Date: 202004
Flight conditions: VMC
Light: Night
Aircraft: B737-900
Operator: Air Carrier
Operating under: Part 121
Flight plan: IFR
Mission: Passenger
Flight phase: Parked
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Powerplant; Maintenance Airframe
Human factors: Communication Breakdown; Time Pressure; Workload
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural MEL / CDL; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Maintenance
When detected: In-flight; Pre-flight
Result: General Flight Cancelled / Delayed; General Maintenance Action
Contributing factors: Company Policy; Aircraft; Human Factors; Procedure; MEL
Primary problem: Human Factors

Narrative: Today I had the shift logs for 5 scheduled ferry flights; Aicraft X; Aircraft Y; Aircraft Z; Aircraft A; and Aircraft B. Started off by verifying departure times and flight numbers. Then reviewed the open items; MEL's; and scheduled Maintenance both assigned and possible expiring. Followed up with planning to confirm that there were no overtime items that I may have missed. Contacted the stations the aircraft were located; ZZZ; ZZZ1; and ZZZ2 and made sure they were aware of the scheduled ferry flights and reviewed the open items with them. Updated all 5 aircraft ferry flight checklist. Aircraft Z at ZZZ2 was the first scheduled out to ZZZ3. On taxi out the crew had the leading edge device amber light on the fwd panel. The aircraft returned to the gate where Maintenance evaluated the light and was unable to reset it. So; we placed it on deferral IAW the MEL. Sent the new arrange meter to request the new MFD (Maintenance Ferry Document) the equivalent of an MRD (Maintenance Release Document). The aircraft taxis back out and they receive a takeoff warning for misconfiguration of the aircraft for takeoff. Back to the gate again. this time we had to have Maintenance work the item as it is not deferrable. They replaced a box and performed the test and returned the aircraft to ferry flight ready status. 3rd time is a charm. the aircraft left ZZZ2 for ZZZ3.In the middle of all of this we had issues with Aircraft B in ZZZ1 with the potable water and a dead MEL along with 2 DIPs that required reinspect. During my conversation with ZZZ1 initially we needed the dead MEL cleared. It had been repaired but needed leak checked. Upon servicing the potable water and leak checking it they found that it still leaked. We were asked to have them fix it prior to departure. After further evaluation it would be a major job. The decision was made to go ahead and let it fly with the dead MEL added to the MFD. keep in mind this is several phone calls and all going on at the same time as Aircraft Z and regular calls for deferrals and any other number of problems and questions. After clearing all that up I went through my other aircraft to see how close to departure they were. that is when I noticed that [Aircraft] X and Aircraft A were airborne. Thought good; hey made it out without any problems. So; I went to update the paper work and download the MFD's and attach them to the logs and send them to the shift managers. that is when I panicked. When I pulled up [Aircraft] X and saw it still showed just an arrange meter I went to verify that it was truly in flight. My fears were confirmed it was. So; I called (Shift Manager) and told him. HE was on a call and told me he would get right back with me. While waiting on his call back I started reviewing the other aircraft and found that the same thing happened with Aircraft A. I sent [Shift Manager] a [message] letting him know about the 2nd aircraft. Shift Manager asked what happened and asked that I contact ZZZ1 to see what I could find out. I contacted ZZZ1 [Maintenance]. He explained that the crews called and they told them that they would have to contact [Maintenance Control] for the MFD as they are unable to issue one.After that call I followed up on Aircraft A as it was due out soon and reviewed the logs and logbook and issued the MFD.During follow up review of what all happened I discovered that the 2 DIPs requested to be worked had not been cleared. So; I notified Shift Manager and [ZZZ1 Maintenance] about the flight with overdue items not addressed on the MFD or cleared prior to flight.A couple possibilities. 1. One would to add to the procedure that prior to any ferry flight the crew should contact [Maintenance Control]  and review the aircraft maintenance status; flight ready status and any special request.2. Would be to setup the ferry flights like the regular flights where if the crew tries to depart without a  valid MFD they receive a warning to the flight deck stating they need a MFD. (I believe this one is possibly in work.)3. Have the auto generated log page for inspection be generated locked so Maintenance has to contact [Maintenance Control] when the ferry flight inspection is complete. With this option I think we should include in the inspection item discrepancy a statement like ***THIS ITEM MUST BE CLEARED PRIOR TO ANY FLIGHT CONTACT [Maintenance Control]***. This would reduce the possibility of Maintenance thinking that the inspection item is part of the ferry flight and supposed to remain open.




Synopsis: Maintenance Controller reported miscommunication and excessive workload caused multiple errors in releases for aircraft requiring ferry flight permits resulting in non compliance.