"Reports are coming out that an Alenia Aeronautica employee using
incorrect fasteners caused damage to the fuselage of Boeing's already
long-delayed 787 Dreamliner at the Global Aeronautica facility in
North Charleston............

.............According to sources, incorrect fasteners were improperly
installed in the wrong holes causing damage to the composite structure
during the join process in Charleston. When installed, each fastener
"splintered out the hole" causing significant enough damage to
postpone delivery of the center fuselage."

http://thedigitel.com/top-stories/boeing-fuselage-damaged-worker7089

I understand that fellow workers became suspicious when the worker was
observed using a spokeshave from his personal toolbox trying to tidy
up the the carbon-fiber threads which had broken out of the composite
structure plastic resin. When challenged he protested that he'd been
working with composites for years and knew exactly what he was doing.

"Boeing spokeswoman Lori Gunter said Alenia had hired some mechanics
locally. Neither she nor an Alenia spokesman knew whether the mechanic
who did the damage was experienced or a relatively new hire."
www.seattletimes.com

Following a Federal Aviation Administration (FAA) audit the entire
plant was shut down for 24 hours.

"The production shutdown at the Global Aeronautica plant in
Charleston, S.C., was ordered by plant management, which required all
workers on three shifts to attend eight-hour training sessions on
proper work procedures and policies...........

The chief focus of the training was proper procedures to avoid foreign
object debris, or FOD..................

A contractor inside the plant described what the sessions entailed.

"They had us review all the FOD procedures,' said the contractor, who
spoke on condition of not being named. "Everybody had to walk the
floor [looking] for FOD and search the airplanes for missing tools."

He said it wasn't surprising the FAA found issues, given the high
number of workers there who "never worked on airplanes before."

However, more experienced contractors are also a potential problem.
The contractor said some colleagues, who have come from all over the
U.S, have brought their own toolboxes to the job.

"There's a big concern about personal toolboxes" because usually
mechanics work with company-issued tools and put them in storage racks
at the end of the shift. With personal tools, there's no way to check
all have been accounted for.

"In the beginning ... they were basically looking the other way to get
the plane built," said the contractor."
http://seattletimes.nwsource.com/html/businesstechnology/2008028852_global020.ht...

It was only when they examined the errant workers toolkit and found a
set of plans for a U-Bild Dolls House....
http://www.woodcraft.com/family.aspx?FamilyID=6704
a brace and bit, set of chisels, string line, sandpaper and finally a
Stanley plane that they realised what he meant when he'd claimed he
had been working with planes for twenty years.

50%% of all this is true. Sadly it's the most unbelievable bits!

Ned