Boeing Still Doesn’t Know How a Plane Missing Four Bolts was Sent to Alaska Airlines

Boeing’s Missing Bolts Mystery: NTSB Investigation Highlights Safety Lapses and Criticisms
In a revealing investigation spanning seven months and nearly 10 hours of hearings, neither Boeing nor the National Transportation Safety Board (NTSB) have determined how a 737 Max aircraft was delivered to Alaska Airlines missing four critical bolts needed to secure a door plug. The January 5 incident, where a door plug blew out mid-flight, has cast a harsh spotlight on Boeing’s manufacturing practices and raised concerns about the company’s safety protocols.

The door plug in question was removed during maintenance at Boeing’s Renton, Washington, factory in September to repair rivet issues. However, Boeing’s senior vice president of quality, Elizabeth Lund, admitted under NTSB questioning that the paperwork for the door plug removal was never filed. This oversight led to the door plug being reinstalled without the necessary bolts, creating a serious safety hazard.

NTSB Chair Jennifer Homendy expressed frustration over the lack of clarity regarding who was responsible for the oversight, stating, “We don’t know and neither do they, and that’s a problem.” The investigation has also revealed that Boeing’s safety management and quality control systems, in place for several years, failed to prevent the incident.

During the hearings, Boeing executives acknowledged “gaps” in their systems, with Hector Silva, Boeing’s vice president of regulatory compliance, admitting he could not guarantee such an incident would not happen again. The NTSB members voiced their dissatisfaction with Boeing’s responses, questioning the effectiveness of past agreements between Boeing and the Federal Aviation Administration (FAA) intended to address quality control issues.

The investigation also revealed that two Boeing employees involved in the Alaska Airlines jet have been “sidelined” as part of the inquiry. Homendy criticized this action, arguing it could discourage other employees from reporting mistakes due to fear of retaliation.

In response to the incident, Boeing is considering implementing a warning light in the cockpit to alert pilots if a door plug moves, though this change may take a year to roll out. In the meantime, Boeing has introduced a simpler measure: attaching a laminated tag to door plugs at the factory, warning workers not to open them without consulting quality assurance.

Testimonies from Boeing employees painted a picture of a company under pressure, with concerns about inadequate training, relentless speed demands, and frequent defects in planes. The hearings highlighted a broader issue within Boeing’s operations, where a shift to a “lean” manufacturing model, aimed at cutting costs, led to the reduction of inspections and oversight.

NTSB documents released during the hearings included troubling accounts from Boeing workers and FAA officials, who described a company struggling with quality control. One worker noted that the planes regularly arrived on the assembly line “jacked up,” requiring extensive rework.

James Phoenix, a retired FAA manager, criticized Boeing’s shift to lean manufacturing, stating it compromised safety. He argued that Boeing only made meaningful changes after two fatal 737 Max crashes in 2018 and 2019, which brought significant scrutiny to the company’s practices.

As the investigation continues, Boeing has pledged to improve its quality systems. However, the NTSB and the public remain skeptical, with concerns that Boeing may not be doing enough to prevent future incidents. Homendy emphasized the need for proactive changes, warning that further improvements should not be reactive but part of a continuous commitment to safety.