QAEs work closely with contractors to keep aging fleet clean, top shape

Published July 13, 2006
By Tech. Sgt. Melissa Phillips
436th Airlift Wing Public Affairs

DOVER AIR FORCE BASE, Del. -- A group of seasoned technicians have a job description many would love to get paid for – people watching.

The 436th Maintenance Group Quality Assurance office is responsible for making sure every move of more than a dozen Starlight Corporation (a military contractor) workers who clean one of the world’s largest vehicles, the C-5 Galaxy, is done safely.

That’s especially important when the person they’re watching is balancing on top of a strip of metal on the C-5 tail section almost six stories above the hangar floor while scrubbing away.

“It’s our responsibility to ensure everyone receives all the proper training, equipment and follows safety precautions,” said 1st Lt. Gerard Carisio, 436th MXG Quality Assurance Evaluator officer-in-charge, who leads a handful of military inspectors who watch over the contract.

From his vantage point, washing a C-5 isn’t all that different from washing a car; it’s just 100 times the magnitude.

“Undertaking anything on this jet is always impressive because of the pure size of it,” Lieutenant Carisio said.

Utilization of resources
In January, the majority of the lube and wash rack process was turned over to Starlight Corporation, who work closely with quality assurance inspectors from the 436th MXG to ensure the plane comes out sparkling clean.

Military specialists from the 436th Aircraft Maintenance Squadron still play a part in the process. They prepare the C-5 for the process. They configure and de-panel parts of the plane and then turn it over to the contractors. After the wash and lube, 436th AMXS workers reverse the process.

The entire wash takes approximately 24 hours and frees military maintainers to focus on more technically demanding jobs and fulfill deployment requirements, according to Lieutenant Carisio.

Washing hazards
The wash process isn’t a walk in the park either.

“Working around aircraft is by nature a hazardous job,” said the lieutenant. “Whenever you introduce water into a medium full of electronics, it’s hazardous.”

There are falling and pressurized hydraulic hazards to contend with, as well.
“The human body is insignificant to an aircraft door,” he said. “If it’s going to move, it will move regardless if you are there or not.”

That’s were Lieutenant Carisio says Operational Risk Management comes in to play. ORM is a method to reduce hazards through a process designed to balance the risk against precautions and safety procedures.

A cleaner aircraft is a safer aircraft
One might ask: how does a little dirt hurt anyway? Why the suds and duds treatment?
“The wash rack process helps prevent corrosion,” said Lieutenant Carisio. “The C-5 is very rarely stored in a hangar like smaller aircraft.”

The planes, which are designed to carry oversized cargo such as helicopters and tanks, deliver supplies around the world to aid troops supporting the Global War on Terror. In the process, the transporters collect a lot of dirt and debris.

“It’s exposed to the elements, and we need to ensure the different materials don’t fatigue and fail, especially with an aircraft this age (the plane has been in the Air Force fleet since 1970).”

So every 120 days each plane, which measures close to the length of a football field at 247 feet and can carry six Greyhound buses, gets treated to some special attention and approximately 20 gallons of soap.

Another bonus of washing down the gigantic transport vehicle, which can fly 373 troops comfortably, is a cleaner aircraft is a safer aircraft.

“The Isochronal inspection is more accurate when the C-5 is clean,” said the lieutenant. “It’s easier to find metal fatigue or damaged components, and it can help prevent catastrophic aircraft accidents.”

The lieutenant also said more often than not it can reduce the cost of repairs. When the contractor technicians get up close and personal, it helps maintenance specialists pinpoint problems like hairline cracks and panels that de-laminate, a problem where the honey-comb material sandwiched in between the two metal panels start to separate from each other.

“If that happens in flight, it’s not a good day for anyone on board. So the wash rack works in conjunction with several inspection agencies to prevent that,” he said.

Patriotism in the ranks
It’s a job one retired aircraft mechanic says he and his crew are up to the challenge.
“We are as much of the machine that gets (the mission) done east of Atlantic Avenue, as anyone else,” said Michael Vekasy, Starlight Corporation project director, who overseas the wash rack process.

With a front-row seat to the flightline’s frantic pace, Mr. Vekasy watched one July 4th as planes were delayed six hours. The retired senior master sergeant looked on as transfer cases containing the remains of 12 servicemembers, who gave the ultimate sacrifice for their country in Afghanistan, were carried from a KC-10.

He said it’s moments like these that are one of the many reasons he continues to perform the same job now as he did for the military years ago.

“Just because I don’t wear the uniform anymore doesn’t mean I don’t have patriotism for my job,” said Mr. Vekasy. “Because of our training and experience there are certain processes that we provide simultaneously with government employees that hasten the aircraft back to fully mission-capable status.

“We (are a part of the process to) help the planes get ready to go carry another load of cargo, which might save lives in Iraq,” Mr. Vekasy said.

It’s all in a days work for the Starlight Corporation and QAE, who work together to service the giant transporter, so it remains a reliable aircraft for many years to come.

From beans to bullets, the C-5 Galaxy, which is responsible for 29 percent of the Nation’s strategic airlift, transports more than just cargo to their customers.
It’s a symbol of hope to help supply those fighting to attain a priceless commodity – freedom.

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