hotrod180 wrote:Wasn't Navworx working on addressing the problem(s)?
I believe they had something to do with using non-approved internal parts,
or substituting unapproved parts for previously approved ones.
The learning curve tends to be steep for companies who attempt to certify something with the FAA. Lancair, Rans, Van's all had perfectly good designs in production and probably thought certifying would be straight forward. I used to do tooling for the certified Lancair. There was only one fuselage bulkhead in common with the kit built plane when they were done.
For the supplier of something small (a product for an STC or a piece of avionics) they don't seem to understand that you can't just substitute something you
know deep down inside is just as good as the one you promised the FAA you would be using.
Traceability, clear back to the hole in the ground the ore was dug up from. You can't even substitute a washer that has a different finish without the FAA finding out what you ate for Thanksgiving.
Retaining audit-proof records of everything in and out of your doors is why certified airplanes parts are so expensive. It's a pain in the a**. You can't have a single part laying around that doesn't belong to a job (shop guys often like to save an extra part or two to use as setup next time they make them, or to fill in when they scrap a part. NO CAN DO). Have one pair of calipers that don't have a certification sticker? Oops! Missing one signature on a work order that some audit gut pulls out at random? You're toast.
About 8 years ago I went to bat for a supplier who makes sun visors (yes that one). We (my giant employer) had a source inspector with a Jekyl & Hyde personality (he was diabetic) who FLIPPED out on them one day because they didn't do quality the way he thought they should. There were some things they couldn't justify but they still made a great product, exactly as we had been asking them to do for many years.
It took most of a year to sort out and I still have a bad taste in my mouth about the way they were treated. Once I got past the "I'm from the big ass company and I'm here to help" part I was able to discover that they had been documenting everything perfectly well, but no one asked the right workers.