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Boeing, Not Spirit, Mis-installed Piece That Blew Off Alaska MAX 9 Jet (seattletimes.com) 98

Dominic Gates, reporting for Seattle Times: The fuselage panel that blew off an Alaska Airlines jet earlier this month was removed for repair then reinstalled improperly by Boeing mechanics on the Renton final assembly line, a person familiar with the details of the work told The Seattle Times. If verified by the National Transportation Safety Board investigation, this would leave Boeing primarily at fault for the accident, rather than its supplier Spirit AeroSystems, which originally installed the panel into the 737 MAX 9 fuselage in Wichita, Kan.

That panel, a door plug used to seal a hole in the fuselage sometimes used to accommodate an emergency exit, blew out of Alaska Airlines Flight 1282 as it climbed out of Portland on Jan. 5. The hair-raising incident drew fresh and sharp criticism of Boeing's quality control systems and safety culture, which has been under the microscope since two fatal 737 MAX crashes five years ago. Last week, a different person -- an anonymous whistleblower who appears to have access to Boeing's manufacturing records of the work done assembling the specific Alaska Airlines jet that suffered the blowout -- on an aviation website separately provided many additional details about how the door plug came to be removed and then mis-installed.

"The reason the door blew off is stated in black and white in Boeing's own records," the whistleblower wrote. "It is also very, very stupid and speaks volumes about the quality culture at certain portions of the business." The self-described Boeing insider said company records show four bolts that prevent the door plug from sliding up off the door frame stop pads that take the pressurization loads in flight, "were not installed when Boeing delivered the airplane." the whistleblower stated. "Our own records reflect this." NTSB investigators already publicly raised the possibility that the bolts had not been installed.
Further reading:
Alaska Air CEO Says Loose Bolts Found in 'Many' Boeing Jets.
Delta Air Lines Boeing 757 Lost Nose Wheel Before Takeoff, FAA Says.
FAA Calls for Door-Plug Checks on Second Boeing Jet.
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Boeing, Not Spirit, Mis-installed Piece That Blew Off Alaska MAX 9 Jet

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  • by mosch ( 204 ) on Wednesday January 24, 2024 @11:07PM (#64186404) Homepage

    This article was sourced from these [leehamnews.com] two [leehamnews.com] comments on the Leeham News website. I found the original comments more informative than the Seattle Times version, and while I can't be certain, the author seems credible.

    I'm half tempted to apply for a job over at Boeing, just so I can understand if they're learning the right lessons from this (about fixing their culture and processes), or if they're doubling down on the post-McD merger nonsense.

    • Re: (Score:1, Insightful)

      by Anonymous Coward

      Boeing: Putting the DIE in DEI!

      • by battingly ( 5065477 ) on Thursday January 25, 2024 @12:52AM (#64186512)
        Blaming every problem in the world on DEI is rapidly becoming code for "I'm a moron".
        • by Kokuyo ( 549451 )

          It's funny how your post comes right after https://news.slashdot.org/comm... [slashdot.org] currently.

          • It's only funny if you switch off your brain. Turn it back on and show how diversity and inclusion was a problem here. It may come as a surprise to you (until you turn your brain on) but incompetence occurs when employees are 100% white skinned with a penis too.

            But if you can point to someone hired as a diversity number, who was incompetent, who had a causal relationship to this problem, then we can start taking you seriously.

          • It's funny how in the Seattle times article it has zero mentions of "DEI" but your first instinct is to blame DEI. In the very long article, it describes how the plug door was removed and repaired at Boeing but it may not have been reinstalled with the crucial bolts. Also it details how in the system the repair was not marked as a part removal but merely an opening. Thus the work was not flagged for inspection as it should have been for a removal. Nowhere in the Times article any mention of diversity. But t
    • by Anonymous Coward on Wednesday January 24, 2024 @11:27PM (#64186430)

      I'm half tempted to apply for a job over at Boeing, just so I can understand if they're learning the right lessons from this (about fixing their culture and processes), or if they're doubling down on the post-McD merger nonsense.

      Narrator: Boeing learned nothing from this incident.

    • by bradley13 ( 1118935 ) on Thursday January 25, 2024 @04:44AM (#64186654) Homepage

      Those links make for fascinating reading. Here's the money quote:

      there are 4 bolts that prevent the mid-exit door plug from sliding up off of the door stop fittings that take the actual pressurization loads in flight, and these 4 bolts were not installed when Boeing delivered the airplane

      Emphasis mine. If true, then it has nothing to do with "loose bolts". This is far more serious, and a total failure of QA.

      • Re: (Score:2, Insightful)

        by buck-yar ( 164658 )
        How is loose bolts any different from missing from a completeness standpoint? Loose or missing, same difference. Did you read the supposed post from a Boeing employee at the bottom of the Leeham article? According to that post, the door install team concluded that they didn't "remove" the door and that the typical inspection required by such work wasn't required. They found a loophole to avoid inspection. How is that a failure of QC? QC should have been called to inspect the work but that step was purposefu
        • by Shinobi ( 19308 )

          The answer is false confidence. If you can't see any bolts, there's a glaringly obvious issue there. Loose bolts risk being overlooked as long as they are seen.

        • How is loose bolts any different from missing from a completeness standpoint? Loose or missing, same difference.

          Loose indicates a failure to secure them in place, or a failure to double-check post-installation. This can simply be accidental.

          Missing means a) no one bothered to install (or criminally neglected to do so), and b) no one double-checked post-installation (also criminal negligence.)

          Also, their net effects might not be the same. A loose bolt might or might not come off - it's an installation Russian roulette, and typically a function of incompetence.

          A missing bolt, that's another level of negligence be

        • One thing the article is weird about the title of the article is that it says "Boeing, not Spirit, mis-installed" the door. Reading the article leads me to believe that a Spirit employee at Boeing may have incorrectly installed the door. Now Boeing did not adequately inspect the door but how that happened is detailed too.
        • How many times have I been told 'Stop Testing, you're finding too many defects.'

          • The only time I saw something similar to this was during the pandemic when "that florida guy" said that there were too many cases of Covid-19 being discovered.

            ""If we stop testing right now, we'd have very few cases, if any," Trump asserted."

            www.voanews.com/a/covid-19-pandemic_trump-if-we-stop-testing-wed-have-fewer-cases/6191165.html

        • If you have extra parts left over when you build IKEA furniture, ya did it wrong.

          If you have extra parts left over when you build a plane, ya did it really, really wrong.

        • The 4 bolts are work by shear not by grip. They have crenelated nuts with cotter pins to insure they don't get loose.

          Without the bolts the plug door can move and depart the airframe.

          "How is loose bolts any different from missing from a completeness standpoint?"....... Moron.

      • Those links make for fascinating reading. Here's the money quote:

        there are 4 bolts that prevent the mid-exit door plug from sliding up off of the door stop fittings that take the actual pressurization loads in flight, and these 4 bolts were not installed when Boeing delivered the airplane

        Emphasis mine. If true, then it has nothing to do with "loose bolts". This is far more serious, and a total failure of QA.

        Reading the source posts, it's a leap to say the bolts weren't installed at all. It reports that reinstallation of the bolts is not documented, but neither was their removal in the first place - that was the real point, the removal and refitting should have been properly documented and then subject to QA checks. So it's not actually clear what went wrong with the undocumented refitting.

        • Most of these bolts are castle like nuts, so even if loose, they cant come off. It makes more sense they just werent installed. There are videos describing the downward spiral of quality after the McDonnel Douglas merge (Boeing turned into McDonnel Douglas since their leadership team took over)
        • We will probably get more from the FAA/NTSB analysis of the door plug. They will more than likely be able to tell that there were no bolts.
        • Boeing has admitted, according to an anonymous whistle blower, that the door plug on the airframe was not installed correctly in Kansas. In Renton BOEING removed it and "worked on the plug". There is no paperwork, meaning that the process was not followed and it is quite possible that the bolts were not re-installed.

          This is on Boeing and the white (had to do this because of all the DEI BS) guy did not do his job.

        • I am a bit surprised that Boeing does not have everyone who works on these planes wear Go-Pro cameras. I suppose they could be reviewed by AIs. In any case, who left the bolts out or failed to tighten them would be on record.

    • by jythie ( 914043 )
      For the most part they are just being very self congratulatory... and the lesson that they learned is that they can always drive up stock price through buybacks so problems like this do not actually impact their bottom line.
    • by tlhIngan ( 30335 )

      Well, their headquarters are still in Chicago, so no, they're not improving things.Because the executives are isolating themselves from the engineers. What made Boeing was the fact that the management staff routinely walked the line and talked to the engineers and things were communicated.

      With the management hidden away in some Chicago office, they're not listening to the engineering teams. They can implement all the processes they want, but management and engineering just aren't communicating. Right now it

      • As of 2023, the Boeing Company's corporate headquarters is located in the Crystal City neighborhood of Arlington, Virginia.

        AHH - that ain't Chicago.

        " the door plug will have to be removed and re-installed by Boeing in order to have the interiors fitted out properly."
        Pure dishonest Bull Shit. In order to "open" a plug door, you need to remove the side wall panels and the insulation covering the door. This myth is idiotic and flat out wrong.

        Thanks for playing mr. Trump.

    • "Safety culture" ? What kind of phrase is that? That's gross negligence. Would you buy a car if you knew they only installed 2 bolts on each tire? Maybe they had to make a deadline, or didn't have all the parts available at the time of assembly, so instead of waiting, they went ahead anyway and push it out the door. Do you really think I'm going to be flying on anything made by Boeing for the next 10-15 years?
  • Boeing.. (Score:5, Insightful)

    by Anonymous Coward on Wednesday January 24, 2024 @11:18PM (#64186422)

    Just came from a YouTube video where an NTSB spokesman speculated that the four bolts were not installed. Sad story really.

    Boeing, once an icon of America's might, now a poster child of America's decline..

    • Re:Boeing.. (Score:5, Interesting)

      by Rosco P. Coltrane ( 209368 ) on Thursday January 25, 2024 @01:49AM (#64186548)

      Boeing, once an icon of America's might, now a poster child of America's decline..

      More a poster child of the corporate world's unashamed willingness to sacrifice safety, product quality and respect for the workforce for the sake of saving a few bucks and cutting fat checks to the company officers. That's not American, that's a worldwide trend.

      Also, it's the symptom of something much more worrying: the FAA can be "convinced" to gloss over pretty damning design faults.

      I worked in aeronautics as a quality engineer, and the one thing everybody knew was that if your shit didn't pass muster - either design, processes, quality system or quality docmentation - the FAA or the EASA was going to strike you down. And if it was bad enough and either the FAA / EASA or any of the workers in the chain was found to be the cause, voluntarily or not, someone was going to do hard time, and that's why people who worked aero jobs were paid so good.

      The FAA I knew would never have allowed the MAX in the air. If you know anything about how aero designs are reviewed, you just know someone got paid to sign off on stuff they shouldn't have signed off on.

      That's what really concerns me about the whole Boeing: I don't care about the Boeing company, I care about boarding a plane that wasn't maintained properly because the maintenance people now have that idea that if they fuck up and it's not too bad, or of their boss is buddy-buddy with someone in the right position at the FAA, it's okay - instead of knowing they'd better do their job right or the police will for sure come and get em when the plane crashes 15 years later after they've retired.

      • Ain't capitalism efficient?

        • It is! It's just not very safe...

          It seems that the FAA allows aircraft manufacturers to serf-certify to a degree in order to make the whole process more efficient. As someone who is a proponent of a free market (with oversight and interference where needed), the notion of companies self-certifying critical safety items seems like a spectacularly bad idea to me. You'd think Boeing would have lost that particular privilege after the whole earlier mess with the MAX. More worryingly, according to that w
        • Ain't capitalism efficient?

          Oh yes, it is very efficient. But at what?

      • by ranton ( 36917 )

        I care about boarding a plane that wasn't maintained properly because the maintenance people now have that idea that if they fuck up and it's not too bad, or of their boss is buddy-buddy with someone in the right position at the FAA, it's okay - instead of knowing they'd better do their job right or the police will for sure come and get em when the plane crashes 15 years later after they've retired.

        As if those maintenance people wouldn't get thrown under the bus in a heartbeat if it is determined they were at fault for an equipment failure. I wouldn't feel any safer as a maintenance or factory worker just because my CEO can figure out how to avoid personal responsibility. That isn't going to save me from being fired.

      • by hey! ( 33014 )

        Well, it's financially efficient to discount the future. Of course then the future sucks, but you the manager are long gone by then and likely the smart stockholders have cashed out.

    • Aren't they more a poster child of American capitalism?

      You get what you measure. They switched from measuring engineering excellence to profit margin. Which is exactly what the most American companies strive for. Profit above all else.

      This isn't the decline of America, this is peak America.

  • Deliberate Confusion (Score:5, Interesting)

    by sound+vision ( 884283 ) on Wednesday January 24, 2024 @11:27PM (#64186428) Journal

    I'm starting to wonder if Spirit Aerosystems was deliberately named to create confusion with Spirit Airlines.

    Boeing bigwigs spun off Spirit Aerosystems from the main company and named it as such. "A contractor did it" is standard-issue plausible-deniability. And Boeing has been blaming airlines for this particular problem.

    "Spirit AeroLineSystems? Those are those cheapos who lose your luggage, right? Can't have anything to do with that respectable company Boeing..."

  • by atomicalgebra ( 4566883 ) on Wednesday January 24, 2024 @11:48PM (#64186460)
    Boeing executives focused on stock price above everything else. It is that single-mindedness which is going to result in the largest stock decrease in the companies history.
    • t is that single-mindedness which is going to result in the largest stock decrease in the companies history.

      That is the future and the future is not guaranteed. The profits are now and real. What the fuck do you think they will choose? They are drug addicts looking for a drug.

  • in order to deal with issues more efficiently.
    It could have been one of those lines in the movie Idiocracy that were supposed to be funny.
    But Boeing doing their on safety and quality checks comes scary close to the world envisioned in Idiocracy.

  • by Miamicanes ( 730264 ) on Thursday January 25, 2024 @12:46AM (#64186510)

    The appropriate punishment to Boeing would be its forced division back into Boeing and McDonnell Douglass. Divide their manufacturing facilities more or less down the middle, with both new companies starting out with equal ownership of the present company's intellectual property.

    Best-case, the US ends up with two vigorously-competing aviation companies. Worst-case, all of Boeing's present-day shittiness gets condensed into one of them and the bad one goes bankrupt, taking the rot along with it and leaving the other to once again become a world leader.

    At this point, Boeing's reputation is so badly tarnished, forced-division would probably end up being a hidden blessing to Boeing's current stockholders.

    • by Savage-Rabbit ( 308260 ) on Thursday January 25, 2024 @01:37AM (#64186540)

      The appropriate punishment to Boeing would be its forced division back into Boeing and McDonnell Douglass. Divide their manufacturing facilities more or less down the middle, with both new companies starting out with equal ownership of the present company's intellectual property.

      Best-case, the US ends up with two vigorously-competing aviation companies. Worst-case, all of Boeing's present-day shittiness gets condensed into one of them and the bad one goes bankrupt, taking the rot along with it and leaving the other to once again become a world leader.

      At this point, Boeing's reputation is so badly tarnished, forced-division would probably end up being a hidden blessing to Boeing's current stockholders.

      What would actually happen is that you'd get two mini-McDonnell Douglass'es that both inherit Boeings present-day shiftiness and that would both go bankrupt. The problem here is the shittyness of modern US corporate culture in general, not McDonnell Douglas' shitty corporate culture specifically.

      • "you'd get two mini-McDonnell Douglass'es that both inherit Boeings present-day shiftiness"

        We can see that right here in Boeing vs. Spirit. They are neither independent nor distinct, so blaming one over the other doesn't really bring any clarity.

      • by mjwx ( 966435 )

        The appropriate punishment to Boeing would be its forced division back into Boeing and McDonnell Douglass. Divide their manufacturing facilities more or less down the middle, with both new companies starting out with equal ownership of the present company's intellectual property.

        Best-case, the US ends up with two vigorously-competing aviation companies. Worst-case, all of Boeing's present-day shittiness gets condensed into one of them and the bad one goes bankrupt, taking the rot along with it and leaving the other to once again become a world leader.

        At this point, Boeing's reputation is so badly tarnished, forced-division would probably end up being a hidden blessing to Boeing's current stockholders.

        What would actually happen is that you'd get two mini-McDonnell Douglass'es that both inherit Boeings present-day shiftiness and that would both go bankrupt. The problem here is the shittyness of modern US corporate culture in general, not McDonnell Douglas' shitty corporate culture specifically.

        Yep, it's clear the private sector can't be trusted with something so valuable, partial nationalisation (the government gains a significant share of Boeing, but is essentially another shareholder) and greater oversight would probably be a vast improvement even given how incompetent the US is at oversight.

        • The problem is, the federal government can't just declare itself the owner of something like 1/3 of Boeing... it would have to buy the shares at a premium price, as if it were a private equity firm attempting a hostile takeover via a leveraged buy-out. Even in its wounded state, Boeing stock is worth hundreds of billions of dollars.

          Now, granted, the government could borrow the money for a near-pittance (relatively speaking), so it wouldn't be quite as handicapped as a normal LBO, and in a sense it would be

    • The question is when do you demand external inspections and why. And, to be fair, the actual record of air safety across the world remains remarkable - at least in civilised countries. So on the whole it is working well.

  • I really can't put the blame on Boeing because we don't know if the customer remembered to click the checkbox for the optional door retention mechanism when ordering the plane. /s
  • I recommend this video for a good explanation
    https://youtu.be/XhRYqvCAX_k?s... [youtu.be]

  • Somewhere along the line, someone decided to make change to the assembly procedure that didn't get properly documented and and they didn't followed that new procedure.

    • by hey! ( 33014 )

      Well, my understanding is that there was a problem with the door seal as delivered from Spirit. To correct this, Boeing had to remove the retaining bolts. They *could* have recorded this as the door plug being "removed", but that would have triggered additional inspections of the door plug's retaining bolts. Instead they recorded the door plug as being "opened" -- as if it were a *door* -- because opening a door doesn't trigger additional inspection of how the door is attached.

      So Spirit *and* Boeing both

  • Boeing was supposed to adopt Six-Sigma when my old GE Information Services boss, Jim McNerney, became the boss. Six-Sigma was a quality improvement program that Chairman Jack Welch pushed through GE. It reminds us that fixing a defect early in production is far cheaper than having to recall product after the defects cause the product to fail as customers use it. When I was training as a Six-Sig "Green Belt", the instructors warned us, over and over, against defects that might cause an air-liner to crash. A

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