The Federal Aviation Administration (F.A.A.) recently conducted a six-week audit of Boeing’s production of the 737 Max jet, revealing numerous issues throughout the manufacturing process at the plane maker and one of its key suppliers, Spirit AeroSystems. The audit was initiated after a door panel blew off a 737 Max 9 during an Alaska Airlines flight in early January.
According to a slide presentation reviewed by The New York Times, the F.A.A. found “multiple instances” where Boeing and Spirit AeroSystems failed to comply with quality-control requirements. The presentation detailed specific findings, including instances where mechanics at Spirit used a hotel key card to check a door seal and applied liquid Dawn soap as lubricant in the fit-up process.
Boeing passed 56 out of 89 product audits conducted by the F.A.A., while Spirit AeroSystems passed only 6 out of 13 audits. The findings have raised concerns about manufacturing lapses at both companies.
In response to the audit, Boeing and Spirit AeroSystems have committed to implementing immediate changes and developing comprehensive action plans to strengthen safety and quality. Boeing’s CEO, Dave Calhoun, stated that the company has a clear picture of what needs to be done to address the audit findings.
The F.A.A. has given Boeing 90 days to develop a plan for quality-control improvements, and the agency is actively investigating the Alaska Airlines incident. The National Transportation Safety Board and the Justice Department have also launched investigations into the matter.
The audit at Boeing covered various parts of the 737 Max, including its wings and other systems. Many of the issues identified by auditors were related to not following approved manufacturing processes or procedures, as well as problems with quality-control documentation.
Overall, the audit findings have underscored the need for both Boeing and Spirit AeroSystems to enhance their quality-control practices to ensure the safety and reliability of the 737 Max jet. The companies are working closely with the F.A.A. to address the issues raised during the audit and improve their manufacturing processes.
