FAA Boeing Audit Illuminates 737 Production Issues

The aircraft manufacturer failed 33 of 89 tests in a production audit, according to the aviation safety agency.

Tuesday, March 12, 2024 at 04:10 PM ET

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A federal investigation revealed the Alaska Airlines door plug failed due to four missing bolts after maintenance, with Boeing criticized for failing to provide documentation on its reinstallation and "stonewalling" the NTSB.
FAA audits uncovered extensive manufacturing process control issues at Boeing and its supplier Spirit AeroSystems, including numerous failed product audits and observed instances of unapproved tools and procedures.
In response, the FAA has significantly increased oversight, halted 737 Max production expansion, and mandated a comprehensive quality improvement plan from Boeing, with the Department of Justice also investigating.

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A federal investigation has intensified after Boeing failed product audits and has not provided documentation on the removal and subsequent reinstallation of a door plug that failed on a Alaska Airlines Boeing 737 Max 9 flight in January.

According to the preliminary report by the Nation Transportation Safety Board (NTSB), the four bolts that were supposed to hold the door plug in place were not installed. The investigation revealed the door plug had been removed for maintenance because of improperly installed rivets.