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An FAA inspection reveals numerous deficiencies in Boeing’s 737 Max manufacturing process, prompting the company to confront a 90-day ultimatum for overhauling its quality assurance procedures, prompting concerns regarding safety protocols.
(Photo : JASON REDMOND/AFP via Getty Images)
A Boeing 737 MAX jet comes in for a landing following a Federal Aviation Administration (FAA) test flight at Boeing Field in Seattle, Washington on June 29, 2020.
Examining Boeing’s 737 Max Production Facilities
Boeing faces yet another public relations crisis as safety concerns resurface following the tragic death of former employee-turned-whistleblower John Barnett. His demise sheds light on Boeing’s persistent quality control issues, sparking scrutiny over the aerospace giant’s commitment to safety standards.
In the wake of Barnett’s passing, the Federal Aviation Administration (FAA) undertook a comprehensive six-week examination of Boeing’s 737 Max production facilities, uncovering troubling discrepancies.
This scrutiny comes in the aftermath of a peculiar incident in January involving an Alaska Airlines 737 Max 9, where a door panel detached mid-flight.
A detailed report from The New York Times suggests potential shortcuts in manufacturing processes by Boeing and its principal supplier, Spirit AeroSystems, leading to potential safety hazards for passengers.
The audit unearthed numerous troubling findings, including a significant number of instances of noncompliance. Out of the 89 product audits conducted on Boeing, only 56 met the standards, with 33 failing to comply, resulting in 97 instances of non-conformity.
Also Read: Boeing Faces Delivery Delays as 50 Jets Encounter Fuselage Issues, CEO Acknowledges Quality Concerns
Similarly, Spirit AeroSystems had a poor record, with only six of their 13 product audits passing and the remaining seven failing, raising serious concerns about the efficacy of their quality control measures.
During an inspection at Spirit, technicians were observed using unconventional methods, such as a hotel key card for checking door seals and Dawn dish soap as a lubricant during door fitting. These practices, deemed unauthorized by the FAA, were criticized for their vagueness and lack of clarity in instructions.
However, the issue extends beyond procedural discrepancies. The FAA’s investigation uncovered that Boeing had previously failed an audit related to the same door plug component involved in the Alaska Airlines incident.
Both Boeing and Spirit were cited for deficiencies in fundamental plant hygiene, including inadequate tool management. The FAA’s findings raise serious concerns about Boeing’s manufacturing standards, posing potential repercussions for the aviation sector at large.
What’s Next?
With Boeing now mandated to overhaul its quality-control procedures within a 90-day timeframe, doubts linger regarding the restoration of trust in the 737 Max among passengers.
Boeing’s unbridled self-regulation may be a thing of the past as the FAA’s audit and ongoing investigations loom large, signaling potential seismic shifts ahead.
Anticipate stringent oversight of Boeing’s manufacturing practices, extensive revisions to quality-control protocols, and the looming specter of fines or legal repercussions.
Associated Press reported that Boeing is hastily addressing procedural lapses, pledging to collaborate with employees who deviated from established protocols. Boeing’s commercial plane division president, Stan Deal, outlined the company’s latest corrective measures in a memo to staff.
The circumstances surrounding Barnett’s untimely demise are shrouded in suspicion, prompting speculation about a possible link between his whistleblowing activities and Boeing’s recurrent safety crises. This unsettling question adds a sinister dimension to an already dire predicament.
Related Article: FAA Initiates Formal Investigation into Boeing 737 Max 9 Door Plug Incident
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