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100% Inspection Instructions (Post Brotje) Revised 24 November 2010

100% Inspection Instructions (Post Brotje) Revised 24 November 2010.

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100% Inspection Instructions (Post Brotje) Revised 24 November 2010

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  1. A/P # _133 Section # _48____

  2. A/P # 133 Section # _48____

  3. 100% Inspection Instructions (Post Brotje) Revised 24 November 2010

  4. To begin the 100% Brotje inspection you must start with the Interior of the barrel or IML (Inner Mold LINE), measuring pin protrusion and collar swage. Documenting all missing fasteners and collars, pilot holes, and fasteners without collars installed, in the appropriate AP inspection book. Use orange tape to mark any discrepancies found on the inspection with LP (long pin), SP (short pin), or BS (Bad Swage) next to the appropriate fastener on the OPB. Once the IML is complete you can proceed to measure and document the flushness of all fasteners on the exterior of the barrel or OML (outer Mold Line). • Pin Protrusion (measurement) • Starting on the IML (Inner Mold Line) of the “entire” OPB (One Piece Barrel) measure Pin Protrusion of each fastener that is common to the IML of the OPB. • Measure all fasteners using the required and appropriate Brotje pin gauge checking pin height as well as collar swage. For all fasteners that meet the BAC requirements highlight the corresponding fastener (point) blue in the appropriate AP 100% inspection book. • For all collars that are above or below the Pin Protrusion requirements, circle the corresponding fastener (point) in the 100% inspection book and mark it with LP (long pin), SP (short pin) whichever is appropriate and Do Not Highlight.

  5. EXAMPLE: • Missing Fastener(s) • For all full sized holes common to the OPB that do not have a fastener installed at that location, circle the corresponding fastener (point) in the 100% inspection book and document the condition by marking next to the corresponding fastener (point) with an NF (No Fastener). Do NotHighlight.

  6. EXAMPLE: • Missing Collar(s) or Fastener Installed w/No Collar. • For all fasteners common to the OPB that DO NOT have a Brotje installed collar at that location or are missing a collar, circle the corresponding fastener (point) in the 100% inspection book and document the condition with an NC (NO Collar). Do Not Highlight.

  7. EXAMPLE: • Missing Collar(s) or Fastener Installed w/No Collar. • For all fasteners common to the OPB that DO NOT have a Brotje installed collar at that location or are missing a collar, circle the corresponding fastener (point) in the 100% inspection book and document the condition with an NC (NO Collar). Do Not Highlight.

  8. EXAMPLE: • Pilot Holes/DA Holes • For all holes common to the OPB that are not drilled to full size (i.e.: pilot holes/DA holes), circle the corresponding fastener (point) in the 100% inspection book and document the condition with a DA (Pilot Holes). Do Not Highlight.

  9. EXAMPLE: • When all of the above is completed, proceed to the OML for the fastener flushness checks. Using orange tape on the OPB running adjacent to each fastener location in order to document with a check mark for a fastener that meets requirements or to record the out of tolerance measurement found for the fastener. • Fastener Flushness (measurement) • Starting on the exterior of the barrel or OML (Outer Mold Line) of the “entire” OPB (One Piece Barrel) measure Fastener Flushness of each Brotje installed fastener that is visibly seen. • For all fasteners that meet the required Spec Tolerance to the BAC, highlight the corresponding fastener (point) yellow in the 100% inspection book and place a check mark on the orange tape adjacent to the fastener measured. • For all fasteners that are above or below the fastener flushness requirements of +0.002, -0.005 only measuring to the thousandths place, circle the corresponding fastener (point) in the 100% inspection book, Do Not Highlight, and document what the measurement is next to the corresponding fastener (point) in the inspection book and on the orange tape adjacent to the fastener measured.

  10. For fasteners that do not have a Brotje installed collar, measure and document a check mark or measurement on the tape on the OPB only. Do Not Document any measurement in the inspection book. That fastener (point) should have an NC already placed at the corresponding fastener (point) in the inspection book. Do Not Highlight. • EXAMPLE: • Documenting Progress • While you are doing the 100% Inspection for the Post Brotje Shake, it may be appropriate to document what you’ve completed so the following shift/person will know where you left off so they may continue work. To accomplish this there are sheets in the front of the inspection book with areas for each station to be stamped with your inspection stamp to signify you have completed that section. For partial completion, mark the appropriate page and station with a stamped buy at the point you began and the place you finished.

  11. Legend : • LP – Long Pin • SP – Short Pin • BS – Bad Swage • DA – Pilot Hole • NF – No Fastener • NC – No Brotje installed Collar NB – Non Brotje collars (i.e.: collars installed but not by Brotje - hand installed) • MH – Missing Hole

  12. FRAME 1 STA 1900

  13. A/P # _____ Section # _48_

  14. A/P # _____ Section # _48_

  15. A/P # _____ Section # _48_

  16. A/P # _____ Section # _48_

  17. FRAME 2 STA 1918

  18. A/P # _____ Section # _48_

  19. A/P # _____ Section # _48_

  20. A/P # _____ Section # _48_

  21. A/P # _____ Section # _48_

  22. FRAME 3 STA 1942

  23. A/P # _____ Section # _48_

  24. A/P # _____ Section # _48_

  25. A/P # _____ Section # _48_

  26. A/P # _____ Section # _48_

  27. FRAME 4 STA 1962

  28. A/P # _____ Section # _48_

  29. A/P # _____ Section # _48_

  30. A/P # _____ Section # _48_

  31. A/P # _____ Section # _48_

  32. FRAME 5 STA 1982

  33. A/P # _____ Section # _48_

  34. A/P # _____ Section # _48_

  35. A/P # _____ Section # _48_

  36. A/P # _____ Section # _48_

  37. A/P # _____ Section # _48_

  38. FRAME 6 STA 2003

  39. A/P # _____ Section # _48_

  40. A/P # _____ Section # _48_

  41. A/P # _____ Section # _48_

  42. FRAME 7 STA 2023

  43. A/P # _____ Section # _48_

  44. A/P # _____ Section # _48_

  45. A/P # _____ Section # _48_

  46. FRAME 8 STA 2044

  47. A/P # _____ Section # _48_

  48. A/P # _____ Section # _48_

  49. A/P # _____ Section # _48_

  50. SERVICE ACCESS DOOR

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