Date: 201203
Local time of day: 0601-1200
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: B777-200
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Parked
Aircraft component: Aileron
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Communication Breakdown; Confusion; Situational Awareness
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Published Material / Policy; Ground Event / Encounter FOD
Detector: Person Maintenance
When detected: Other Repair Shop  Audit
Result: Aircraft Aircraft Damaged; General Flight Cancelled / Delayed; General Maintenance Action
Contributing factors: Aircraft; Procedure; Manuals; Human Factors; Company Policy; Chart Or Publication
Primary problem: Procedure

Narrative: Aircraft X; a B777-200 aircraft was here; at the ZZZ Maintenance Base; because of damage caused by an engine fire of sorts.  There were several parts damaged on the wing.  The  Left-hand (L/H); Outboard (O/B) Flap and Flaperon were beyond repair; so other units were acquired.  Our Air Carrier policy and procedure is that parts are supposed to be routed to the home shop for inspection and to have the proper documentation attached to it.  We are required to put a company parts tracking tag and a company Part Number (P/N) tag on the unit and issue an FAA-8130 serviceable tag [for the unit] that documents several things about the unit specific. The Flap and Flaperon were not sent to the Shop and the proper inspection was never accomplished.  Also; the company parts tracking tag and P/N tags were never put on these two units.  Also; no FAA-8130 tag from our Air Carrier was issued for either part [Flap-Flaperon].  According to the General Maintenance Manual (GMM) 9-20-25; the parts are 'Not Serviceable' until the Inspection and documentation is complete. I have not been able to find any supporting documentation; that any of our policies or procedures were followed.  If that is the case; the Flap and Flaperon [installed] on Aircraft X are not serviceable.  It is very clear in the GMM and FAR Part 145 dealing with parts that are 'Received'; that the home shop is responsible for making the unit Serviceable and that procedure was ignored in this case.

Callback: Reporter stated that there was a fireball on engine start on the left engine of one of their B777-200 aircraft.  This splattered fuel on the L/H O/B Flap and Flaperon lower surfaces that ignited in which caught fire; burning the Flap and Flaperon.  The fire damage was severe enough that both parts (units) had to be destroyed (made Not-Serviceable).  That's why new units were purchased. Reporter stated that repeated attempts by Shop Production and Inspection Management to have the new parts 'Received';  routed; into their Flight Control Shop per the practices and procedure requirements of their General Maintenance Manual (GMM) were ignored by a different Manager.  The same Manager also ignored and overrode the required proper documentation; inspections and tagging of the units.  The installed Flap and Flaperon units are still flying on the B777; but reporter believes they are not legal under their FAR 121 Operating Certificate and GMM requirements.



Synopsis: A Maintenance Base Mechanic reports their General Maintenance Manual (GMM) policies and procedures were ignored when a new Left-Hand (L/H) Outboard (O/B) Flap and Flaperon did not go through their Flight Control Shop prior to being installed on a company B777-200 aircraft.  No Inspections were accomplished; no company tracking or Parts Tags; nor FAA-8130 Serviceability Tags were issued.