Narrative:

Two main rotor blades have exceeded a 2400 hour inspection. These particular two blades are not original to the aircraft. The last time that a 2400 hour inspection was done on the aircraft was at 2;386.3 aircraft total time (actt). Since that time; these two blades have been installed on the aircraft. The 2400 hour vibration absorber / blade fitting non-destructive testing (ndt) inspection was previously done on one of these blades prior to removal off of another aircraft and the other only had 1800 hours on it and came from repair at eurocopter. This inspection has only been tracked as a single line item on a report list and has never been tracked by blade serial number (south/north) until implementation of our maintenance tracking software. When the maintenance tracking software went live; the single line item inspection had not made it over to the tracking program's generated sheet and after weeks of trying to get it added; it was; but by blade south/north. This is when one blade was flagged overdue in september 2011. At that time; aircraft was placed 'out of service' and blade replaced. October 2011; the second blade was determined to be overflown [exceeded service hours] and aircraft was placed 'out of service' again and blade ordered. The event occurred both times while aircraft was at base. This seemed to be a tracking system error. The inspection has never been tracked by individual blades on the report list. Other blade inspections have been tracked individually on the blades like the 600 hour / 24-month lug inspection and we have not had a problem overflying those. As much as I hate to say this; I believe that the maintenance tracking software discovered this deficiency in the system and would be a solution for avoiding recurrence of this event. I also strongly believe that an annual trip to headquarters by one mechanic per base; to spend time with the records auditor doing an audit; would be beneficial.

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Original NASA ASRS Text

Title: A Eurocopter EC-145 Air Taxi Mechanic reports about their inaccurate Maintenance Records that allowed two main rotor blades to exceed a 2400-hour inspection requirement. The discrepancies were noted during the company's transition to a software program for maintenance tracking and planning.

Narrative: Two Main Rotor blades have exceeded a 2400 Hour Inspection. These particular two blades are not original to the aircraft. The last time that a 2400 Hour Inspection was done on the aircraft was at 2;386.3 Aircraft Total Time (ACTT). Since that time; these two blades have been installed on the aircraft. The 2400 Hour Vibration Absorber / Blade Fitting Non-Destructive Testing (NDT) Inspection was previously done on one of these blades prior to removal off of another aircraft and the other only had 1800 hours on it and came from repair at Eurocopter. This Inspection has only been tracked as a single line item on a Report List and has never been tracked by blade Serial Number (S/N) until implementation of our maintenance tracking software. When the maintenance tracking software went live; the single line item inspection had not made it over to the Tracking Program's generated sheet and after weeks of trying to get it added; it was; but by blade S/N. This is when one blade was flagged overdue in September 2011. At that time; aircraft was placed 'Out of Service' and blade replaced. October 2011; the second blade was determined to be overflown [exceeded service hours] and aircraft was placed 'Out of Service' again and blade ordered. The event occurred both times while aircraft was at base. This seemed to be a tracking system error. The Inspection has never been tracked by individual blades on the Report List. Other blade inspections have been tracked individually on the blades like the 600 Hour / 24-month Lug Inspection and we have not had a problem overflying those. As much as I hate to say this; I believe that the maintenance tracking software discovered this deficiency in the system and would be a solution for avoiding recurrence of this event. I also strongly believe that an annual trip to headquarters by one Mechanic per Base; to spend time with the records auditor doing an audit; would be beneficial.

Data retrieved from NASA's ASRS site as of April 2012 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.