This article appears to be slanted towards recent events.(March 2024) |
A number of significant oversights have occurred in the manufacturing of aircraft produced by Boeing. Such oversights have been reported in the news as far back as 1987. Scrutiny over Boeing's process of addressing manufacturing issues began increasing in the aftermath of two fatal crashes involving the Boeing 737 MAX—Lion Air Flight 610 in late 2018 and Ethiopian Airlines Flight 302 in early 2019. [1]
In August 2023, Boeing discovered improperly installed aft pressure bulkheads in certain Boeing 737 MAX aircraft. Concerns over Boeing manufacturing issues mounted in January 2024, when an emergency exit door ejected from Alaska Airlines Flight 1282, causing uncontrolled decompression. The Federal Aviation Administration and the National Transportation Safety Board initiated inquiries in response to the incident; the former's investigation discovered further instances of manufacturing lapses.
In August 2023, Boeing discovered improperly drilled holes in aft pressure bulkheads in certain 737 MAX aircraft, forcing manufacturing delays. [2]
In December 2023, Boeing urged airlines to inspect 737 MAX aircraft for loose bolts in their rudder control systems after an unnamed international airline discovered a bolt with a missing nut. Boeing discovered an additional improperly-tightened nut in an undelivered 737 MAX. [3]
On January 5, 2024, Alaska Airlines Flight 1282 experienced uncontrolled decompression after door plugs securing the emergency exit door panel ejected on the Boeing 737 MAX 9 aircraft used on the flight; the configuration on the 737 MAX 9 included fewer seats than Boeing designs for, necessitating a door plug to obstruct an unneeded exit on row 26 adjacent to two unoccupied seats. [4] The fuselage and door plugs were initially manufactured by Spirit AeroSystems and the 737 MAX 9 involved in the incident was certified in November. [5]
In April 2024, Boeing engineer and whistleblower Sam Salehpour alleged that Boeing took shortcuts in the manufacturing of its 777 and 787. When joining the different parts of the fuselage together, Salehpour alleged that the tiny gaps were not filled. [6] He claims there are thousands of affected aircraft that can catastrophically "break up" in mid air. [7] Boeing denied these allegations. [8]
Following Alaska Airlines Flight 1282, the Federal Aviation Administration ordered a mass grounding of Boeing 737 MAX 9 planes in order to conduct inspections. Alaska Airlines canceled approximately one hundred flights on January 6, 2024, and United Airlines suspended uninspected 737 MAX 9s, leading to sixty cancellations. [5] By January 7, Alaska Airlines had canceled 170 flights, affecting 25,000 customers. [4]
The National Transportation Safety Board initiated an inquiry into Boeing following Alaska Airlines Flight 1282, discovering that bolts intended to secure a fuselage panel were not installed prior to the flight. [9]
In March 2024, The New York Times reported that Boeing failed nearly three dozen audits during an examination. [10]
In March 2024, The Wall Street Journal reported that the United States Department of Justice had started a criminal investigation into Boeing, interviewing the crew on Alaska Airlines Flight 1282. [11]
The Boeing 737 is an American narrow-body airliner produced by Boeing at its Renton factory in Washington. Developed to supplement the Boeing 727 on short and thin routes, the twinjet retained the 707 fuselage width and six abreast seating but with two underwing Pratt & Whitney JT8D low-bypass turbofan engines. Envisioned in 1964, the initial 737-100 made its first flight in April 1967 and entered service in February 1968 with Lufthansa. The lengthened 737-200 entered service in April 1968, and evolved through four generations, offering several variants for 85 to 215 passengers.
The Boeing 787 Dreamliner is an American wide-body airliner developed and manufactured by Boeing Commercial Airplanes. After dropping its unconventional Sonic Cruiser project, Boeing announced the conventional 7E7 on January 29, 2003, which focused largely on efficiency. The program was launched on April 26, 2004, with an order for 50 aircraft from All Nippon Airways (ANA), targeting a 2008 introduction. On July 8, 2007, a prototype 787 without major operating systems was rolled out; subsequently the aircraft experienced multiple delays, until its maiden flight on December 15, 2009. Type certification was received in August 2011, and the first 787-8 was delivered in September 2011 before entering commercial service on October 26, 2011, with ANA.
Boeing Commercial Airplanes (BCA) is a division of the Boeing Company. It designs, assembles, markets, and sells commercial aircraft, including the 737, 767, 777, and 787, along with freighter and business jet variants of most. The division employs nearly 35,000 people, many working at the company's division headquarters in Renton, Washington or at more than a dozen engineering, manufacturing, and assembly facilities, notably the Everett Factory and Renton Factory, and the South Carolina Factory.
Spirit AeroSystems Holdings, Inc. is an American manufacturer of aerostructures for commercial airplanes, headquartered in Wichita, Kansas. The company produces fuselage sections for Boeing's 737 and 787 aircraft, as well as the flight deck sections for a majority of Boeing airliners. Spirit also supplies Airbus with fuselage sections and front wing spars for the A350 and wings for the A220. Spirit's primary competitors in the aerostructures market include Collins Aerospace, Kawasaki Heavy Industries, Leonardo, and Triumph Group.
The Boeing Yellowstone Project was a Boeing Commercial Airplanes project to replace its entire civil aircraft portfolio with advanced technology aircraft. New technologies to be introduced include composite aerostructures, more electrical systems, and more fuel-efficient turbofan engines. The term "Yellowstone" refers to the technologies, while "Y1" through "Y3" refer to the actual aircraft.
The Boeing Everett Factory, officially the Everett Production Facility, is an airplane assembly facility operated by Boeing in Everett, Washington, United States. It sits on the north side of Paine Field and includes the largest building in the world by volume at over 472 million cubic feet (13,400,000 m3), which covers 98.3 acres (39.8 ha).
David L. Calhoun is an American executive who was the president and chief executive of Boeing from January 2020 to August 7, 2024. In March 2024, Boeing announced that Calhoun would step down as chief executive by the end of 2024.
The Boeing 737 Next Generation, commonly abbreviated as 737NG, or 737 Next Gen, is a twin-engine narrow-body aircraft produced by Boeing Commercial Airplanes. Launched in 1993 as the third generation derivative of the Boeing 737, it has been produced since 1997.
Dubai Aviation Corporation, doing business as flydubai, is an Emirati government-owned low-cost airline based in Dubai, United Arab Emirates. The airline mainly operates out of Terminal 2 at Dubai International Airport, though some flights fly out from Terminal 3. The airline operates a total of 124 destinations, serving the Middle East, Africa, Asia and Europe from Dubai. The company slogan is Get Going.
The Boeing Company is an American multinational corporation that designs, manufactures, and sells airplanes, rotorcraft, rockets, satellites, and missiles worldwide. The company also provides leasing and product support services. Boeing is among the largest global aerospace manufacturers; it is the fourth-largest defense contractor in the world based on 2022 revenue and is the largest exporter in the United States by dollar value. Boeing was founded by William E. Boeing in Seattle, Washington, on July 15, 1916. The present corporation is the result of the merger of Boeing with McDonnell Douglas on August 1, 1997.
An emergency airworthiness directive (EAD) is an airworthiness directive issued when unsafe conditions require immediate action by an aircraft owner or operator. An EAD is published by a responsible authority such as the FOCA, EASA or FAA related to airworthiness and maintenance of aircraft and aircraft parts. It contains measures which must be accomplished and the related periods to preserve their airworthiness. Technical information is addressed to operators and maintenance organisations of affected aircraft only. EADs become effective upon receipt of notification.
Boeing South Carolina is an airplane assembly facility built by Boeing in North Charleston, South Carolina, United States. Located on the grounds of the joint-use Charleston Air Force Base and Charleston International Airport, the site is the final assembly and delivery point for the Boeing 787 Dreamliner. Boeing opened the site in July 2011, after purchasing the facilities of suppliers Vought and Global Aeronautica in 2008 and 2009. The final assembly building covers 1,200,000 square feet (110,000 m2) and opened on November 12, 2011. As of September 28, 2017, the site employs 6,943 workers and contractors.
The Boeing 737 MAX is the fourth generation of the Boeing 737, a narrow-body airliner manufactured by Boeing Commercial Airplanes. It succeeds the Boeing 737 Next Generation (NG) and competes with the Airbus A320neo family. The series was announced in August 2011, first flown in January 2016, and certified by the US Federal Aviation Administration (FAA) in March 2017. The first 737 MAX delivered to a customer was a MAX 8 to Malindo Air, which accepted and began operating the aircraft in May 2017.
As of 26 September 2024, the United Airlines fleet consists of 972 mainline aircraft, making it the second largest commercial airline fleet in the world. United Airlines operates a mix of Airbus and Boeing narrow-body and all Boeing wide-body aircraft.
In 2013, the second year of service for the Boeing 787 Dreamliner, a widebody jet airliner, several of the aircraft suffered from electrical system problems stemming from its lithium-ion batteries. Incidents included two electrical fires, one aboard an All Nippon Airways 787 and another on a Japan Airlines 787; the second fire was found by maintenance workers while the aircraft was parked at Boston's Logan International Airport. The United States Federal Aviation Administration (FAA) ordered a review of the design and manufacture of the Boeing 787 Dreamliner and grounded the entire Boeing 787 fleet, the first such grounding since that of the McDonnell Douglas DC-10 in 1979. The plane has had two major battery thermal runaway events in 52,000 flight hours, neither of which were contained safely; this length of time between failures was substantially less than the 10 million flight hours predicted by Boeing.
The Boeing 777X is the latest series of the long-range, wide-body, twin-engine jetliners in the Boeing 777 family from Boeing Commercial Airplanes. The changes for 777X include GE9X engines, composite wings with folding wingtips, greater cabin width and seating capacity, and technologies from the Boeing 787. The 777X was launched in November 2013 with two variants: the 777-8 and the 777-9. The 777-8 provides seating for 395 passengers and has a range of 8,745 nmi while the 777-9 has seating for 426 passengers and a range of over 7,285 nmi.
The ecoDemonstrator Program is a Boeing flight test research program, which has used a series of specially modified aircraft to develop and test aviation technologies designed to improve fuel economy and reduce the noise and ecological footprint of airliners.
The Boeing 737 MAX passenger airliner was grounded worldwide between March 2019 and December 2020 and again in 2024 – after 346 people died in two similar crashes in less than five months: Lion Air Flight 610 on October 29, 2018, and Ethiopian Airlines Flight 302 on March 10, 2019. The Federal Aviation Administration initially affirmed the MAX's continued airworthiness, claiming to have insufficient evidence of accident similarities. By March 13, the FAA followed behind 51 concerned regulators in deciding to ground the aircraft. All 387 aircraft delivered to airlines were grounded by March 18.
Alaska Airlines Flight 1282 was a scheduled domestic flight operated by Alaska Airlines from Portland International Airport in Portland, Oregon, to Ontario International Airport in Ontario, California. Shortly after takeoff on January 5, 2024, a door plug on the Boeing 737 MAX 9 aircraft blew out, causing an uncontrolled decompression of the aircraft. The aircraft returned to Portland for an emergency landing. All 171 passengers and six crew members survived the accident, with three receiving minor injuries. An investigation of the accident by the National Transportation Safety Board (NTSB) is ongoing. A preliminary report published on February 6 said that four bolts, intended to secure the door plug, had been missing when the accident occurred and that Boeing records showed evidence that the plug had been reinstalled with no bolts prior to the initial delivery of the aircraft.
John Mitchell Barnett was an American whistleblower who was known for his substantiated safety and quality reports to the Federal Aviation Administration (FAA) about Boeing's production of the Boeing 787 Dreamliner and death which occurred amidst a lawsuit he brought against Boeing. Barnett worked in quality control at Boeing for 32 years, serving for seven as a manager at Boeing South Carolina. Barnett was one of several employees to go public about malpractices at Boeing beginning in 2019 with The New York Times and was featured in the 2022 Netflix documentary titled Downfall: The Case Against Boeing.
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