The Federal Aviation Administration (FAA) uncovered numerous quality control issues within Boeing’s 737 Max jet production process, with alarming findings showing mechanics at a key supplier using makeshift tools like a hotel key card and dish soap for compliance testing. This revelation came following an incident where a door plug detached from a 737 Max 9 mid-air, prompting the FAA to conduct an audit into Boeing and its supplier Spirit AeroSystems. The audit exposed troubling inconsistencies and failures in the manufacturing process, including Boeing failing 33 out of 89 product audits and Spirit AeroSystems failing seven out of 13 product audits.
The FAA’s audit report highlighted concerning practices at Spirit AeroSystems’ fuselage manufacturing plant in Kansas, where mechanics were observed using unconventional methods such as a hotel key card to check a door seal and applying dish soap as a lubricant during the fit-up process. These revelations raise serious questions about the oversight and quality control measures in place throughout the production of Boeing’s 737 Max jets. Both Boeing and Spirit AeroSystems are now under scrutiny to address the systemic issues identified in the audit within a specified timeframe.
Boeing has yet to comment on the specific findings of the audit, as the FAA continues its investigation into the door plug incident and the company’s response. With the FAA mandating a comprehensive plan of action to rectify the quality control issues within 90 days, the repercussions of these revelations extend beyond just the manufacturing process. The National Transportation Safety Board and the Justice Department are also conducting separate investigations into the incident, underscoring the gravity of the situation and the need for swift corrective measures.
