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addressed the Boeing Long Beach airplanes, the DC-9, DC-10, MD-80 / -90, MD-11, and 717.
5.4.1 Team Composition
Figure 5-1 below shows the internal Boeing Engineering organizations and the air carriers that
comprise the Boeing Working Group:
Figure 5-1: Boeing Airplane Working Group Organization
Each team, though similar in makeup and purpose, established individual procedures with respect
to the industry commitment. Each team met regularly to track progress, report findings, and
provide feedback to improve the process.
5.4.2 Team Activities
Periodic meetings of the entire Boeing Working Group were held in which detailed reviews of the
inspection program status were provided and any resulting analysis was discussed. Working group
discussions identified issues that were either resolved at the meetings or gave rise to action items
for resolution outside the meeting. Group telephone conferences were also used within individual
teams to address questions that came up during the inspection process. Altogether, a total of five
meetings and several working-group telecons were held in addition to countless individual phone
calls and telexes between the airlines and Boeing.
Boeing Working Group
Puget Sound
Twin-Aisle Programs
747, 767, 777
_____________________
Define Engineering
Service Engineering
Maintenance Engineering
Airline members:
BAB, UAL, CAT, AAL, NWA,
AFA, KLM, UPS, ACN,
TWA, USA, CAL, ANA,
COR, JAL, QAN
Puget Sound
Single-Aisle Programs
707, 727, 737, 757
_____________________
Define Engineering
Service Engineering
Maintenance Engineering
Airline members:
USA, UAL, QAN, AAL,
NWA, SWA, ASA, CAL
Long Beach
DC-9, DC-10, MD-80/-90,
717, MD-11
_____________________
Define Engineering
Service Engineering
Maintenance Engineering
Airline members:
FED, NWA, TWA, DAL, CAL
5.0 Boeing Working Group Report (continued)
August 4, 2000 Industry AFFSP Report Page 41
5.5 Working Group Approach
Two objectives of the AFSSP were to have the manufacturer validate (1) design principles and
manufacturing processes and (2) maintenance programs and processes. To accomplish the first of
these objectives, Boeing reviewed
! Fuel system design requirements.
! Drawings used to build Boeing airplanes.
! Processes used to manufacture and install fuel systems in Boeing jetliners.
5.5.1 Inspection Program
Fuel system design requirements—to verify that design features for ignition prevention are
robust, Boeing performed a review of the basic requirements used in the design of its airplanes.
Industry standards for ignition prevention can be traced back to before the first commercial jet
transports. Boeing’s fuel system design requirements were reviewed and confirmed to be based on
industry standards as well as on testing and analysis performed by Boeing and its suppliers.
Although detailed requirements have evolved from model to model, the basis for the requirements
are generally the same. This review found that Boeing’s requirements are conservative in
providing design margin and have redundancy built in that enhances the level of safety.
Following this design-requirements review, a review of the design of each commercial fuel system
designed by Boeing was done to ensure that these requirements were implemented into the design
definitions. To date, Boeing has completed requirements reviews and detailed drawing reviews for
the 717, 747, 757, 767, 777, DC-9, MD-80 / -90, DC-10, and MD-11 airplane models. The 707 has
been reviewed for electrical bonding. The 727 and 737 airplane models are still in work.
During these design reviews, items were identified in some cases that warranted specific fleet
inspections. Based on design review and fleet data, Boeing has incorporated, or is in the process of
incorporating, revisions to Boeing production airplanes that provide additional enhancement of the
bonding of parts or components in the fuel tanks. In many cases, these revisions include clearer
instructions for manufacturing. Some changes will also provide improved bonding path designs.
In addition to the requirements and drawing reviews, Boeing conducted reviews of service
bulletins and airworthiness directives for lessons learned that might be applied across all Boeing
designs. Boeing also reviewed airplane maintenance logs, telexes, and component repair
information from the participating airlines. The 747 review is complete, and review of other
models is in progress. The data will be used primarily to enhance the maintenance programs for
the fuel systems of Boeing airplanes.
Drawings used to build Boeing airplanes—the Boeing plan for reviewing manufacturing
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