A recent report has shed light on concerning quality control issues within Boeing’s 737 Max jet production process. The Federal Aviation Administration (FAA) conducted an audit into Boeing and its supplier Spirit AeroSystems after a door plug flew off a 737 Max 9 mid-air. The audit revealed numerous issues, including the use of unconventional tools such as hotel key cards and dish soap by mechanics during compliance testing.
Boeing faced a significant number of failures in their product audits, failing 33 out of 89, with a total of 97 alleged noncompliance counts. Meanwhile, Spirit AeroSystems failed seven out of 13 product audits conducted by the FAA. One particular failure involved the incorrect installation of the plane’s door plug.
The most alarming details emerged from Spirit AeroSystems’ fuselage manufacturing plant in Wichita, Kansas. FAA auditors observed mechanics using a hotel key card to check the seal on a door, and in another instance, mechanics applied dish soap as a lubricant during the fit-up process. The instructions provided to mechanics were reportedly vague and unclear, leading to inconsistencies in their actions.
Spirit AeroSystems, which Boeing is currently in talks to reacquire, has stated that they are reviewing all identified nonconformities for corrective action. However, Boeing did not immediately comment on the findings of the audit. The FAA has chosen to keep the audit’s findings private due to an ongoing investigation into the door plug incident and Boeing’s response to it.
As a result of the audit, Boeing is required to develop a comprehensive plan of action within 90 days to address the systemic quality-control issues raised. In addition to the FAA investigation, the National Transportation Safety Board is looking into the door panel blow-out incident, while the Justice Department has opened a criminal probe into Boeing.
This report highlights the troubling issues within Boeing’s production process and raises concerns about the overall quality and safety of their aircraft. The findings emphasize the importance of stringent quality control measures and adherence to industry standards. It remains to be seen how Boeing will address these issues and regain the trust of regulators and the flying public.
