It is another PR nightmare for Boeing; the aviation giant is again under fire for safety scandals. The death of John Barnett, a former Boeing employee-turned-whistleblower, has cast a harsh spotlight on Boeing’s ongoing quality control problems.
Barnett’s tragic passing comes as the aircraft manufacturer is under fire for allegedly flouting manufacturing safety standards and risking passenger lives.
(Read Sean Brady's articles on the Boeing 737 Max 8 issues and two crashes here.)
FAA audit uncovers shoddy manufacturing practices
The Federal Aviation Administration (FAA) recently conducted a thorough six-week audit of Boeing’s 737 Max production lines and found some alarming problems. This follows the bizarre incident in January when a door panel ripped off an Alaska Airlines 737 Max 9 mid-flight.
A detailed presentation retrieved by The New York Times reveals Boeing and its key supplier, Spirit AeroSystems, might be cutting corners – putting passenger safety at risk.
The audit presented a list of troubling findings, including multiple instances of non-compliance. Of the 89 product audits conducted on Boeing, only 56 passed, while 33 failed, resulting in 97 instances of non-compliance. Similarly, Spirit AeroSystems fared even worse, with a mere six of its13 product audits passing and seven failing. These findings concern both companies and raise questions about their commitment to quality control.
The first Boeing 737 MAX 9 airplane is pictured during its rollout for media at the Boeing factory in Renton, Washington on March 7, 2017.JASON REDMOND/AFP via Getty Images.
Improper tools and questionable methods
At Spirit, mechanics were seen using a hotel key card to check a door seal and Dawn dish soap as a makeshift lubricant during the door fitting. These are not approved practices, and according to the FAA, the instructions were “vague and unclear”.
It’s not just about paperwork, though. The FAA discovered that Boeing had failed an audit of the same door plug component that had blown off the Alaska Airlines jet. Both Boeing and Spirit found fundamental plant hygiene, like proper tool management, needed to be improved.
The FAA’s probe adds weight to concerns about Boeing’s manufacturing practices, with implications that could ripple throughout the aviation industry. Boeing is now facing a 90-day deadline to revamp its quality-control programme, raising questions about whether passengers can ever truly trust the 737 Max again.
The timing of this revelation could not be worse for Boeing. It is currently entangled in talks to fully acquire Spirit AeroSystems, a move that would only intensify scrutiny on its manufacturing processes.
Adding to Boeing’s woes, the FAA’s investigation into the detached door panel remains ongoing. However, parallel to this, the National Transportation Safety Board is also investigating the incident, and the Justice Department has kicked off a criminal probe.
What happens next?
The era of unchecked self-regulation for Boeing may be over. The FAA’s audit, along with the other investigations, could have far-reaching consequences. Expect tighter oversight of Boeing’s manufacturing, a big overhaul of quality-control programmes, and potentially even fines or legal penalties.
Naturally, Boeing is scrambling to save face, promising to work with employees who did not follow procedures.
The aircraft maker has detailed its latest steps to correct lapses in quality in a memo to employees from Stan Deal, president of Boeing’s commercial plane division, as per an Associated Press report.
The timing of Barnett’s death is chillingly suspicious. Could there be a connection between his whistleblowing and the seemingly never-ending stream of Boeing safety issues? This question hangs in the air, adding a sinister element to a dire situation.
One thing is clear – Boeing’s woes are far from over. The public’s trust in the aviation giant erodes with each new revelation and Boeing shares took a significant dip with the trend.