FAA Audit reveals manufacturing quality control Failures at Boeing and Spirit AeroSystems

Tuesday, March 5, 2024

The Federal Aviation Administration (FAA) conducted a six-week audit of Boeing and Spirit AeroSystems following the January 5 incident involving a new Boeing 737-9 MAX aircraft. The audit revealed numerous instances where the companies allegedly fell short of meeting manufacturing quality control requirements.

The FAA’s investigation uncovered issues related to Boeing’s manufacturing process control, parts handling and storage, and product control. This information is being made public to update the ongoing investigation.

Prompted by the incident on Alaska Airlines Flight 1282, where a left mid-cabin door plug blew out during flight, the FAA took immediate oversight actions, including this audit. In a recent meeting at FAA Headquarters in Washington, DC, Administrator Mike Whitaker informed Boeing’s CEO and other top executives that the company must address the audit’s findings as part of a comprehensive corrective action plan. This plan should also tackle issues highlighted in an expert review panel report on Boeing’s safety culture. Boeing has been given 90 days to outline its action plan.

In response to the production quality concerns, the FAA has paused the expansion of Boeing 737 MAX production. Additionally, the FAA is considering employing a third party for independent reviews of quality systems and will maintain an increased onsite presence at Boeing’s Renton, Washington, facility and Spirit AeroSystems’ Wichita, Kansas, facility.

The FAA will carefully evaluate Boeing’s corrective measures to ensure they adequately address the agency’s findings. Both companies have been provided with a summary of the audit findings by the FAA.

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