Maintenance Airframe; Maintenance Powerplant
Fatigue; Communication Breakdown; Time Pressure; Workload
Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural Published Material / Policy; Ground Event / Encounter Object
Aircraft Aircraft Damaged; General Maintenance Action
Procedure; Human Factors; Aircraft
Technician and I were assigned a [maintenance visit] with multiple MELs to work on aircraft. I spent nearly 1 hour searching for parts that were not in pre-draw or in stock. We completed the [maintenance] and other MELs and Technician and I proceeded to change engine 1 filter bypass switch. After the installation was complete we proceeded to the flight deck to perform bite tests. All tested passed and an engine idle leak check was still required. We called Lead AMT to clear the road; I prepared the flight deck and Technician went down to the engine to observe and leak check the idle run. Once I was prepared I asked if we were clear to turn Number 1 over the handheld radio; Technician replied 'Clear.' Shortly after starter cut out on the Number 1 engine start I was told to shut down over the radio. Technician came to the flight deck and informed me that we had ingested the engine inlet plug. I completed the post engine run check list and proceeded down to the engine for an initial damage evaluation. Technician 2; Technician 1 and myself picked up the large debris off the ramp and then the three of us went to the Supervisors office to inform them of the incident. We then returned to the aircraft to complete the ramp clean up.Technician 1 and I still had an additional aircraft to work with and additional work cards assigned. I felt pressed for time; and I felt fatigued. Ramp has inconsistently installed engine inlet plugs for the last couple work days.
My assigned work for the night was a maintenance visit with 3 MELs on an aircraft that landed at XA:00 and a heavier maintenance check on an aircraft coming in an hour later at XB:00. Technician and I planned to work the maintenance check and then the MELs. While doing my walk around on aircraft while the ramp was still downloading the aircraft Number 1 engine did not have an engine plug installed in it. After my check was done; Technician and I worked all the MELs which resulted in the Number 1 engine needing an idle leak check to be completed. So while Technician started the pre-engine run check in the flight deck I went downstairs to make sure the road was blocked and then watch for leaks. Technician then started the engine after I gave the all clear over the radio and that is when the engine ingested the inlet plug. I then called over the radio to Technician to have him shut the engine down. I then went upstairs to inform him of the ingestion. Afterwards we cleaned up the FOD on the ramp to prevent further and or other aircraft damage before returning to the shop to notify Supervisor.
Technician reported distraction and fatigue interfered with proper procedures and caused an aircraft to ingest an engine plug.