FAA Audit Reveals Quality Control Lapses at Boeing and Spirit AeroSystems

The Federal Aviation Administration (FAA) has spotlighted significant quality control deficiencies at Boeing and its key supplier, Spirit AeroSystems, following a comprehensive audit initiated after a 737 Max 9 experienced an in-flight door plug failure in January. This six-week evaluation unveiled several instances of non-compliance with established manufacturing quality standards at both companies.

The audit scrutinized various aspects of Boeing's manufacturing processes at its facilities, including the 737 assembly line in Renton, Washington. The FAA's findings pointed to issues in process control, parts handling, storage, and product management, signaling a need for systemic improvements.

While the FAA has briefed Boeing and Spirit AeroSystems on the audit results, the specifics of the findings remain under wraps, and the agency has yet to publicly detail its conclusions or respond to inquiries regarding the matter.

In response to the audit and an additional investigation by an independent safety panel, the FAA mandated Boeing to outline a remedial action plan within 90 days. This directive aims to ensure that Boeing addresses the identified quality control failings, with the FAA set to rigorously evaluate Boeing's corrective measures for adequacy.

Boeing has expressed a commitment to transparency and action, pledging to devise a thorough plan to tackle the challenges highlighted by the audit and safety panel. The company's leadership has emphasized their dedication to overcoming these hurdles.

The incident with the Alaska Airlines 737 Max 9, which safely landed despite the mid-cabin door plug failure, has placed increased scrutiny on Boeing's manufacturing practices. Preliminary investigations suggest that bolts intended to secure the door plug may have been improperly managed, raising questions about the oversight of critical safety components.

Amid these quality concerns, Boeing has shown interest in acquiring Spirit AeroSystems to enhance control over the manufacturing process. This interest marks a shift from Boeing's previous strategy of outsourcing production, a move that now appears to be under reconsideration in light of recent quality issues.

As Boeing and Spirit AeroSystems work to address the FAA's findings, the aerospace industry watches closely, recognizing the importance of stringent quality control measures in ensuring the safety and reliability of air travel. The FAA's ongoing oversight and potential third-party review of Boeing's quality systems underscore the critical nature of these efforts.