The US Federal Aviation Administration has found dozens of problems throughout the production process for Boeing’s 737 Max jets, including a mechanic at one of its major suppliers who ordered hotel key cards and dishwashing detergent, according to a report. This includes the use of “as a makeshift tool for conformance testing”.
The FAA found “unacceptable” quality control issues during an audit of Boeing and supplier Spirit AeroSystems, which was launched after a 737 Max 9’s door plug flew off at 16,000 feet on Jan. 5.
The agency did not release its findings to the public, but gave a presentation detailing the findings. Review by New York Times It reveals a problematic and inconsistent manufacturing process.
Auditors found that Boeing failed 33 of 89 product audits (examinations of specific aspects of production lines), for a total of 97 nonconformities, the paper said.
Spirit AeroSystems, which makes the airframe for the 737 Max jet, failed seven of 13 product audits conducted by the FAA, the magazine reported. One of those failures involved installing an airplane door plug.
Some of the most shocking details of the presentation occurred at Spirit AeroSystems’ airframe manufacturing plant in Wichita, Kansas.
According to a report in the Times, FAA auditors observed a company mechanic using a hotel key card to check a door seal, and another Spirit mechanic was “lubricating the installation process.” He was seen applying Dawn liquid soap to the door seal, the Times reported. .
In the latter incident, the mechanic used wet cheesecloth to wipe up dish soap and clean the door seal. A document obtained by the dealership detailing the audit results said instructions provided to mechanics were “vague and unclear as to what specifications and actions mechanics should follow or record.” it is written like this.
A spokesperson for Spirit AeroSystems, which Boeing is negotiating to reacquire, told the Times that the company is “reviewing all identified nonconformities for corrective action.”
Boeing did not immediately comment on the audit results, but the FAA has declined to release them as it continues to investigate the Alaska Airlines flight door plug incident and Boeing’s response to it.
Companies must develop a comprehensive action plan within 90 days to address “systemic quality control issues” raised by the audit.
The National Transportation Safety Board is also investigating the horrific door panel blowout incident, and the Justice Department has launched a criminal investigation into Boeing.
