An investigation released on Monday by Consumer Reports reveals that the outsourcing of airline maintenance and current government oversight of the industry could be setting the stage for disaster.

Most of the 20 largest U.S. airlines have been outsourcing more than half of their maintenance to other companies, with some of them being overseas.

"Our investigation found maintenance work being done in Mexico, Singapore and the Philippines, and with unlicensed mechanics," said Consumer Reports' Bob Tiernan.

Federal rules allow that, as long as once licensed mechanic signs off on the work, as well as proper training, security is another concern, 10TV's John Fortney reported.

"Undocumented workers have been found and, at one facility, a terrorism suspect was arrested," Tiernan said.

At the same time, the airlines have cut back on in-house maintenance.  Consumer Reports' investigation revealed that the Federal Aviation Administration is changing how it oversees that maintenance.

"Our investigation found that the FAA is increasingly relying on statistical measures instead of doing a visual inspection," Tiernan said.

"I would think that would be something you would want to keep in the homeland, just for security purposes," said Wesley Holt, who occasionally flies out of Port Columbus International Airport, mainly for business. 

A Government Accountability Office report said what is happening at the FAA "represents a cultural shift in the way the agency oversees the aviation industry."

Rep. James Oberstar, chairman of the House Transportation Committee, said that is not acceptable.

"They, the FAA, need to be in-country," Oberstar said.  "They need to be on-site.  They need to be hands-on."

Airlines officials contacted by Consumer Reports said safety is their No. 1 priority but note outsourcing is more economical.  In a statement, the FAA said, "There has been no indication that the margin of safety has been reduced because of outsourced maintenance."

The probe by Consumer Reports suggests otherwise, Fortney reported.  Oberstar's committee has now begun its own investigation.

"You have to know your facts," Oberstar said.  "Do the work right.  And then, you have to call the airlines and the FAA to account.  And we will do that."

Port Columbus supports extra questions about maintenance, Fortney reported.

"From what I can see, from their reaction to it, can only help improve the process," said Port Columbus spokesman David Whitakker. 

Oberstar told Consumer Reports that he plans to begin formal hearings within six months.
Holt said he realizes it's up to others to make sure his flight is mechanically ready to go.

"I have to trust it's not something I can go and see with my own eyes, so I generally put my life in their hands" Holt said.