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processes included a series of inspections of each model currently in production. The intent was to
ensure that the design and build instructions contained in the engineering drawings were being
properly implemented in the factory. Minor issues were identified and corrected during these
inspections. None of them could adversely affect the safety or airworthiness of an airplane. Boeing
Long Beach inspected its in-production models as a validation of the inspection documents.
5.0 Boeing Working Group Report (continued)
Page 42 Industry AFFSP Report August 4, 2000
A detailed review of the 747 manufacturing planning instructions was conducted to audit the
process by which Manufacturing Engineering (planning) takes the engineering product definition
and converts the information into instructions for the factory. This review identified a couple of
areas where improvements could be made. These improvements have assisted in the capture of
certain types of requirements found on engineering drawings to ensure consistent implementation
in the factory across the entire Boeing product line.
Processes used to manufacture and install fuel systems in Boeing jetliners—the inspection
plan defined by Boeing included inspections of center wing tanks and main wing tanks on hightime
and low-time aircraft in the commercial fleet. The purpose of the inspections has been to
gather data on the condition of fuel tank systems aboard in-service airplanes and determine the
possible effects of aging. The data would be used to develop an enhanced maintenance program.
The inspection plan focused on the models with the majority of the current fleet experience (727,
737-200, 737-300 / -400 / -500, 747, 757, 767, DC-9, MD-80 / -90, DC-10, and MD-11). Various
airplanes from the relatively young 777 fleet were inspected at a limited level. While 707 airplanes
were not physically inspected, 707 drawing reviews and similarity of the fuel system details to the
727 and 737 fuel systems will allow development of enhanced maintenance programs for the 707.
The DC-9 fleet was the primary focus at Boeing Long Beach because it had more hours and
cycles, and thus provided a better indicator of how the fuel system design was aging. The Next-
Generation 737 and the 717, both of which entered service after the inspection program began, did
not undergo fleet inspections but will receive the applicable enhancements to their maintenance
programs based upon drawing reviews and similarity to the other models that were inspected.
The inspections established by the Boeing Working Group teams were designed to verify (1) the
integrity of wiring and bond straps; (2) the conditions of fuel pumps, fuel lines, and fittings; and
(3) the electrical bonding on all equipment. To accomplish this, each team decided to inspect a
number of aircraft as determined by that team. The process used by the Boeing Puget Sound
Single-Aisle and Twin-Aisle Programs was to develop service bulletins that could be used by the
airline, with or without Boeing assistance, to conduct the inspection, record the results, and
provide the data to Boeing. Boeing Long Beach developed inspection documents that were used
by Boeing personnel to perform each inspection.
Boeing Puget Sound developed and released service bulletins to conduct inspections of the 727,
737, 747, 757, and 767 airplane models. The center wing tank inspection service bulletins were
applicable to all airplanes built at the time of release. To cover the large range of configurations,
the center tank service bulletins were somewhat generic and covered the major configurations of a
model, with notations where differences were expected. The main wing tank inspection service
bulletins were designed for specific targeted airplanes, and the inspections were accomplished by
the airlines with on-site support from Boeing.
The following two tables (figures 5-2 and 5-3) show the inspection documents developed for each
affected aircraft model.
5.0 Boeing Working Group Report (continued)
August 4, 2000 Industry AFFSP Report Page 43
Airplane
model
Service bulletin
number
Service bulletin subject Availability date
727 727-28-0122 FUEL – Storage – Center Wing Fuel
Tank Inspection
March 1999
727 727-28-0123 FUEL – Storage – Inspection of the
Number 1 and Number 3 Fuel Tanks
July 1999
737
-100/-200
737-28-1123 FUEL – Storage – Integral Fuel Tanks –
Center Wing Fuel Tank Inspection
October 1998
737
-100/-200
737-28-1124 FUEL – Storage – Main and Surge Fuel
Tank Inspection
July 1999
737-300/
-400/-500
737-28-1117 FUEL – Storage – Center Wing Fuel
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