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The FAA completed its six-week audit of Boeing and Spirit AeroSystems, finding multiple instances where both companies allegedly failed to comply with manufacturing quality control requirements. The FAA has halted production expansion of the 737 MAX, is exploring the use of a third party to conduct an independent review of quality systems and continues to increase its onsite presence at Boeing's facility in Renton, Washington and Spirit AeroSystem's facility in Wichita, Kansas.
The audit was launched in response to the Jan. 5 depressurization incident on Alaska Airlines Flight 1282 on a Boeing 737 MAX-9 in which a door plug blew out of the aircraft midflight. This was one of many immediate actions taken as a response to the near-catastrophic incident. The FAA said that last week Administrator Mike Whitaker told Boeing's CEO and other company senior leaders that Boeing must address the findings as part of a comprehensive action plan to fix systemic quality-control issues. The new plan must also address findings from the recent expert review panel report on Boeing's safety culture. The FAA gave Boeing 90 days to outline its action plan.RELATED STORIES:FAA panel calls Boeing safety culture 'inadequate and confusing'Boeing CEO admits 'mistake' as FAA launches safety probeLatest on 737 MAX 9 Alaska Airlines emergency - aircraft had prior issues before panel ripped off mid-flight
On Feb. 26 the FAA released its final report and recommendations from an expert panel convened to address Boeing's safety culture. The report said there was a disconnect between senior management and other organization members on the safety culture. Interviewees and Organization Designation Authorization Unit Members questioned the company safety culture reporting systems and whether they would function in such a way to enable open communication and non-retaliation. This panel convened on March 1, 2023 under the Aircraft Certification, Safety and Accountability Act passed in 2020 to propose changes to the FAA's airplane certification process in the wake of the two deadly 737 MAX crashes that killed over 300 people.
The FAA began the review of Boeing's safety culture nearly one year before the January depressurization incident. The panel was not directed to investigate any specific crashes, like the two 737 MAX crashes in 2018 and 2019, or the January door plug blowout. The final report did not that while the panel was working there were several occasions where serious quality issues with Boeing products became public, amplifying concerns over safety-related messages or behaviors.
After the incident on Alaska Airlines Flight 1282 Boeing remained transparent and continued to update the public on the investigation process and steps it was taking to change and prevent another similar occurrence. On Jan. 11 the FAA notified Boeing of the investigation to determine whether Boeing failed to ensure completed products conformed to the approved design. One day later, the FAA shared that it was increasing oversight into Boeing's production and manufacturing, including the audit of the MAX production line and suppliers, increased monitoring of in-service events and an assessment of safety risks around delegated authority and quality oversight.
"It is time to re-examine the delegation of authority and assess any associated safety risks," Whitaker said. "The grounding of the 737-9 and the multiple production-related issues identified in recent years require us to look at every option to reduce risk. The FAA is exploring the use of an independent third party to oversee Boeing's inspections and its quality system."
On Jan. 15 Boeing said it would take immediate action to bolster quality assurance and controls in the 737 production. This included additional inspections throughout the building process at Boeing and Spirit, planned quality sessions with teams, deploying a team to work alongside Spirit to review work on the ground, opening factories for additional oversight and bringing in an outside party for a thorough review. On Jan. 17 Boeing and Spirit held an employee town hall to discuss the depressurization incident and how to improve. On Jan. 23 Boeing shared it would hold a "Quality Stand Down" on the 25th, allowing employees to take part in work sessions focused on quality. At the same time, the FAA suspended any expansion to the 737 MAX production line, while allowing the planes that passed inspection to return to service.
"We're going to get better, not because the two of us are talking, but because the engineers at Boeing, the mechanics at Boeing, the inspectors at Boeing, the engineers at Spirit, the mechanics at Spirit, the inspectors at Spirit — they're going to speak the same language on this in every way, shape or form," Boeing CEO Dave Calhoun said. "We're going to learn from it, and then we're going to apply it to literally everything else we do together."RELATED STORIES:Boeing's head of 737 MAX program is leaving, other leadership changesBoeing 737 MAX 9 was missing bolts before depressurization eventFAA stops 737 MAX production expansion, allows eligible planes to return to service
The NTSB released its preliminary report about one month after the incident, finding that the bolts were missing before the door blew off. On Feb, 12 Whitaker walked the floors at Boeing's Renton factory to see the 737 production line and hear directly from engineers and mechanics about the quality control processes. Whitaker also went to the Alaska Airlines headquarters to discuss the depressurization incident. By the end of February, it was announced that the head of the 737 MAX program was leaving the company after 18 years, along with several other leadership changes within Boeing's commercial division.
On Feb. 28 the FAA shared that during an all-day safety discussion at FAA Headquarters Whitaker told Boeing officials they must develop a comprehensive plan to address systemic quality-control issues to meet the FAA's non-negotiable safety standards.
"Boeing must commit to real and profound improvements," Whitaker said. ?"Making foundational change will require a sustained effort from Boeing's leadership, and we are going to hold them accountable every step of the way, with mutually understood milestones and expectations."??
The plan, expected within 90 days, must include steps to mature the Safety Management System program that Boeing committed to in 2019. Boeing must also integrate its SMS program with a Quality Management System to ensure the same level of rigor and oversight that is applied to the company's suppliers and to create a measuring, systemic shift in manufacturing quality control.
"Boeing must take a fresh look at every aspect of their quality-control process and ensure that safety is the company's guiding principle," Whitaker said.
Boeing and Spirit have both confirmed ongoing discussions of an acquisition. Spirit AeroSystems has a history with Boeing dating back to 1929. In 2005 Boeing sold its Wichita division and Spirit began to operate independently. The majority of Spirit's revenue comes from Boeing and most of Boeing's aircraft components, like the fuselage, are made by Spirit. If Boeing buys Spirit, it will be back under the company umbrella for the first time in nearly 20 years.RELATED STORY:Boeing talks about possible Spirit AeroSystems buy
"We have been working closely with Spirit AeroSystems and its leadership to strengthen the quality of the commercial airplanes that we build together," Boeing said in a statement. "We confirm that our collaboration has resulted in preliminary discussions about making Spirit AeroSystems a part of Boeing again. We believe that the reintegration of Boeing and Spirit AeroSystems' manufacturing operations would further strengthen aviation safety, improve quality and serve the interests of our customers, employees, and shareholders. Although there can be no assurance that we will be able to reach an agreement, we are committed to finding ways to continue to improve the safety and quality of the airplanes on which millions of people depend each and every day."
Now that the audit is complete, the FAA will thoroughly review all of Boeing's corrective actions and determine whether they fully address the recent findings. The FAA has provided both Boeing and Spirit with a summary of its audit findings. Boeing and Spirit have not posted about the findings at the time of publication.