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wrong size screws were used on the windshield replacement of the Boeing 737
Aircraft maintenance requires a cool head. When someone is working on a job, they must be honest with the job and the company they work for. Sometimes, a person may work with a group, and everyone should be sincere in their job. Normally, this is the case, but sometimes, people working together are not harmonious, which causes problems.
We were assigned to change the windshield of a Boeing 737. My companion was Mr. Tim, and we started arranging the work setup. This requires the aircraft to be in a hangar and special stands. So, we began the job. You might have noticed a normal phenomenon: when anything is required to be removed or dismantled, the crew will try to do it as fast as possible. Often, when it comes time to reinstall, people start looking for the panels, hardware, etc.
My procedure of work was that whatever is removed from its location should be numbered, organized, and kept properly in general. So, when we started removing the windshield, Mr. Tim was in a bit of a hurry, as usual, giving a lot of unwanted, unrelated talks. Well, it’s okay, as some people enjoy listening, but we should concentrate on the job as a priority. So, when we were removing the screws, and I was collecting them in a bag, Mr. Tim dropped a few of them on the floor, telling me it’s okay because they were bad and we had to change them anyhow. I kept quiet.
Finally, the windshield was removed, and we started installing the new one after the avionics tested the heating element of the anti-ice. We started putting the new one in its place. You know, the bolts are tightened in a special order. We were doing well, but at the end, we were short of those special screws that had fallen to the ground. Bad luck was that we were short of four special screws.
Now, Mr. Tim was worried. As I told him, those screws were out of stock, and we didn’t have those special length screws anywhere. Another thing that came to head was the hangar shift manager, who was pushing us to finish the job. Tim got a little nervous but told the manager that we were short of three bolts or special screws. The manager got in a high tone and started cursing. He said he had given us enough time, and we were holding up the aircraft just for these two screws. Tim told him we didn’t have the proper length screws. The manager exclaimed, “God dammit, one or two screws will not make any difference!”
Sometimes, when I think of these words, the face of the manager comes to mind. So, Mr. Tim told me, “Hey Abbas, I am going to sign off on it. We will install the other bolts.” So, the job was completed, and the aircraft was released for service. It was its first flight to Medina. The pilot made a semi-emergency landing there. The reason was that soon after the aircraft took off and reached the required altitude, a sharp whistle sound started coming from the windshield. The pilot contacted the control tower and was given priority and a special altitude until he landed safely.
The investigation, conducted as the aircraft was grounded there, revealed that a longer screw was used and the windshield was not properly seated. Well, what happened after these findings is another story, and you can only imagine what conversation took place between Mr. Tim and the shift manager. I was out of it, as the paperwork indicated the signatures and all.
The only words I will say are: never take any aircraft maintenance job lightly. A big responsibility rests on the shoulders of the personnel involved.
Listen to this story on my website in English
at the following link https://youtu.be/P9JqSlJ-az0
Story of M1181/ON 01/01/1981
on THIS LINK https://www.youtube.com/watch?v=XPB3FjooXsQ&t=25s&ab_channel=SHUJAT.A.ABBASIANMFAHM
https://www.youtube.com/watch?v=XPB3FjooXsQ&t=25s&ab_channel=SHUJAT.A.ABBASIANMFAHMS
This particular story is in the URDU language
maybe it reminds you of YOUR FRIEND.. ABBASI a long time back worked with you
MECHANIC IN THE WING 
AIRCRAFT BOEING 707
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