Boeing Claims Significant Quality Improvements in 737 Max Production After High-Profile Incident
Boeing has announced major strides in improving the quality of its 737 Max aircraft production following a concerning incident in January where a door plug detached in mid-flight on an Alaska Airlines flight. While the incident did not result in any serious injuries, it sparked fresh concerns about the safety and quality control measures employed by Boeing, particularly considering the two fatal crashes involving the Max in 2018 and 2019. Now, Boeing is asserting that it has implemented several significant changes aimed at bolstering quality and mitigating the risk of such incidents recurring.
Key Takeaways:
- Increased Supplier Oversight: A significant change implemented by Boeing since the January incident involves requiring more rigorous inspections of 737 Max plane bodies before they are shipped to Boeing’s Renton, Washington factory for final assembly. Previously, bodies were made by Spirit AeroSystems in Wichita, Kansas, a supplier Boeing is expected to acquire soon. By implementing stricter inspections at the supplier level, Boeing is attempting to ensure that parts arrive at their factory with fewer defects, leading to a more streamlined production process.
- Improved Training and Safety Culture: Boeing has also committed to expanding training for new hires and enhancing on-the-job training for existing employees. This includes deploying over 160 workforce coaches, including veterans and retired mechanics, to support newer workers and ensure that they are adequately equipped to meet safety standards. The company has also placed a stronger emphasis on fostering a culture of open communication, encouraging workers to raise concerns and provide feedback on improving production quality.
- Simplification of Processes and Reduced Defects: Boeing is taking steps to simplify and streamline its production plans and procedures, minimizing the potential for errors. This includes reducing traveled work, or tasks performed out of sequence, which can increase the likelihood of mistakes and production bottlenecks. The company reports that it has achieved a more than 50% reduction in traveled work thanks to these changes.
Going Beyond the January Incident
While the January incident served as a wake-up call, Boeing emphasizes that the changes implemented go beyond addressing the specific issue that led to the door plug detachment. The company contends that these measures represent a broader commitment to ensuring aircraft quality and safety, building on lessons learned from the previous Max crises.
Elizabeth Lund, Boeing’s senior vice president for quality in the commercial airplane division, underscored that the earlier Max crashes necessitated an overhaul of the company’s engineering practices. However, the recent incident prompted a focus on production process improvements. “When this accident came along, it gave us a chance to look at a different area,” Lund stated.
The Critical Incident and Its Aftermath
The January incident, involving a 737 Max flight carrying 172 passengers and crew, occurred after the plane was already in service and after a series of changes were implemented following the 2018 and 2019 crashes. The incident involved a panel, known as a door plug, being partially detached in flight at a high altitude. The panel was meant to be secured by four bolts, but due to a lack of documentation regarding the panel’s removal for a prior repair, they were not installed.
The incident reignited concerns about the company’s commitment to safety and raised questions about whether its previous efforts to rectify the issues identified after the 2018 and 2019 crashes had been sufficient.
The Role of Regulators
The National Transportation Safety Board (NTSB), investigating the incident, has criticized Boeing for the lack of appropriate documentation regarding the removal of the door plug. The Federal Aviation Administration (FAA), Boeing’s primary regulator, has also issued demands for significant improvements to the company’s quality control measures.
A New Chapter for Boeing?
While these recent changes represent a significant step toward rebuilding trust and restoring confidence in Boeing’s aircraft, the company still faces an uphill battle. The legacy of the Max crashes casts a long shadow, and the public will be closely watching to see if these latest improvements translate into tangible and lasting changes in the quality and safety of its aircraft.
The coming years will be crucial for Boeing as it strives to demonstrate its commitment to safety and regain the public’s trust. The success of these changes will depend not only on the implementation of new procedures but also on a fundamental shift in the company’s culture and approach to quality control.
