A just released report by the U.S. Department of Transportation’s Inspector General says the Federal Aviation Administration (FAA) has failed to correct maintenance deficiencies at American Airlines.

The damning audit was made public a day after the FAA proposed a $2.9 million civil penalty against American Eagle Airlines for operating more than 1,000 flights using airplanes on which improper repairs were performed on landing gear doors.

And it followed by two weeks disclosure that the aviation agency was fining American Eagle $2.5 million for not making sure crews had accurate information about the weight of baggage on dozens of flights.

An American Eagle spokeswoman said company officials disputed the penalties "and believe they are excessive and inappropriate."

The FAA alleges that between January and October 2008, American Eagle conducted at least 154 passenger flights when the baggage weight listed on airplane cargo load sheets disagreed with data entered into the company’s Electronic Weight and Balance System.

The FAA alleges that between February and May 2008, American Eagle conducted at least 1,178 passenger-carrying flights using four Bombardier jets with main landing gear doors that had not been repaired in accordance with an Airworthiness Directive that became effective in August 2006.

An airworthiness directive requires operators of certain Bombardier regional jets to inspect the left and right main landing gear inboard doors for cracks and other damage, including loose or missing fasteners. The directive requires operators to remove affected doors and replace them with new or repaired ones, or that the doors be removed and the discrepancy noted in the aircraft’s records.

The FAA alleges that American Eagle found such damage on four aircraft. Rather than removing the doors, the airline repaired them while they remained on the planes.

FAA inspectors found that the airline operated at least 961 flights while it was unaware that the situation existed on these aircraft. The FAA further alleges that after the situation was discovered, the airline continued to operate these airplanes on 217 additional flights.

American Eagle subsequently removed the landing gear doors on each of the affected aircraft and repaired them in accordance with the AD.

The company spokeswoman is quoted as saying that American Eagle is “disappointed” with the proposed fine. “The case didn’t present a safety issue. Eagle conducted the inspections as called for in the airworthiness directive and made repairs when the inspection indicated a repair was required. Eagle self disclosed to the FAA that the repairs on certain aircraft may have been performed while the landing gear doors remained on the aircraft,” she added.

The report by the DOT watchdog found fault with the FAA’s oversight of aircraft maintenance at American Airlines. It said the audit raises questions about the effectiveness of the FAA's maintenance oversight of airlines in general.

The Office of Inspector General (OIG) audit was prompted by allegations that the overall aircraft operational reliability had decreased at American Airlines and American Eagle, its regional air carrier affiliate.

The audit objectives were to assess (1) FAA’s oversight of American Airlines’ maintenance program and identify any underlying weaknesses and (2) FAA’s response to the allegations.

OIG reported that FAA’s oversight “lacked the rigor needed to identify the types of issues identified in the allegations, at least four of which were found to be valid.”

Specifically, FAA failed to assess systems for monitoring air carrier maintenance programs, identify root causes of maintenance deferrals, ensure properly trained mechanics performed certain required inspections, and ensure prompt responses to safety recommendations and service bulletins. 

In addition, FAA’s internal reviews of the allegations “were not comprehensive.  As a result, FAA missed opportunities to identify potential maintenance issues and put corrective actions in place.” 

OIG recommended several actions to enhance FAA’s oversight in key maintenance areas at American—such actions could also improve FAA’s maintenance oversight at other air carriers as well as its processes for assessing industry-wide safety allegations.

FAA generally concurred with the recommendations; however, many of the actions FAA has taken are still underway.  Therefore, OIG has requested additional information to validate that the issues identified have been fully addressed.

Ramon Lopez also serves as editor-in-chief of Air Safety Week; he has been covering air safety for more than three decades (rlopez@accessintel.com).

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