monthly safety review may -met

COPYRIGHT © 2010 BOEING SHANGHAI AVIATION SERVICES CO., LTD.

Date: May. 27th, 2011

安全/质量会议2011年 5月Safety/Quality Committee Meeting May, 2011

Review Meeting Date: May. 27th, 2011

CEO Approval:


Monthly Safety/Quality Committee Meeting Agenda – Mar.

Time Scheduled

No. Business Item (Responsible Member) Materials Action Required

5 Minutes 1.0 Opening comments (CEO) None Information Sharing

5 Minutes 2.0 Review attendance – Safety Director Roster Evaluate attendance of members

3.0 Key Q&S Events Level 1&2 Items (Quality Manager)

Non conform, Safety & Customer item list

Status by prime responsible manager

3.1 Items requiring special attention (Prime responsible manager)

List of Late, missing items

Responsible manager to provide explanation and recovery plan“


More than 90 days opening items

Responsible manager to provide explanation and recovery plan

3.3 MET user metric Human factory Metric

QS Director

40 Minutes

5 Minutes 4.0 Surveillance – (QS Manager) Surveillance Metrics Evaluate trend, initiate actions for bad trends

10 Minutes 5.0 Audit Activities (Q&S Audit Leader) Standard Audit Reports

Evaluate trends, identify areas for emphasis, (Review repeat items, closures, re-openings)

6.0 EHS Metrics Review (Mike Zhang) EHS Manager15 Minutes

6.1 EHS Statistics Injuries, waste, energy and water

Review trends and determine if unfavorable trends exist and if emphasis needed

5 Minutes 7.0 Violations and Disciplinary Action (HR Director)

Discipline Report Determine if quality and safety related disciplinary actions in accord with Just Culture

10 Minutes 8.0 Wrap up

5 Minutes 8.1 Action Status Review

10 Minutes 8.2 Status Review of Emphasis Programs Safety Policy and performance metric

QS Director

5 Minutes 8.3 Open Discussion/Emergent Issues


Monthly Safety/Quality Committee Meeting Agenda – May

Time Scheduled














QS Director

40 Minutes












QS Director



Safety Committee Attendance RecordCommittee Member

Role Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Bernard CEO A A A A

Wang Xioadong

VCEO A D A A

John CFO A X A D

Elizabeth Planning A A A A

Lily Quality A A A D

Daniel Ni Ops A A D A

Rebecca HR X A A A

Guo Lin Supply Chain

A D A A

Roger X X D A D

Fred Eng & +

A A D D

A – In attendance (Green)

D – Sent delegate (Yellow)

X – Absent (Red)



Time Scheduled














QS Director

40 Minutes












QS Director



Level One Items- None

CAS GSMS Item List

Management Emphasis TrackingHome My MET Site Map Contact Us Help Log Off

CAS Global Safety Management System Item List

Search: Designator like BSH* and (Problem Type = CA) and (Status Code = O) and Review ID like *2 and ( ( Item Assigned Between 04-29-2011 and 05-24-2011)) Sort: CAPA_REVIEW_NO Asc

New Search Page 1 of 1 Total Items: 14 Preferences

Source

Item No (View/Edit)

Item Title (Attach)(URL)

Review ID Category

Status (History)

ID by Person

Created On

CAPA Plan Due Date

CAPA Impl Due Date

CAPA Impl Cmpl Date

Prime Resp Person

Resp Person

Last Status Dt

Audit - Internal

101147 Taskcard turned in for QS audit completely blank except audit(2)(0)

145-2 Non Compliance

O(5) Olson, G

04-28-2011

05-23-2011

Chen, Junrong

Ou, J; Chen, J; Zhu, S

05-23-2011

CAPA Finding: Taskcard P01 was turned into QS as completed, but the taskcard was blank, and the BSAS coversheet had been stamped by Planning and Production indicating that the taskcard was complete.

CAPA Remedial Action:

1. Have backshop mechanic signed off task card; bachsop inspector stamped it.(Completed on 28Apr) 2. Have QS re-checked the task card, it was accepted.

CAPA Plan: 1.Backshop manager James Ou did further analysis about the issue on May 16 and divided the issue into two parts: part 1 for HM, Backshop guy signature; part 2 for final inspectors and planning signature. For part 1, HM, Backshop guys should follow the requirement to sign job card after the work being done; For part 2, final inspectors and planning should double check the signature in part 1 before signature; 2.HM, Backshop, Planning dep. will brief to authorized staff and signature by June 3, 2011.

CAPA Root Cause: 1. Backshop mechanic didn't signoff task crad before submitting papaer work. 2. Production engineer and planner didn't review all task cards before signing off coversheet.

Last Status Desc: Remedial Action is reported accomplished on 26Apr, but attached document is signed,stamped of 28Apr, and MET "Remedial Action Completed Date"shows 29Apr. I changed dates to match the aircraft record document.

Audit - Internal

101169 Some O-rings are not sealed in the original manufacturer's packaging.(4)(0)

145-2 Non Conformance

O(1) Xue, C 05-08-2011

06-08-2011

Guo, Lynne

Liang, D; Hong, H; Guo, L

05-15-2011

CAPA Finding: PRO-10-M05R3 2.C.b: O-rings and rubber products must be sealed in the original manufacturer's packaging. Audit found, some O-rings are not sealed in the original manufacturer's packaging. For example: B/N 0000009603 fuel seal are stored in self-sealed white transparent bag.


CAPA Plan: 1. Warehouse keeper will check all inventory and find whether has the same situation in May 2011. 2. All material inspectors and buyers should be understand the packing requirements of O-rings or rubber products. The O-rings should be sealed in the original manufacturer's packaging. 3.Warehouse personnel should arrange a meeting with related departments(Procument/Quality) and reach a consensus in Jun 2011

CAPA Root Cause: The material inspectors did not understand the packing requirement clearly.

Last Status Desc: Warehouse keeper has checked all inventory and found 3 items has the same situation on 10th May 2011. P/N:91322-001(1EA) supplier:AVIALL AIRSTOCKS LIMITED P/N:2-234N674-70(4EA) supplier: Boeing Commercial Air P/N:69-77135-1(1EA) supplier:Kun ming li dun Please check the picture in the attachments.

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CAS GSMS Item List

Audit - Internal

101170 Receiving inspector had no ESDS training records.(1)(0)


O(1) Xue, C 05-08-2011

06-08-2011

06-30-2011

Guo, Lynne

Liang, D; Hong, H; Guo, L

05-12-2011

CAPA Finding: PRO-10-1M05R3 2.E: Anti-static material must be inspected on an anti-static work table per Aircraft Electronic and Electric Equipment Static Prevention Safety Rules. After receiving inspection is completed, the material shall be re-packed, as appropriate. PRO-12-M30R2 2.A: Only personnel who have received ESDS training may receive, handle, install or transport ESDS devices. Audit found, receiving inspectors have no ESDS training records. For example: checked receiving inspector Chen Zixue's training records and didn't find the ESDS training records.


CAPA Plan: Warehouse supervisor check the training records of all staff and apply the training request to training department in May 2011.

CAPA Root Cause: The training requirement does not follow the procedure PRO-10-M05R3.

Last Status Desc: The warehouse has applied the training request to training department on 6th May 2011. Please check the attachment.

101177 Work signed -off before work accomplished.(1)(0)

145-2 General Workflow Activity

O(0) Olson, G

05-14-2011

06-17-2011

Chen, Junrong

Li, E; Chen, J

CAPA Finding: During paperwork audit QS found EO step signed off on the 9th of May and work not performed, work planned for that morning the 12th of May. EO #767-53-018 STA 955 Rear bulkhead side fittings-fail-safe strap-inspection EO page13 part4-restoration step 3 is Cabin Pressure leakage test.


E2 Wen Bin (employee number 180),E1 Lai Xiao Zhen (employee 486) and mechanic Gu Zhou Wei (employee number 82) accomplished the task regarding EO #767-53-018 STA 955 Rear bulkhead side fittings-fail-safe strap-inspection EO page13 part4-restoration step 3 (Cabin Pressure leakage test) at 12MAY11.

CAPA Plan: 1.makeing read&sign to request all HM staff that HM guys should get SB or EO from Planing or Engineering to fully understand the requirement of task while they meet problem or potential mis-understood the job card description. 2.request planing to highlight the critical items which potential impact to mis-understand, or transfer the big inspection and complex task to EO during the preparation and evaluation the work package.

CAPA Root Cause: 1. Maintenance crews mis-understood the job card description. 2. Maintenance crew need more detailed instructions in the task card to avoid misleading.

Last Status Desc:

Audit - Boeing

101179 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Quality Assurance Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Sun, Xianghua

Chen, C; Xue, C; Qiu, L; Zhang, Q; Sun, X




























CAS GSMS Item List

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Quality Assurance Department as the owner of corrective actions / preventive actions.


CAPA Plan: CAPA Root Cause: Last Status Desc:

Audit - Boeing

101180 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Quality Control Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Olson, Gary

Olson, G

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Quality Control Department as the owner of corrective actions / preventive actions.



Audit - Boeing

101181 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Supply Chain Owned Items(4)(0)


O(1) 05-18-2011

05-27-2011

Guo, Lynne

Hong, H; Yan, K; Guo, L

05-18-2011

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Supply Chain Department as the owner of corrective actions / preventive actions.


CAPA Plan: CAPA Root Cause: Last Status Desc: Three correct action items have been uploaded in the attachment on 18th May 2011.

























CAS GSMS Item List

Audit - Boeing

101182 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Planning Department Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Zhu, Space

Zhu, S

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Planning Department as the owner of corrective actions / preventive actions.



Audit - Boeing

101183 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Facility Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Zhang, Mike

Zhang, M

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Facility Department as the owner of corrective actions / preventive actions.



Audit - Boeing

101184 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Operation Department Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Ni, Daniel Ni, D





































CAS GSMS Item List

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Operation Department as the owner of corrective actions / preventive actions.



Audit - Boeing

101185 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - HM Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Chen, Junrong

Chen, J

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai HM Department as the owner of corrective actions / preventive actions.



Audit - Boeing

101186 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Back Shops Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Ou, James

Ou, J

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Back Shops Department as the owner of corrective actions / preventive actions.


CAPA Plan: Backshop Manager James ou have been asigned related persons to corrected on May 9,2011 and plan will be completed by May 22, 2011.

CAPA Root Cause: Last Status Desc:























CAS GSMS Item List

Audit - Boeing

101187 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Line Maintenance Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Song, Chengzhe

Song, C

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Line Maintenance Department as the owner of corrective actions / preventive actions.


1. GC-201104-BSH-48: BSH have not performed borescope on Untied aircraft; if performed BSH will keep one time authorization at station. 2. GC-201104-BSH-53: a). reviewed with UA team for taking checklist while working on preflight; b). monitoring a period of pne month for team perform preflight check with checklist;

CAPA Plan: 1. GC-201104-BSH-48: BSH have not performed borescope on Untied aircraft; if performed BSH will keep one time authorization at station. 2. GC-201104-BSH-53: a). review with UA team for taking checklist while working on preflight; b). monitoring a period of one month for team perform preflight check with checklist;

CAPA Root Cause: 1. GC-201104-BSH-48: have not performed borescope yet. 2. GC-201104-BSH-53: duty staff did not take checklist to perform preflight check, because duty staff did not follow regulatory requirement.

Last Status Desc:

Audit - Boeing

101188 Boeing Base / Line Maintenance Supplier Approval Pre-assessment - Operation Support Owned Items(1)(0)


O(0) 05-18-2011

05-27-2011

Xu, Haiqiang

Xu, H

CAPA Finding: Boeing Quality System conducted a pre-assessment to help Boeing Shanghai reach readiness as an approved base / line maintenance supplier per Boeing Specification D6-83992 Rev. A. The pre-assessment identifies the attached opportunities for improvement and assigned to Boeing Shanghai Operation Support Department as the owner of corrective actions / preventive actions.




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CAS GSMS Item List

Time: 0.8281




Time Scheduled














QS Director

40 Minutes












QS Director


CAS GSMS Item List



Search: Designator like BSH* and Items are Past Due and (Problem Type = CA) and Review ID like *2 Sort: CAPA_REVIEW_NO Asc

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QS Director


CAS GSMS Item List



Search: Designator like BSH* and (Problem Type = CA) and (Status Code = O) and Review ID like *2 and ( ( Item Assigned Between 12-02-2009 and 02-28-2011)) Sort: CAPA_REVIEW_NO Asc


Source

Item No (View/Edit)

Item Title (Attach)(URL)

Review ID Category

Status (History)

ID by Person

Created On

CAPA Plan Due Date

CAPA Impl Due Date

CAPA Impl Cmpl Date

Prime Resp Person

Resp Person

Last Status Dt

Audit - Special Investigation

100775 Taskcards completion error rate is trending above set standards (2.0)(5)(0)


O(14) Olson, G

08-19-2010

11-30-2010

06-30-2011

Ni, Daniel Ni, D; Chen, J; He, X

05-08-2011

CAPA Finding: Based on the Boeing Shanghai Maintenance Issue Matrix the quality of Jobcards properly/timely completed/stamped has been trending over the treshhold of 2.0. Currently the average severity is 3.2. The current error rate on taskcards on first review is average 30+%, last aircraft far exceeds at near 50%.


1. Made correction when mistake were found.

CAPA Plan: Set paper work improvement project to follow up the problems. 1. Create a taskcard sign-off procedure to specify the process, responsibility, training time requirement (for 1st aircraft, one week before the aircraft gets in), training courseware, exams, recurring training requirement and emergent training plan. 2. Create a discipline policy for repeated mistakes, (Internal management, recurring training & exam, withdraw of the authorization, etc.) 3. Review the procedure and include the specific requirements on: What kind of material or service tags need to be attched? Which level of reference documents are required to attach? What/How to N/A? 4. Publish the CPM and keep updating it. 5. Check the missing items and record the total numbers of defects according to each team at the first sign-off time. Detail please refer to the project.

CAPA Root Cause: Project team is locating the root cause, will find a effective action plan for improvement. 1. Lack of in-time effective communication/training/briefing 2. Working Attitude 3. Poor English 4. QC standard Detail please refer to Paper-work improvment project

Last Status Desc: According to internal discussion with Quality Director and CEO, we all agree to extend the implementation due date to 30 Jun 2011 due to we need to keep monitoring until target achieved (<=5%)

Audit - Internal

100817 Job Card Buy-Off Without Work Being Performed Properly(1)(0)


O(12) Olson, G

09-21-2010

11-30-2010

06-30-2011

Chen, Junrong

Ni, D; Chen, J; He, X

05-05-2011




































CAS GSMS Item List

CAPA Finding: During walk-around on Evergreen RD773 (N488EV)it was discovered that incorrect grease applied to #3 and #6 Trailing Edge Flap Ball screw gimbals and yokes. Found Aeroshell 7 (light tan) and JC 3125002, and 3126002 requires Aeroshell 33 (Kelly Green).


Relubricate the #3 and #6 TE flap gimbal and yokes with Aeroshell 33, purging all Aeroshell 7 from the joint. This work was performed on Sep 20-21. relubricated the total 10 points of LUB spot which were missed on L/R BLG and TE flaps for WOA 747 A4 check

CAPA Plan: 1. Investigate the issue with involved person. (Engineer admitted that he miss-read the AMM, and gave wrong instruction to his crew.) 2. Assigned 2 HM engineers for 100% buy back, will evaluate the result after 5 aircraft. (The first 100% buy back was done on Jeju ¡°C¡± check, quality is improving) 3. Inventory greasing pump and gun, and request for additional items to support operation. New grease pump and guns are available for HM maint from 10JAN11. 4.Assigned LUB team to accumulate the LUB experience for 747 and enhance 100% buy back.( we have a significantly improvrment for LUB service during the next N499MC A check)

CAPA Root Cause: Related engineer lack of responsibility for reading the AMM step by step carefully so as to give incorrect instruction to mechanics. Total 10 LUB spots missed during A check. Both L/H and R/H BLG missed one same LUB spot due to mechanic have not catched this LUB spot ref job card. and F/C LUB team missed 8 LUB spots for L/R inboard TE flap which Removed&Reinstalled for EO accomplish during WOA A4 check and F/C LUB team performed the LUB service for L/R TE FLAP after compelted inboard flap Reinstallation which was only 3 hours ahead of A check released.

Last Status Desc: I was requested and agreed upon at the weekly Quality Safety meeting to move the implentation date 30 days to the right.

Operator/Customer Input

100994 Complaints after C-Ch VP-BVH(4)(0)

145-2 Safety - Hazard/Risk Product

O(8) Chen, S

02-16-2011

06-03-2011

06-30-2011

Chen, Junrong

Chen, J; He, X

05-17-2011

CAPA Finding: The customer complains three failure of defect item which has been fixed in PVG were recurring again after C-Check.


1.Inform managment of the event. -HM Manager (JR) was informed of this enent on 2/24/2011. Action completed 2. Forwarded the investigation report to customer regarding customer concern by project manager Eric on 28FEB11. detail as attachment. Action completed 3. waiting the customer feedback for above issues and action follow based on customer requirement.Action open.

CAPA Plan: 1. Establish standarard procedure how to reply the customer complaint or quality issues after aircraft finished the base maintenance check and released from BSH. Quality will lead. 2. Production should fully cooperate the quality department for the investigation if any defect reported by customer during ferry flight

CAPA Root Cause: 1. No standard procedure to handle ferry flight defect and costomer complaint

Last Status Desc: attached customer feedback, item recommend to close.

Audit - Internal

101049 Not all the authorized personnel have valid proof of the physical examination(2)(0)

2 Non Conformance

O(0) Xue, C 02-24-2011

03-18-2011

06-30-2011

Sun, Xianghua

Zhang, Q; Sun, X


















CAS GSMS Item List

CAPA Finding: PRO-10-M19R5 2.A.vi: Authorization applicant must be healthy and competent for assigned duties and responsibilities, every year such personnel shall be provided with issued by a legal medical organization. Audit found not all the authorized personnel have valid proof of the physical examination. For example: the authorized personnel Li Chi has no physical check-up record for 2010.


CAPA Plan: 1.The QA Manager sent e-mail to related department to require all the authorized personnel applies for Type C to provide a valid proof of the physical examination. Completion date: 03-Mar-2011 2.Acording to CCAR145, the physical requirement of the authorized personnel applies for Type C is added. Estimated completion date:18-Apr-2011 3.Be strictly in accordance with the procedure to check the medical certificate of all the authorized personnel applies for Type C in June 2011, after the medical checks arranged by Boeing Shanghai. Estimated completion date:30-Jun-2011

CAPA Root Cause: 1.CCAR145R3 145.23(b)"The maintenance, management personnel and certifying, and supporting staff shall be physically healthy and competent for the assigned duties and responsibilities, every year such personnel shall be provided with the valid proof of the physical examination issued by a legal medical organization." It is not clearly defined that the medical certificate is only applicable to the authorized personnel applies for Type C in working procedure PRO-10-M19R5. 2.The authorization management personnel are not strictly in accordance with procedure requirement check the medical certificate.

Last Status Desc:





Time: 0.8281





















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QS Director

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Human Error Rate<Per ten thousand Man hours>

Boeing Shanghai human error event rate 不安全事件万时率

Unsafe event 不安全事件数, 4






Unsafe event 不安全事件数, 1Unsafe event 不安全事件数, 1




1

2

3

4

5

6

7

2010.07~2011.05

0

1

2

3

4

5

6

7

8

Rough Hours工时(万工时）

Unsafe event不安全事件数

Rate 万时率

Rough Hours 工时(万工时） 0.9816 0.3969 0.6243 1.7072 1.9405 0.5037 1.7011 0.7177 2.808 2.6 2.3Unsafe event 不安全事件数 4 3 0 1 5 0 1 1 6 1 0Rate 万时率 4.07498 7.558579 0 0.585754 2.576656 0 0.587855 1.39334 2.136752 0.384615 0

Jul/10 Aug/10 Sep/10 Oct/10 Nov/10 Dec/10 Jan/11 Feb/11 Mar/11 Apr/11 May/11


Open MET Items MetricsBSH Open MET Item Metrics

0

5

10

15

20

25

Current 0 0 1 8 21 0 3 4

Late 0 0 0 0 0 0 1 0

Missing Date 0 1 0 1 0 0 0 2

Total 0 1 1 9 21 0 4 6

BSH Operations Eng & Plng Production Quality Training Facilities SM&P

As of 5-17-2011


Monthly MET Statues Report

0

10

20

30

40

50

60

70

80

Created this period 18 41 17 16 24 21 19 24 16 31 35 45 7 17

Closed & Suspended 70 33 27 31 15 7 27 34 20 23 12 43 21 14

Open & Pending 38 46 36 21 30 44 37 26 22 30 53 55 41 44

Current Past Due * 16 14 3 6 7 5 15 5 3 2 21 10 4 0

Current Past ECD * 9 0 0 0 1 0 1 0 0 0 0 1 0 0

Candidate 0 0 0 0 0 0 0 0 0 0 0 0 0 0

4/30/10 5/31/10 6/30/10 7/31/10 8/31/10 9/30/10 10/31/10 11/30/10 12/31/10 1/31/11 2/28/11 3/31/11 4/30/11 Today

As of:

CAS Global Safety Management System5/23/2011 9:36:09

* Candidate items are not included in Current Past Due and Current Past ECD counts



Time Scheduled














QS Director

40 Minutes












QS Director


5-10-2011 Maintenance Surveillance Matrix

Type of Check A4 C2 A1 A1 TLW HIDE ACFT C-CHECK C-CHECK A check C-check C-check

Induction Date 02/01/10 03/02/10 03/18/10 04/13/10 04/28/10 Unhide columns 02/15/11 03/02/11 03/23/11 03/09/11 03/30/11

Completion Date 02/02/10 03/17/10 03/19/10 04/14/10 04/28/10 to view 03/10/11 03/17/11 03/25/11 04/11/11 05/14/11

Registration N492MC MSN35793 N497MC N492MC N409MC VP-BAX HL8206 N740WA VP-VVF UR-DNM Rolling 5 acft Last 5

FOD 2 2 2 2 2 4 2 2 2 4 10 142 3 2 2 2 3 2 2 2 3 11 122 2 2 2 2 1 2 2 2 2 10 92 2 2 2 2 3 2 1 1 2 10 92 2 2 2 2 1 1 1 3 2 10 82 2 2 2 2 1 1 1 1 2 10 62 2 2 2 2 2 1 2 1 1 10 7

1 1 2 1 4 4 1 122 1 1 1 1 1 1 1 2 3 6 82 2 2 2 2 1 1 1 4 3 10 103 3 2 2 2 1 1 1 1 3 12 72 2 2 2 2 1 1 1 1 1 10 52 2 2 2 2 2 3 1 3 2 10 112 2 2 2 2 3 3 3 4 3 10 162 3 2 2 2 4 1 1 2 3 11 112 3 3 3 2 2 3 3 4 3 13 153 2 2 2 2 2 2 2 3 2 11 112 2 2 2 2 2 2 2 1 3 10 102 2 2 2 2 2 1 1 2 3 10 92 4 3 3 3 2 2 3 3 4 15 142 3 3 3 2 3 3 2 4 3 13 152 4 2 2 2 2 2 2 3 2 12 113 3 2 2 2 3 2 2 3 3 12 13

047 53 46 46 45 47 41 38 56 61 245 243

Target 44 44 44 44 44 44 44 44 44 44 Total Discrepancies

Assortment of FOD

HazMat control

Entrance/work stands

Container labeling/storage

Hou

seke

epin

gA

ircra

ft

Tooling certification/calibration

Lighting/electrical

Work benches/work stations

Tubing/ducting capped or plugged

Positioned/grounded safe for maintenanceSystems safed/tagged

Electrical/ESD componentscapped/grounded/protected

Parts/area identified/segregated/protected

Safety practices/PPE

PTP

Panels/tape/covering properly installed

Tool utilization

Spills/clean-up

Workmanship

Total by Aircraft

Documentation/processing of non-routine itemsApproved data for non-routines

Tracking/reporting of work flow and progress

Doc

umen

tatio

n

Jobcards properly/timely completed/stamped

Approved data for jobcards

UR-DNM #1 Engine Fuel& HYD lines disconnect protection Removal ENGINE 3

#1 Engine Fuel& HYD lines collectively covered, no protectivecaps and HYD fluid lines above fuel line 4oz of hyd fluid in bottom of plastic

UR-DNM #1 Engine O/B Fwd engine mount security Removal ENGINE 4Engine mount adapter attached bolt not properly tightened 1/4"gap

UR-DNM Fuel tank Safety Open FLT CTL 4Open fuel tanks procedures NOT followed (PRO 12 M22 and AMM)

UR-DNM Pitot-Static covers Protection Pre-dock Av/Elect 4 Aircraft not protected until advised on 4.2.2011UR-DNM #1 Engine Electrical disconnects protection Removal Av/Elect 3 #1 Engine Electrical Disconnects not covered

UR-DNM Fuel tank Safety Open FLT CTL 4Follow up on 4-2-2011 no warning tag in Flt Deck per the read & sign

UR-DNM Aircraft Shoring Jacking/Shoring PM 4 Aircraft being shored in the incorrect configuration

UR-DNM Aircraft Jacking Jacking/Shoring PM 3RH body gear lock ring not in locked position per SB and BestPractices

UR-DNM Hydraulic line disconnect Removal Ldg 3After line disconnect not capped and plugged, just baggedwhich creates potential safety risk to workers.

UR-DNM Damage to all four C-duct carts Removal ENGINE 3 Tongues damaged from over steering

UR-DNM C-duct carts usage Removal ENGINE 2Safety risk - fixture not tilted up to match hoisting angle, requied6 people to support 50% of the weight of c-duct.

UR-DNM Body cradles floating Jacking/Shoring PM 4Jacks not depressurized, four jack lifted off mechanical lock, STA 1197 twice the amount of others

UR-DNM Body cradles floating Jacking/Shoring HM 2HM staff member rotated the mechanical locks when over pressure condition.

UR-DNM Swarf in Sealant Sealing BACKSHOP 4Failure to Clean as you Go - Need to establish that inspection must stamp for inspection block before next task step worked

UR-DNM Installation of #1 Engine Install ENGINE 3Tension bolt were used to lift engine weight 6000-3000 dyno change twice.

UR-DNM CIC not applied before Horiz stab LE closed CIC FLT CTL 3 CIC not applied UR-DNM Lube of #2 window Lube Cabin 1 No defects noted, lubricatedUR-DNM CARGO ROLLERS Lube FUS 4 4 ROLLERS NOT LUBRICATED PROPERLYUR-DNM LUBE OF AFT CGO DOOR Lube FUS 4 SOME POINTS NOT LUBRICATED PROPERLYUR-DNM LUBE OF RUDDER PCA Lube FLT CTL 4 SOME POINTS MISSED - 11 POINTSUR-DNM TOOL CONTROL TOOL CTL BACKSHOP 3 TOOLS WERE NOT VERIFIED AT END OF SHIFT.UR-DNM Restore of flt ctl after Sta 955 mod Install FLT CTL 3 2 Bolts missing, cotter pins missing, rod not connectedUR-DNM Installation of winglet grounding stud Install 2 Installed backwards which made removal very difficul

UR-DNM Cap sealing of stringer Hi-Locs Sealant BACKSHOP 3Cap sealing quality poor should be individual caps on tails of HLocs.

UR-DNM Lube of FWD CGO DOOR Lube FUS 4 Some points missed, 6-8 not lubricated properly

UR-DNM Failure to perform Cabin Pressure leakage test Test 4Sta 955 EO required Cabin Pressure test, signed may 9th but not performed.

UR-DNM Error Rate for the Project not including Planning 87 1449 6.00%UR-DNM Total Error rate for the Project 100 1449 6.90%

Rolling 12 month 5 acft to last 5 acft

00.5

11.5

22.5

33.5

Workman

ship

Safety

practi

ces/P

PE

Docum

entat

ion/pr

oces

sing o

f non

-routi

ne ite

ms

Jobc

ards p

roperl

y/tim

ely c

omple

ted/st

ampe

d

Assort

ment o

f FOD

Trackin

g/rep

orting

of w

ork flo

w and p

rogres

sHaz

Mat co

ntrol

Positio

ned/g

round

ed s

afe fo

r main

tenan

ce

Approv

ed da

ta for

non-r

outin

es

Spills/

clean

-upToo

l utiliz

ation

Parts/a

rea id

entifi

ed/ s

egreg

ated/p

rotec

ted PTP

Tubing

/ducti

ng ca

pped

or pl

ugge

d

Contai

ner la

belin

g/stor

age

Entran

ce/w

ork st

ands

Approv

ed da

ta for

jobc

ards

System

s safe

d/tag

ged

Toolin

g cert

ificati

on/ca

librat

ion

Work be

nche

s/work

stati

ons

Electric

al/ESD co

mpone

nts ca

pped

/grou

nded

/pro..

.Lig

hting

/elec

trical

Panels

/tape

/cove

ring

prope

rly in

stalle

d

First 5 Aircraft of 2010Last 5 aircraft

% of total/total 16.00% 26.00% 14.00% 6.00% 1.00% 24.00% 0.00% 13.00% ######

% of R/total R 2.50% 5.86% 4.56% 3.50% 0.00% 0.61% 0.00% 1.28%% of n/total n 20.97% 37.50% 21.43% 1.92% 2.08% 10.31% #DIV/0! 0.00%

% of error to team paper total

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00%

1 2 3 4 5 Bckshp NDT PLNG

RoutineNON-Routine



Time Scheduled














QS Director

40 Minutes












QS Director



Monthly Safety/Quality Committee Meeting Agenda – Mar.

Time Scheduled














QS Director

40 Minutes












QS Director


上海波音质量安全政策 Boeing Shanghai Quality and Safety Policies

上海波音航空改装维修工程有

限公司管理总政策：安全第一、

严格标准、注重质量、树立信

誉。

General Policies of Boeing Shanghai: Safety First, Strict Standards, Excellent Quality, and High Credibility.

●上海波音航空改装维修工程

有限公司坚持“安全第一，预

防为主”的方针。公司参与生

产运行与管理的所有人员，必

须牢固树立“安全第一”的思

想，在确保安全的前提下，认

真履行其职责，提供优质服

务。

Boeing Shanghai holds the principle of “Safety First and Prevention First”. All the employees must firmly follow the value of “Safety First’ and perform their duties seriously to provide excellent service.

●我们的质量标准最低要达到

局方要求，致力于高于局方要

求，超出客户预期。

To set our quality standards at or above the level required by the Regulatory Authorities and strive to exceed the expectations of customers.

●公司接受局方的持续监督检

查。在实施的所有生产运行

中，遵守局方的航空法规、规

章、《国际民用航空公约》及

其附件，以及公司维修许可证

与运行规范的授权、限制和要

求。任何情况下，不低于局方

规章的标准，保证达到并坚持

公司贯彻以上规章而制定的

各种手册和文件要求。

Boeing Shanghai will be continuously supervised and audited by the airworthiness authority and abide by the Aviation laws and regulations, “Convention on International Civil Aviation” and its attachments as well as the authorities, limitations and requirements of company certification and operation specification.

●公司实行标准化、程序化、

制度化的管理与作业。参与公

司生产运行与管理的所有人

员，必须严格按照公司制定的

各类程序、确认的各种岗位职

责，杜绝人为差错，确保生产

安全、正常、有序进行。

The company promotes management of standard, procedure, and system. All the employees who are involved in company operation and management must follow the procedures made by the company completely and be certain with their job responsibilities, avoid human errors and make sure that production runs safely, properly and in good order.

●公司参与生产作业与管理的

所有人员，必须经过培训并取

得相应资格后，方可上岗。公

司通过严格执行规定的持续

合格培训和监督检查制度，以

保证所使用人员持续合格达

到履行其职责要求的资格水

平。

All the employees who are involved in company operation and management shall not be on board until they receive relevant training and qualification for the jobs. Company will ensure that the employees are constantly qualified for their responsibilities by qualification training and supervision system.

●公司鼓励所有参与运行的员

工进行安全问题报告且不受

到报复。

It is encouraged that all the employees report the safety issues without worrying of getting punishment.

●公司按局方要求建立并实施

安全管理体系。建立对风险管

理的制度，不断识别、减缓或

消除安全风险，并提供必要的

人力和财务资源，持续改进公

司安全管理水平。

Company establishes and implements the Safety Management System according to CAAC requirements. It will help to manage risks, continuously identify, mitigate or eliminate safety risks, and provide necessary human resources and financial resources to improve safety management.

●对于发生的各类不安全事

件，公司注重识别系统和组织

缺陷。

Great attention will be paid to identify the defects of the system and organization for all kinds of hazard incidents.

●公司管理层为安全目标的设

定和评审提供管理指导。安全

目标的设定应根据行业安全目

标要求，结合公司生产实际运

行设定。公司管理层负责安全

绩效的考评，全体员工必须遵

照安全目标的要求执行。

Managements of company will provide guides of management for setting and reviewing of safety target. The safety target is developed according to the requirements of industry safety target and company production. Managements will be responsible for the assessments of the safety performances to make sure that all the employees’ behaviors are based on the safety goals.

●公司为质量安全政策的实施

提供必要的人力和财务资源。

Company will supply human resource and finance resource as needed for Quality and safety policy implementation,

●公司建立了员工手册，明确

了安全奖惩相关规定。 Company developed employee manuals and rewards and punishment policy to clarify relevant safety policy.

●上海波音航空改装维修工程

有限公司在适航当局持续监

督、检查下，不断完善生产管

理体系，及时修订、完善被批

准和认可的各类手册，确保手

册在生产运行中的符合性、有

效性和可行性。不断提高安全

控制能力。

Boeing Shanghai will improve the production management system continuously, revise the approved and accepted manuals timely based on the supervision of the authority, and ensure the compliance, effectiveness and feasibility to improve the safety control.

●通过实施系统的质量安全审

核工作，推动持续改进，确保

所有人员都对质量审核人员

采取合作的态度。

To promote the concept of Continuous Quality Improvement through systematical quality and safety audit. To seek to ensure that all personal cooperate with the Quality Auditors.

●确认遵守程序、标准、安全

标准及条例是从CEO到基

层员工所有上海波音雇员

的责任。每一流程所有者都

有责任持续地审视现有的

系统和程序，并在符合本质

量管理政策的前提下对其

进行优化。

To recognize that compliance with procedures, standards, safety standards and regulations is the duty of all levels of staff in BSAS, from the CEO to the maintenance floor. Each process owner of the company is responsible for constantly reviewing existing systems and procedures, and revising them to achieve optimization, in line with this quality policy.

●本公司每个人都有责任、有

义务理解本政策，并致力于本

政策的落实和执行。

Each and every individual in the company is accountable, responsible, and committed to understand and execute this policy.

上海波音航空改装股份有限公司首席执行官 Chief Executive Officer

BSH Annual safety target indicator design protocol A. Annual company maintenance error-event review

From Jun ,2010 To Mar,2011， there happened 8 Maintenance error in 9 Months, 4 event related to Heavy Maintenance, another

4 event related to Line Maintenance.

I. Operation department maintenance error statistics 1.HM

2. LM

3. Backshop and other department

None II. Maintenance error rate statistics

i. Company Business (2010.07.01-2011.03.01 ）

Total Man Hours ： 155000 RH(Rough Hours)

（Including general maintenance error 4, serious maintenance errors 3; Maintenance incident 1.）

Totally Maintenance error-rate is 8/155000≈0.52/10 thousands RH

(Serious Maintenance error rate 3/155000≈0.19/10 thousands RH）

Total 99400 Rough Hours

10000

15000

20000

25000

0

5000

Jul 2010 Aug 2010 Sep 2010 Oct 2010 Nov 2010 Dec 2010 Jan 2011 Feb 2011

Total

Sum of HM Rough Hours

ii. Overhaul and Backshop （2010.07.01-2011.03.01 ）

Total Man Hours ： 99400 Rough Hours

Month

Totally Line maintenance error rate: 4/99400≈0.40/10 thousands RH

（Maintenance General error rate: 2/110400≈0.20/10 thousands RH

Serious error rates the same as 0.20/10 thousands RH ）

iii. Line Maintenance (2010.07.01-2011.03.01 ）

Total Man Hours: 56000 Rough Hours

Totally Line maintenance error rate: 4/56000 ≈ 0.7/10 thousands RH

（Maintenance when the general rate for: 2/56000≈0.36/10 thousands RH

Serious Maintenance error rates the same as 1/56000≈0.17/10 thousands RH ）

III. 2011 Annual safety targets:

According to company workload estimates this year, there is approximately 200 thousand RH

for overhaul and 75 thousand RH for Line Maintenance this year. Totally Man Hours is 275

thousand RH.

Annual safety targets of company are as follows:

1． Maintenance accident (including major, significant, General accident) is 0;

2． Maintenance incident to 0;

3． Maintenance error rate is less than 0.5/10 thousands RH, and serious maintenance

error rate is less than 0.2/10 thousands RH.

Targets of each department setting are as follows:

i. HM

Annual safety targets for maintenance error rate is less than: 0.3/10 thousands RH (including general maintenance

error rate: 0.2/10 thousands RH , Serious Maintenance error rate: 0.1/10 thousands RH ）

ii. Line Maintenance

Annual safety targets for maintenance error rate is less than: 0.7/10 thousands RH (Including general error rate: 0.4/

10 thousands RH, Serious error rate: 0.2/10 thousands RH ）

iii. Backshop Annual safety targets for: maintenance error rate is less than 0.1/10 thousands RH (Including general error rate: 0.1/10 thousands RH, serious maintenance error rates 0)

iv. Operational support department Annual safety targets for maintenance error event is less than 1

v. Supply chain Department, Engineering Department, quality Department Annual maintenance errors event is 0

vi. Department of facilities: Maintenance accident is 0 ；

Fire accident is 0 。

vii. Vehicular traffic:

-Department has responsibility on the reported traffic accidents, the safety target setting up as: 1 incident per 100,000 km (Ground Traffic distance) Where: operations: 0.8 incident/ 100,000 km Department of facilities as: 0.1/100,000 km Supply chain department as: 0.1/100,000 km



Time Scheduled














QS Director

40 Minutes












QS Director



Monthly Safety/Quality Committee Meeting Agenda – May.

End

monthly safety review may -met

Documents