Agencies to Fault American on Maintenance
By Andy Pasztor
Wall Street Journal
February 8, 2010
American Airlines is about to come under sharp criticism from two separate federal agencies accusing it of serious maintenance lapses, according to government and industry officials familiar with the details.
In the next few days, these officials said, the Department of Transportation’s inspector general is slated to release a report outlining apparent failures by the AMR Corp. unit to identify and promptly resolve aircraft-maintenance problems in 2008. The alleged deficiencies range from multiple faulty repairs of engine-start systems to repeated deferrals of other repairs, as well as mechanics signing off on work without the necessary authority.
Separately, senior Federal Aviation Administration officials are close to proposing a civil penalty against American, wrapping up an enforcement case stemming from different maintenance lapses dating back to roughly the same period. The penalty is likely to be the largest the agency has levied against an airline, the officials said.
American spokesman Tim Wagner said, “It would be inappropriate for American to comment” until the report’s release. “We have cooperated fully with the DOT’s review, and our responses are included in the report,” he said. He declined to discuss any possible FAA action.
The proposed American penalty, government and industry officials said, is likely to top $10 million, and could be as much as $20 million, unless the agency changes course. It stems from repairs alleged to have been performed improperly on wiring near the landing gears of American’s McDonnell Douglas MD-80 aircraft. In April 2008, those problems forced the temporary grounding of American’s entire MD-80 fleet, causing flight cancellations affecting more than 300,000 passengers.
A spokesman for the DOT’s inspector general and spokeswoman for the FAA declined to comment. But FAA officials have indicated the agency and the airline have taken steps to resolve many of the issues covered by the inspector general’s report.
No final decision has been made on the size of the penalty, and no specific figure has been communicated to the airline, the officials said. In 2008, the FAA proposed what would have been a record penalty of $10.2 million against Southwest Airlines Co., but it was later negotiated down to $7.5 million.
In the past, American officials have said the MD-80 wiring issues didn’t pose an imminent safety hazard, and some have signaled the company most likely would challenge a large fine.
Industry officials said outside consultants, brought in after American’s MD-80 wiring snafus, found that a shortage of maintenance supervisors at American, vaguely worded engineering orders and the tendency of some line mechanics to improvise on certain repairs contributed to the problem.
Since then, American has sharply increased the number of employees monitoring maintenance trends and changes in the reliability of aircraft systems. The FAA, meanwhile, has improved its capabilities to track deferred maintenance tasks and determine when to order corrective actions.
American’s mechanics union said it has “worked closely with the company to pinpoint maintenance problems and correct them.” John Conley, a senior official of the Transport Workers Union, said in a statement that “most of what is included in the [inspector general's] report are issues that have already been addressed.”
Taken together, the government’s expected actions reflect closer scrutiny of maintenance operations at the country’s No. 2 carrier by passenger traffic, as well as the difficulty of resolving aircraft-maintenance disputes without prolonged wrangling.
But while the inspector general’s audit is critical of what it indicates were lapses by the airline, it primarily faults the FAA for lax oversight of American’s maintenance practices, government and industry officials said. The audit alleges that the FAA failed to keep close track of safety and reliability trends at the airline.
The auditors also criticize the FAA for failing to appropriately monitor repeated failures of forward landing gears on American’s MD-80 jets. In addition, they criticized the FAA for its delay in issuing safety directives for potentially dangerous windshield heaters.
Officials said the inspector general’s office is expected to urge the FAA to step up verification of American’s maintenance work, instead of relying on agency inspectors’ reviews of the carrier’s records. The report also is expected to call for high-level FAA reviews of whether the agency’s weaknesses are systemic or limited to the office that keeps tabs on American.
The inspector general’s audit was prompted by safety complaints from American’s pilots union, which remains locked in bitter labor negotiations with the carrier. The document, among other things, identifies engineering and process failures related to delays in changing out suspect parts that could cause short circuits, smoke and cracks in cockpit windshields on Boeing 757s and other models.
Senior managers at American, which performs more repairs in-house than any other large U.S. airline, have been aware of nagging maintenance difficulties for years, industry officials said. They said that even though American’s internal safety-oversight system flagged substandard repairs early on, airline management failed to understand or promptly act on such warnings.
In recent years, American has tangled with FAA inspectors and government crash investigators over various maintenance matters, some outside the scope of the inspector general’s audit and the pending FAA enforcement case. Congressional investigators also have been looking into some of the same issues.
In September 2007, the National Transportation Safety Board criticized years of delays by the FAA and industry in replacing potentially hazardous cockpit windshields. The FAA eventually issued a series of safety directives calling for stepped-up inspections of windshields on Boeing 747, 757, 767 and 777 aircraft, and is now expected to issue still another directive dealing with the dangers of smoke or fire. American voluntarily began replacing suspect windshields some time ago, but late last year company officials said the process was only about half finished.
According to Boeing Co., which issued its last maintenance bulletin on this topic two years ago, there have been 29 incidents of windshield smoke or fire on Boeing aircraft since the beginning of 2001.
In August 2008, the FAA proposed a $7.1 million penalty against American for allegedly violating employee drug- and alcohol-testing procedures and knowingly flying airplanes that violated maintenance regulations.
In May 2009, federal crash investigators said American’s faulty maintenance, combined with a deficient internal safety-oversight system, contributed to an engine failure and subsequent fire on an MD-80 plane shortly after takeoff from St. Louis two years earlier. Despite hydraulic and electrical malfunctions, the crippled twin-engine jet managed to return safely to the airport.
But the safety board faulted both American and the FAA for failing to realize, prior to the crash, the significance of certain maintenance data. Mechanics had repeatedly swapped out start valves on the same engine that quit leaving St Louis. Mechanics ended up replacing valves six separate times during a 12-day period leading up to the enmergency, but still failed to get to the bottom of the problem
Last summer, FAA inspectors launched an investigation to determine whether American failed to properly alert them about potential safety problems stemming from scratches on the aluminum skins of some Boeing 737 jets. The planes were damaged from contact with certain types of passenger bridges, or jetways, used at airports nationwide.
Write to Andy Pasztor at andy.pasztor@wsj.com