Boeing has encountered yet another quality issue in the production of its 737 MAX aircraft. The problem involves some fuselages having incorrectly drilled holes. As a result, Emirates, an airline customer of Boeing, has expressed a loss of trust in the manufacturer’s quality management. Emirates plans to send its engineers to inspect Boeing’s production facilities. This recent issue adds to a series of production problems that the 737 MAX line has faced over the past year.
In a statement on February 4, 2024, Stan Deal, the President and CEO of Boeing Commercial Airplanes, addressed the latest production issue. He explained that an unidentified supplier had notified Boeing about nonconformance in the drilling of holes in certain 737 fuselages. While Deal emphasized that this is not an immediate flight safety concern, it could potentially delay some deliveries. Boeing is committed to delivering flawless airplanes and will be conducting additional work on approximately 50 undelivered aircraft to address this issue.
The supplier involved in this case is Spirit AeroSystems, which is a Tier 1 supplier for the 737 program as well as other Airbus and Boeing assembly lines. Spirit AeroSystems supplies Boeing with various components including fuselages, pylons, wing leading edges, thrust reversers, and engine nacelles.
To improve overall quality, Boeing recently held a Quality Stand Down day on January 25, 2024. Approximately 10,000 employees working on the 737 spent the day focused on quality and safety. This was the first time that Boeing paused aircraft production for a stand down specifically dedicated to addressing quality issues.
Over the past year, Boeing has faced several production challenges with the 737 MAX. These include a suspension of deliveries in April 2023 due to a non-standard manufacturing process, elongated fastener holes on fuselages in August 2023, and loose bolts in the rudder control system in December 2023. These issues have tested the patience of customers and regulators, with some expressing frustrations with Boeing’s quality management. In response to the Alaska Airlines incident in January 2024, Boeing has undertaken various measures to improve its quality management, including additional inspections, team sessions, and inviting third-party inspections.
Emirates, although not operating any 737 MAX aircraft, has voiced concerns and is sending its engineers to inspect Boeing’s manufacturing processes. This comes as Emirates recently ordered more Boeing 777X and 787 aircraft, while also expressing criticism of the delayed 777X program.
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