Date: 201208
Local time of day: 1801-2400
Location: ZZZZ.Airport, FO
Aircraft: B777-200
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Parked
Aircraft component: Flap Fairing
Component problem: Failed
Reporter organization: Air Carrier
Reporter function: Other / Unknown
Reporter qualification: Maintenance Powerplant; Maintenance Airframe
Human factors: Confusion; Communication Breakdown
Second reporter function: Lead Technician
Anomaly: Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural MEL / CDL
Detector: Person Flight Crew
When detected: In-flight
Result: General Maintenance Action
Contributing factors: MEL; Human Factors
Primary problem: Human Factors

Narrative: Maintenance personnel called with a flap fairing damaged by ground equipment. After brief view of photos of the damage; I suggested Configuration Deviation List (CDL) 52-03. I asked him to take a look at the CDL and call me back. To expedite matters; I called Dispatch to see if they could live with it. Later Dispatch called back to ask status; I told them I had not heard back yet; and I put the CDL in the computer so Dispatch could use their computers to work their flight plan. At end of shift; I gave verbal turnover that we were waiting for mechanic to call back; item was in computer and still open. Later we found out that the larger fairing was removed instead of the one referred to by the CDL. We plan to rob parts from hangar plane and [install it]. The CDL 57-03 photograph seems to point to larger fairing. Myself; [several] mechanics; and many pilots all saw the same thing. [A] pilot finally figured it out. I should have caught it at time of issue; I was more focused on the close-up detailed damage pictures; than I was on the picture that showed which fairing. Also; I relied on my interpretation of the CDL picture instead of fully reading the CDL description (Inboard Flap Center Track Fairings). A second photo in CDL with arrows would help identify the applicable fairing. Since our CDLs are now online; perhaps digital color photos of the applicable components could be added to each CDL.


Second narrative: While [another] AMT was accomplishing ETOPS check; the right-hand inboard canoe was found damaged. I went out to where the aircraft was parked took photographs which I sent to B767/B777 Maintenance Control and then phoned Maintenance Control to arrange for a Engineering Order for a repair with speed tape. The Maintenance Controller advised me that an Engineering Order cannot be issued if it is coved by a CDL which would be CDL 57-03. I informed the Maintenance Controller that it might take a long time as I had never been involved in removing a fairing before. After the removal I retuned to the office phoned the 777 Maintenance Controller to ask for the CDL. I was told it had already been issued. I return to the aircraft spoke to the Captain and First Officer they both agree the CDL was right and asked Dispatch for a flight plan with more fuel as the CDL requested. Also crew wanted to see operation of flaps to make sure they operated ok which they did.


Synopsis: Maintenance Controller and several maintenance technicians misinterpreted the Configuration Deviation List (CDL) description and removed a fairing that was not covered by this specification.