Boeing's Persistent Manufacturing Issues Exposed in NTSB Hearings
NTSB hearings reveal long-standing manufacturing problems at Boeing, including systemic issues, employee fears, and oversight challenges. New CEO faces urgent tasks to restore trust and address ongoing concerns.
Recent National Transportation Safety Board (NTSB) hearings have shed light on Boeing's long-standing manufacturing issues, revealing systemic problems that extend far beyond the January 2024 Alaska Airlines incident. The hearings, which took place last week, exposed a complex web of challenges facing the aerospace giant.
Boeing's assembly process for the 737 MAX, which first flew in January 2016, has been under scrutiny for years. The company's quality control procedures have been described as convoluted and confusing, with even senior executives struggling to comprehend them. Elizabeth Lund, Boeing's senior vice president for quality, admitted to investigators that she had to "go in a quiet room and read it to myself several times" to understand the 50-plus pages of instructions for removing parts.
The hearings also revealed a concerning culture of fear among Boeing employees. Despite a company policy prohibiting retaliation, many workers are afraid to report safety concerns. This fear was exemplified by the treatment of two factory workers who were reassigned to what they described as a "cage" following the Alaska Airlines incident.
Production disruptions have plagued Boeing for years. Five years ago, when 737 MAX production outpaced engine supply, the company resorted to building planes without engines and later transferring them between facilities. The COVID-19 pandemic further exacerbated these issues, leading to significant workforce turnover and a loss of experienced personnel.
The Federal Aviation Administration (FAA), responsible for overseeing Boeing's operations, has faced its own challenges. FAA inspectors reported difficulties in accessing certain areas of Boeing's facilities and expressed concerns about the complexity of the manufacturing system.
"Is it just me or are we seeing a game of whack-a-mole every five to 10 years on safety? What do you think will be different this time?"
As Boeing attempts to address these issues, newly appointed CEO Robert "Kelly" Ortberg faces several urgent tasks. These include awaiting a federal judge's decision on a plea agreement related to the fatal 737 MAX crashes in 2018 and 2019, addressing concerns about the Starliner spacecraft's safety, and negotiating with the company's largest labor union, whose contract expires in September 2024.
The NTSB's final report on the Alaska Airlines incident is expected to be completed in 12 to 18 months. In the meantime, Ortberg must work to convince federal regulators that Boeing can build safe airplanes and restore trust in the company's manufacturing processes.
