'Shortcuts everywhere': How Boeing favoured speed over quality

In February last year, a new Southwest Airlines Boeing 737 Max plane was on one of its first flights when an automated stabilising system appeared to malfunction, forcing the pilots to make an emergency landing soon after they took off.

Less than two months later, an Alaska Airlines 737 Max plane with eight hours of total flight time was briefly grounded until mechanics resolved a problem with a fire detection system. And in November, an engine on a just-delivered United Airlines 737 Max failed at 37,000 feet.These incidents, which the airlines disclosed to the Federal Aviation Administration, were not widely reported. There were no indications that anyone was in danger, and it was not clear who was ultimately responsible for those problems. But since Jan. 5, when a panel on a two-month-old Alaska Airlines 737 Max 9 jet blew off in midair, episodes like these have taken on new resonance, raising further questions about the quality of the planes Boeing is producing.

“There’s a lot of areas where things don’t seem to be put together right in the first place,” said Joe Jacobsen, an engineer and aviation safety expert who spent more than a decade at Boeing and more than 25 years at the FAA. “The theme is shortcuts everywhere — not doing the job right,” he added.

Such reports, and interviews with aviation safety experts and more than two dozen current and former Boeing employees, paint a worrying picture about a company long considered to be at the pinnacle of American engineering. They suggest that Boeing is struggling to improve quality years after two crashes of Max 8 planes in 2018 and 2019 killed nearly 350 people.

Some of the crucial layers of redundancies that are supposed to ensure that Boeing’s planes are safe appear to be strained, the people said. The experience level of Boeing’s work force has dropped since the start of the pandemic. The inspection process intended to provide a vital check on work done by its mechanics has been weakened over the years. And some suppliers have struggled to adhere to quality standards while producing parts at the pace Boeing wanted them. Under pressure to show regulators and airlines that the company is taking its latest crisis seriously, Boeing announced sweeping changes to its leadership on Monday. The chief executive, Dave Calhoun, will leave at the end of the year, and Stan Deal, the head of the commercial planes division, which makes the 737 Max, retired immediately.

Boeing employees said the incident reflected longstanding problems. Several said employees often faced intense pressure to meet production deadlines, sometimes leading to questionable practices that they feared could compromise quality and safety. One quality manager in Washington State who left Boeing last year said workers assembling planes would sometimes try to install parts that had not been logged or inspected, an attempt to save time by circumventing quality procedures intended to weed out defective or substandard components.

Worrying picture

Current and former Boeing employees offered examples of how quality has suffered over the years
 

 According to employees, workers assembling planes would sometimes try to install parts that had not been logged or inspected
 

Boeing workers in South Carolina and in Washington State said mechanics building planes were allowed in some instances to 

sign off on their own work
 

Numerous problems on planes were assembled, including wires being routed incorrectly, raising the risk that they could rub against one another, resulting in damage

©2024 The New York Times News Service