A comprehensive audit by the Federal Aviation Administration (FAA) on Boeing’s 737 Max jet production has unearthed numerous issues, highlighting widespread noncompliance in manufacturing processes at Boeing and its key supplier, Spirit AeroSystems. Initiated following an incident where a door panel detached from a 737 Max 9 on an Alaska Airlines flight in January, the audit spanned six weeks and involved up to 20 FAA auditors stationed at Boeing’s Renton, Washington plant.
The audit’s findings, which were detailed in a slide presentation reviewed by The New York Times, indicate that Boeing failed 33 out of 89 product audits, marking 97 instances of alleged noncompliance. Meanwhile, Spirit AeroSystems, responsible for constructing the 737 Max’s fuselage, passed only six out of 13 product audits. Notable observations included mechanics using unconventional methods such as a hotel key card to check door seals and Dawn soap as lubricant during the assembly process, methods not documented or specified in production orders.
These lapses raise concerns about the adherence to approved manufacturing processes and the quality control documentation, casting doubts on the manufacturing integrity of the 737 Max. In response to the audit findings, Boeing has been given a 90-day window to propose quality control improvements, acknowledging the need for significant corrective actions.
Spirit AeroSystems has also responded to the preliminary findings, committing to work with Boeing to address the identified nonconformities and aiming to eliminate defects and errors in its manufacturing processes. This initiative underscores the ongoing efforts to enhance safety and quality programs, focusing on minimizing nonconformities.
The audit is part of a broader investigation into Boeing by the FAA, which also includes a criminal probe by the Justice Department and an investigation by the National Transportation Safety Board into the Alaska Airlines incident. These investigations underscore the heightened scrutiny over Boeing’s quality control practices following several high-profile incidents involving the 737 Max jets.
As Boeing and Spirit AeroSystems navigate the aftermath of the audit, the focus remains on implementing comprehensive improvements to ensure the highest standards of manufacturing and safety. This includes addressing the audit’s findings related to documentation, inspection processes, and the overall understanding of quality control procedures among employees. The audit’s revelations serve as a critical reminder of the importance of stringent compliance with manufacturing protocols to safeguard the aviation industry’s integrity.
Sources: AirGuide Business airguide.info, bing.com, nytimes.com
