The Federal Aviation Administration (FAA) has uncovered alarming lapses in manufacturing quality control during its recent 737 MAX production audit, involving aviation giant Boeing and supplier Spirit AeroSystems.
The audit findings have raised serious concerns about the safety standards of the aircraft and prompted the FAA to halt the expansion of Boeing’s 737 MAX production.
According to the FAA, the audit revealed instances of non-compliance in Boeing’s manufacturing process control, parts handling and storage, and product control. While the specific corrective actions required were not detailed in the public statement, both Boeing and Spirit AeroSystems have received a summary of the audit findings.
Spirit AeroSystems, responsible for manufacturing the fuselage of the 737 MAX, acknowledged being in communication with Boeing and the FAA to address the identified issues. Boeing responded by stating, “By virtue of our quality stand-downs, the FAA audit findings, and the recent expert review panel report, we have a clear picture of what needs to be done.”
Audit follows mid-air panel blowout incident
The FAA initiated the audit following a mid-air emergency on January 5 involving an Alaska Airlines 737 MAX 9. In response to the incident, the FAA had already barred Boeing from expanding 737 production, emphasizing that the quality assurance issues observed were deemed unacceptable.
FAA Administrator Mike Whitaker reiterated Boeing’s obligation to develop a comprehensive plan addressing “systemic quality-control issues” within 90 days. This directive came after an extensive meeting on February 27 with Boeing CEO Dave Calhoun. Whitaker emphasized, “Boeing must commit to real and profound improvements. We are going to hold them accountable every step of the way, with mutually understood milestones and expectations.”
The goal of the FAA audit, as outlined by Whitaker in January, was to scrutinize the entire production process, examining inspections, supplier interactions, and the overall workflow to identify potential faults. The urgency of the situation has been underscored by Boeing’s removal of Ed Clark, the head of the 737 MAX program, as part of a broader management shakeup.
Lawmakers, in a bipartisan effort, sought clarification from the FAA regarding persistent quality control lapses in Boeing’s production lines. This scrutiny follows a history of criticism, with Boeing paying a $6.6 million fine to the FAA in 2021 as part of a settlement over past quality and safety-oversight lapses.
The FAA has been consistent in highlighting Boeing’s quality lapses, urging airlines in December to inspect MAX planes for loose bolts in the rudder control system. The recent incident involving a door plug detaching from a MAX 9 aircraft at 16,000 feet has intensified the focus on Boeing’s manufacturing practices. A preliminary report from the National Transportation Safety Board indicated that the detached door panel was missing four key bolts.
Significance of Halting prod
The FAA’s decision to halt the production expansion of the 737 MAX planes underscores the severity of the situation. Boeing’s commitment to implementing necessary changes, along with the FAA’s continued oversight, will be critical in restoring confidence in the 737 MAX program and ensuring the safety of air travel. The aviation industry will closely monitor developments as these corrective measures take center stage in addressing the identified quality control deficiencies.
