Boeing adds new quality control checks nearly one year after door plug blowout

Departing FAA administrator says embattled plane maker needs a 'fundamental cultural shift'

Boeing was thrust deeper into crisis on January 5, 2024 when and Alaska Airlines aircraft was forced to make an emergency landing after a door panel blew out in mid-air. Reuters

Embattled US plane maker Boeing on Friday said it is making progress in rebuilding trust with passengers and regulators, nearly a year after a door panel blew off during an Alaska Airlines 737 Max 9 flight.

The manufacturer said it had introduced more than a dozen new quality control checks as part of its new quality and safety plan, focusing on four key areas: elevating safety and quality culture, eliminating defects, simplifying processes and investing in workforce training.

Boeing was thrust into crisis on January 5, 2024, when the Alaska Airlines aircraft was forced to make an emergency landing after a door panel blew out during a flight from Portland, Oregon. Numerous whistle-blowers came forward after the incident, alleging Boeing overlooked safety and quality standards.

The Federal Aviation Administration conducted a six-week audit of Boeing in March, in which it found multiple non-compliance issues in its manufacturing process. In May, the FAA ordered Boeing to develop a 90-day plan to transform its safety culture.

Roughly 33,000 workers at two major plants began a seven-week strike in September that crippled most of Boeing's production. The strike and enhanced safety checks by the FAA have forced Boeing to delay production of its 737 and 777x aircraft.

And in December, a federal judge rejected a plea deal between Boeing and the US Justice Department in December over two fatal 737 Max crashes that occurred in 2018 and 2019.

Boeing changes

Boeing said it has addressed more than 70 per cent of commercial plane production “action items” based on employee feedback and “significantly reduced” defects in 737 fuselage assembly at supplier Spirit AeroSystems. The plane maker said it also established new random quality audits to ensure compliance.

“Boeing is working to make progress executing its comprehensive plan in the areas of safety, quality improvement and effective employee engagement and training,” FAA Administrator Mike Whittaker said in a blog post on Thursday. “But this is not a one-year project. What’s needed is a fundamental cultural shift at Boeing that’s orientated around safety and quality above profits.”

Mr Whittaker, who is due to step down later this month, said the FAA would continue its enhanced oversight of Boeing indefinitely. The FAA chief previously said the agency was too lenient in its oversight before the January 5 incident.

“Our goal is to develop even more dynamic oversight protocols that enable us to anticipate and identify risks before incidents occur,” he said.

Boeing said it also made improvements to its “Speak Up system” to help protect whistle-blowers. It also said it took steps to ensure accountability by having employees stamp their names on completed work.