A comprehensive six-week investigation conducted by the Federal Aviation Administration (FAA) into Boeing’s manufacturing of the 737 Max jet has unveiled numerous issues across the production line of the aerospace giant and one of its principal suppliers, as per a slide presentation The New York Times had access to.
The safety oversight body embarked on this detailed scrutiny following an incident where a door panel detached from a 737 Max 9 during an Alaska Airlines flight in early January. Last week, the FAA disclosed that the audit revealed “multiple instances” where Boeing and its supplier, Spirit AeroSystems, did not meet quality-control standards, although it stopped short of detailing these findings.
The presentation, despite its technical nature, sheds light on the audit’s findings. Since the Alaska Airlines incident, Boeing has faced intense examination over its quality control practices, with these findings further highlighting manufacturing shortcomings at the company.
In the Boeing-focused segment of the audit, the FAA carried out 89 product audits, examining various aspects of the production process. Out of these, Boeing passed 56 but failed 33, with a total of 97 instances of alleged noncompliance, as indicated in the presentation.
The FAA also performed 13 product audits on Spirit AeroSystems, the company responsible for constructing the 737 Max’s fuselage. These audits resulted in six passes and seven failures, according to the presentation. During the audit, FAA inspectors observed Spirit mechanics employing unconventional methods, such as using a hotel key card to inspect a door seal and applying liquid Dawn soap as a lubricant in the fit-up process, practices not documented in the production order.
Spirit AeroSystems, through its spokesperson Joe Buccino, stated the company is actively reviewing all identified nonconformities for corrective action. Boeing has yet to comment on the audit results. However, in late February, the FAA gave Boeing 90 days to formulate a plan for enhancing its quality control, to which CEO Dave Calhoun acknowledged a clear understanding of the necessary actions, partly informed by the audit’s findings.
Boeing is currently in discussions to acquire Spirit AeroSystems, a company it spun off in 2005. Buccino mentioned that Spirit had received preliminary audit findings from the FAA and is collaborating with Boeing to address the issues raised, aiming to eliminate defects and errors in its processes.
The FAA has refrained from releasing detailed findings due to its ongoing investigation into Boeing following the Alaska Airlines incident. This investigation is part of a broader scrutiny that includes the National Transportation Safety Board’s inquiry into the cause of the door panel detachment and a criminal investigation initiated by the Justice Department.
Throughout the audit, the FAA deployed up to 20 auditors at Boeing and about half a dozen at Spirit, covering various components of the 737 Max, including its wings and several other systems. Many issues identified by the auditors were related to deviations from approved manufacturing processes, procedures, or instructions, as well as concerns with quality-control documentation.
One specific audit related to the component that detached from the Alaska Airlines jet, a door plug, which Boeing failed. The FAA’s examination also delved into Boeing employees’ understanding of the company’s quality-control processes, revealing an average comprehension score of only 58 percent among the six engineers interviewed.
In summary, the FAA’s audit has brought to light significant quality and compliance issues within Boeing and Spirit AeroSystems’ manufacturing processes, prompting both companies to undertake corrective actions to address these concerns and improve overall production quality.