problem | Maintenance Human Performance |
Narrative:
Outsourced maintenance appears to have caused a low level aborted landing and missed approach for us tonight at ZZZ due to their mis-accomplishment of engineering change orders X and Y which were major repairs done to the flap system. In cruise we got a sporadic 'flap/slat elec' status message which is a chronic write-up. On final to runway 28R at ZZZ we got a trailing edge flap disagree caution when going from flaps 20 degrees to 25 degrees. After going around, and accomplishing the appropriate flight manual procedure, we landed flaps 20 degrees with no problem. Ever since the airplane came out of ZZZ1 in mid-december last year it has had daily flap/slat elec status messages and at least one trailing edge flap disagree before we flew it. Our maintenance department remains stymied by this problem. Any review of carrier maintenance history on the airplane will show approximately '42' that's right, 42 log items for this problem in less than 1 month! I don't think this is a situation that flight crews should have to encounter, doing low level go around's and running irregular checklists just because company is trying to save a few pennies on outsourced maintenance. Although we had a successful outcome, safety was negatively affected tonight.
Original NASA ASRS Text
Title: A B767-300 CAPT RPTS A CONTRACT MAINT ORGANIZATION'S FAILURE TO CORRECTLY MODIFY THE TRAILING EDGE FLAPS. MANY RPTS OF 'FLAP DISAGREE' CAUTION.
Narrative: OUTSOURCED MAINT APPEARS TO HAVE CAUSED A LOW LEVEL ABORTED LNDG AND MISSED APCH FOR US TONIGHT AT ZZZ DUE TO THEIR MIS-ACCOMPLISHMENT OF ENGINEERING CHANGE ORDERS X AND Y WHICH WERE MAJOR REPAIRS DONE TO THE FLAP SYS. IN CRUISE WE GOT A SPORADIC 'FLAP/SLAT ELEC' STATUS MESSAGE WHICH IS A CHRONIC WRITE-UP. ON FINAL TO RWY 28R AT ZZZ WE GOT A TRAILING EDGE FLAP DISAGREE CAUTION WHEN GOING FROM FLAPS 20 DEGS TO 25 DEGS. AFTER GOING AROUND, AND ACCOMPLISHING THE APPROPRIATE FLT MANUAL PROC, WE LANDED FLAPS 20 DEGS WITH NO PROB. EVER SINCE THE AIRPLANE CAME OUT OF ZZZ1 IN MID-DECEMBER LAST YEAR IT HAS HAD DAILY FLAP/SLAT ELEC STATUS MESSAGES AND AT LEAST ONE TRAILING EDGE FLAP DISAGREE BEFORE WE FLEW IT. OUR MAINT DEPT REMAINS STYMIED BY THIS PROB. ANY REVIEW OF CARRIER MAINT HISTORY ON THE AIRPLANE WILL SHOW APPROX '42' THAT'S RIGHT, 42 LOG ITEMS FOR THIS PROB IN LESS THAN 1 MONTH! I DON'T THINK THIS IS A SIT THAT FLT CREWS SHOULD HAVE TO ENCOUNTER, DOING LOW LEVEL GAR'S AND RUNNING IRREGULAR CHKLISTS JUST BECAUSE COMPANY IS TRYING TO SAVE A FEW PENNIES ON OUTSOURCED MAINT. ALTHOUGH WE HAD A SUCCESSFUL OUTCOME, SAFETY WAS NEGATIVELY AFFECTED TONIGHT.
Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.