Boeing Failed 33 of 89 FAA Audits Tied to 737 Max: Report

The Federal Aviation Administration (FAA) has revealed that Boeing failed 33 of 89 audits conducted as part of a recent examination, shedding light on numerous issues within the production process of the 737 Max jet.

This revelation comes after an Alaska Airlines flight experienced a door panel blowout mid-air in January, prompting heightened scrutiny of Boeing's practices.

FAA Audit Reveals Manufacturing Lapses Following Door Plug Blowout

The first Boeing 737 MAX 7 aircraft sits on the tarmac outside of the Boeing factory on February 5, 2018 in Renton, Washington.
(Photo : Stephen Brashear/Getty Images)

During the six-week audit, the FAA scrutinized Boeing's manufacturing processes along with its supplier, Spirit AeroSystems. The examination uncovered multiple instances of non-compliance with quality-control requirements.

Specifically, Boeing passed 56 of the audits but failed 33. Additionally, the audit uncovered a staggering 97 instances of alleged noncompliance, further raising concerns about Boeing's adherence to regulatory requirements.

Similarly, Spirit AeroSystems passed six audits out of 13, with seven failures.

Details from the audit include observations of technicians at Spirit using unconventional methods, such as utilizing a hotel key card to check a door seal and applying Dawn soap as a lubricant during assembly. These actions were noted as not conforming to specified procedures, indicating lapses in standard practices.

Last month, Boeing was urged by the FAA to address quality control issues within 90 days. The agency has also halted the production expansion of the 737 Max and is considering third-party reviews of Boeing's quality systems.

Moreover, increased FAA presence at Boeing's facilities in Renton, Washington, and Spirit AeroSystems' facility in Wichita, Kansas, has been mandated.

Boeing Grapples with Safety Concerns Amidst FAA Scrutiny

The FAA's audit is part of a broader investigation into the Alaska Airlines incident, with the National Transportation Safety Board (NTSB) probing the root cause of the door panel detachment.

In a preliminary report released in early February, the NTSB disclosed that four essential bolts meant to secure the door plug of the Boeing aircraft were missing prior to the explosive mid-flight detachment of the plug.

In response to these findings, Boeing expressed its commitment to rectifying the identified shortcomings. Dave Calhoun, Boeing's CEO, acknowledged the need for improvement.

"An event like this must not happen on an airplane that leaves our factory." Calhoun stated. "We simply must do better for our customers and their passengers."

However, NTSB Chair Jennifer Homendy recently condemned Boeing's insufficient cooperation in the ongoing investigation. She emphasized that investigators still lack vital details, such as the identities of those who worked on the door plug that detached from the aircraft midflight despite repeated requests.

The Justice Department, meanwhile, has initiated a review to determine if the deficiencies identified in the audit violate a deferred prosecution agreement signed by Boeing following previous incidents involving the 737 Max.

The outcome of the FAA audit is expected to inform future congressional hearings on Boeing's practices.

Homendy is scheduled to provide updates on the investigation to the Senate committee overseeing aviation, with hearings involving Boeing executives anticipated thereafter.