Boeing Whistleblower on 737 Factory’s Quality Control Process | WSJ
Summary
TLDRThe video script discusses the quality control issues at Boeing's 737 factory, highlighting the Alaska Airlines incident where a door plug blew off midair. It outlines the multiple layers of inspection, including Boeing's own inspectors, the Organization Designation Authorization (ODA), and the FAA. The script reveals past elimination of certain inspections and the pressure to prioritize production speed over quality. It also mentions the whistleblower Ed Pierson and the subsequent management shakeup at Boeing. The FAA's increased oversight and Boeing's proposed changes to address these issues are also covered, emphasizing the importance of producing safe aircraft.
Takeaways
- 🚫 Boeing faced quality control issues leading to a door plug blowing off midair on an Alaska Airlines plane.
- 🏭 The 737 factory where the incident occurred has multiple layers of inspection with different responsibilities and limitations.
- 🔍 Quality inspectors at Boeing are responsible for checking the work of mechanics, but some inspections have been reduced, leading to self-inspection.
- 💭 Ed Pierson, a whistleblower, raised concerns about quality problems at the Boeing factory after the 737 max crashes.
- 🛫 Traveled work, or work outside the ordinary production sequence, was identified as a liability in maintaining airplane quality.
- 🤝 Boeing's CFO acknowledged the prioritization of plane production over quality, indicating a need for change.
- 🔄 The Organization Designation Authorization (ODA), Boeing employees who represent the FAA, are responsible for checking finished work against federal safety rules.
- 🚨 The FAA Inspectors Union criticized the ODA structure, suggesting it allows for potential conflicts of interest.
- ✈️ The FAA conducts audits and inspections on Boeing's quality system and issues airworthiness certificates after flight tests.
- 🛠️ In response to the Alaska Airlines incident, the FAA increased inspectors at the Renton site and promised a more hands-on approach.
- 📉 Boeing's proposed changes to its quality process are under scrutiny, and the company is facing pressure to ensure the production of safe aircraft.
Q & A
What incident prompted an audit at Boeing's 737 factory?
-A door plug blowing off midair on an Alaska Airlines plane led to an audit at Boeing's 737 factory, revealing failures to comply with quality control requirements.
How does the quality in the factory affect the quality of the plane in service?
-The quality in the factory directly correlates with the quality of the plane in service, as the manufacturing process and adherence to quality control requirements ensure the plane's safety and reliability.
How much time was Boeing given to address its quality control issues?
-Boeing was given 90 days to present a plan to regulators for fixing its quality control issues.
What was the criticism regarding Boeing's self-inspection practices?
-The criticism was that Boeing had eliminated some inspections and put mechanics in charge of checking their own work, which could lead to oversights and quality control problems.
What concerns did Ed Pierson, a former Boeing employee, raise about the 737 factory?
-Ed Pierson raised concerns about quality problems he observed during his time at the factory, emphasizing the need for a thorough investigation into the 737 factory's practices.
What is 'traveled work' in the context of airplane manufacturing?
-Traveled work refers to tasks that happen out of the production line's ordinary sequence, which can be a liability when it comes to maintaining airplane quality due to the pressure to complete these tasks quickly.
How has Boeing's management acknowledged the issues with quality control?
-Boeing's CFO, Brian West, acknowledged that the company had prioritized moving airplanes through the factory over ensuring quality, and stated that this approach needs to change.
What is the role of the Organization Designation Authorization (ODA) in Boeing's quality process?
-The ODA's role is to review the finished work by Boeing employees and the Boeing quality team, ensuring that the airplane conforms with federal safety rules. They are Boeing employees who represent the FAA and report to the FAA, even though they are paid by Boeing.
What criticisms have been raised about the ODA structure?
-The FAA Inspectors Union has criticized the ODA structure, stating that it effectively lets the fox guard the henhouse, as ODA employees may feel pressure from Boeing management, which could compromise their independence and objectivity.
What is the FAA's role in the inspection of Boeing planes?
-The FAA's role is primarily to review paperwork and conduct audits of Boeing's quality system during the plane's assembly. They also perform an airworthiness certificate inspection on each plane before delivery, which involves checking specific items against the plane's approved specifications.
How has the FAA responded to the quality control issues at Boeing?
-The FAA has increased the number of inspectors at the Renton site and pledged a more hands-on approach, with a shift towards a system that includes more surveillance and direct interaction with workers and the inspection process.
What steps has Boeing proposed to improve its quality process?
-Boeing has proposed comprehensive actions to strengthen quality and build confidence, including slowing down aircraft production at the factory and increasing audits and oversight.
Outlines
🛫 Quality Control Issues at Boeing's 737 Factory
This paragraph discusses the quality control failures at Boeing's 737 factory, highlighting an incident where a door plug blew off midair on an Alaska Airlines plane. It emphasizes the importance of multiple layers of inspection within the factory and the direct correlation between factory quality and the plane's performance in service. The narrative mentions that Boeing was given 90 days to present a plan to address these issues, delving into each layer of Boeing's quality process, including the role of Boeing's own quality inspectors, the pressure to push planes out the door, and the impact of self-inspection practices. The whistleblower, Ed Pierson, raises concerns about the 737 factory's need for thorough investigation, especially regarding 'traveled work' and the pressure-induced mistakes. Federal investigators identify traveled work as a liability, and Boeing CFO Brian West acknowledges the need for change, emphasizing the importance of quality over speed. Boeing CEO David Calhoun stresses the seriousness of their work, and the narrative notes the departure of key executives as part of a company shakeup.
🚨 FAA Inspections and Pressure on Boeing
This paragraph focuses on the role of the FAA in inspecting and approving Boeing's aircraft, the challenges faced by inspectors at the Renton site, and the increased pressure on the FAA to ensure Boeing improves its practices. It starts by questioning the adequacy of the FAA's inspector presence at the Boeing factory, which employs around 13,000 workers. Following the door plug incident, the FAA sent additional inspectors and committed to a more hands-on approach. FAA Administrator Mike Whitaker discusses the transition to an 'audit plus' system, aiming for more surveillance and interaction with factory workers. The paragraph outlines the sequence of events after the Alaska Airlines incident, including more discovered issues, a federal investigation, and a criminal probe, emphasizing the need for comprehensive solutions. Boeing's CFO outlines planned changes to strengthen quality and build confidence, including slowing down production. The FAA's increased oversight and inspection presence are highlighted, with a note on the temporary halt of Boeing's production increase plans until quality and safety are assured.
Mindmap
Keywords
💡Quality Control
💡Boeing 737 Factory
💡Regulatory Compliance
💡Whistleblower
💡Traveled Work
💡Organization Designation Authorization (ODA)
💡FAA Inspectors Union
💡Safety Culture
💡Airworthiness Certificate Inspection
💡Production Line
💡Regulatory Scrutiny
Highlights
Boeing's 737 factory in Renton faced a quality control issue when a door plug blew off midair on an Alaska Airlines plane.
An audit revealed that Boeing failed to comply with quality control requirements, crucial for maintaining the safety of their planes.
Quality in the factory directly correlates with the quality of the plane in service, as exemplified by the Alaska Airlines accident.
Boeing was given 90 days to present a plan to address the quality control issues to regulators.
Boeing's quality control inspectors are responsible for checking the work of mechanics, but the company has previously reduced these inspections.
Self-inspection by mechanics is now a small percentage of inspection methods, raising concerns about potential oversights.
Whistleblower Ed Pierson raised concerns about quality problems at the 737 factory after the 737 max crashes.
Traveled work, or out-of-sequence production, is identified as a liability due to the pressure to push planes out the door quickly.
Boeing CFO Brian West acknowledged the prioritization of plane movement over correct procedures, indicating a need for change.
Boeing CEO David Calhoun emphasized the seriousness with which work must be approached, following the door plug incident.
Calhoun announced his resignation as CEO, as part of a broader company restructuring.
The Organization Designation Authorization (ODA) is responsible for ensuring finished work complies with federal safety rules, but they are Boeing employees.
The FAA Inspectors Union criticized the ODA structure, likening it to the fox guarding the henhouse.
Boeing has taken steps to address safety culture issues, but an FAA Panel's Report suggests more work is needed.
The FAA conducts audits and paper reviews rather than direct aircraft inspections, with a focus on the quality system.
FAA inspectors perform an airworthiness certificate inspection on each plane before delivery, akin to a final walkthrough on a house.
The FAA increased the number of inspectors at the Renton site following the door plug incident and pledged a more hands-on approach.
Boeing's proposed changes to its quality process are yet to be seen, with a focus on slowing down production and increasing oversight.
The FAA has halted Boeing's plan to increase production until they are satisfied with the quality and safety of the aircraft.
Transcripts
- [Narrator] Months before a door plug blew off midair,
this Alaska Airlines plane rolled off the floor here
at Boeing's 737 factory.
It's where a subsequent audit found the plane maker failed
to comply with quality control requirements
meant to keep that plane safe.
At the factory, there are multiple layers of inspection
handled by groups with different responsibilities
and limitations.
- There's a direct correlation
between the quality in the factory
and the quality of the plane in service,
and the Alaska accident is a dramatic example of that.
- [Narrator] Boeing was given 90 days
to present regulators with a plan
to fix its quality control issues.
To understand what those issues are,
let's look at each layer of Boeing's quality process.
First, Boeing's own quality inspectors.
- When the plane is being assembled inside the factory,
there, generally speaking,
are different types of inspection.
- [Narrator] Boeing's team of quality control inspectors
are in place to perform checks and tests on mechanic's work.
Boeing has in the past eliminated some of these inspections
and put mechanics in charge of checking their own work.
But the company said self-inspection now accounts
for only a small percentage of inspection methods.
- And you may do a great job,
but you may have days where you don't do a great job,
and not having that quality control person there
looking over your shoulder can be a real problem.
- [Narrator] Ed Pierson worked in Boeing's Renton plant
for three years before becoming a whistleblower
after the deadly 737 max crashes.
He raised concerns about quality problems he saw
during his time at the factory.
- Bottom line is the 737 factory
needs to be thoroughly investigated.
- [Narrator] Including work that happens
out of the production line's ordinary sequence,
so-called traveled work.
- There's this incredible pressure
to push the planes out the door
and, you know, mistakes are made when that happens.
- [Narrator] Federal investigators
probing the Alaska incident, have identified traveled work
as a liability when it comes to airplane quality.
On this, Boeing CFO Brian West said recently-
- [Brian] For years, we prioritized the movement
of the airplane through the factory
over getting it done right, and that's gotta change.
- This stuff matters.
- [Narrator] And in an address to employees
after the door plug incident,
Boeing CEO David Calhoun said-
- I know I'm preaching to the choir here.
This isn't a lecture, not by any stretch.
It's nothing more than a reminder
of the seriousness with which we have to approach our work.
- [Narrator] Calhoun has since said he would step down
as CEO at the end of the year
as a part of a broader company shakeup.
The head of Boeing's commercial aircraft business
and the executive in charge of the 737 factory
have also stepped aside.
Another layer of inspection?
The Organization Designation Authorization, or ODA.
- Their job is to look at the finished work
by the Boeing employees and the Boeing quality team
and check to see whether or not the airplane conforms
with federal safety rules.
- [Narrator] The ODA's responsibilities
are approved by the FAA,
but members aren't employed by the FAA.
- These are Boeing employees
who represent the FAA.
They report to the FAA, even though they're paid by Boeing.
- [Narrator] The FAA Inspectors Union
has previously said this structure
effectively lets the fox guard the henhouse.
- There have been problems in the past
where these ODA employees
who work for the FAA felt pressure from management.
- [Narrator] Boeing has said it's made changes
to prevent such interference.
But a recent FAA Panel's Report
said there are still opportunities for retaliation to occur,
and there is a disconnect between Boeing senior management
and other members of the organization on safety culture.
Boeing said it has taken steps to foster its safety culture,
but there is still more work to do.
The final layer of inspection on Boeing planes?
The FAA itself.
While the plane is being assembled,
FAA inspectors check Boeing's quality system.
- By and large, it's an auditing operation.
They're reviewing paperwork,
they're not actually inspecting aircraft.
- [Narrator] But the FAA does inspect each plane
before it's delivered.
After a flight test, the plane is given to FAA inspectors
for final approval.
- They do what's called
an airworthiness certificate inspection,
which is, it's like, you know,
if you build a house, at the end of the house being built,
you do a walkthrough.
- A retired FAA inspector said in the final walkthrough
on an aircraft, inspectors typically pick 10 to 20 items
to double check against the plane's approved specifications.
If those items look good, the plane is cleared.
If not, the FAA may conduct further inspections.
- It is Boeing's job, not the FAA's job
to make quality aircraft.
As somebody who used to work at the agency told me,
"We are not Boeing's quality department."
- [Narrator] Before the Alaska Airlines blowout,
the FAA had eight inspectors assigned to the Renton site,
which employs roughly 13,000 Boeing workers.
- That's not enough to monitor the restaurant operations
at the site, much less the facility
where they're building planes.
- [Narrator] Following the door plug incident,
the FAA sent 20 more inspectors to the factory in Renton
and pledged a more hands-on approach.
- There's a lot of pressure from Congress and the public
to make sure that the FAA is going to push Boeing
to fix itself.
- [Narrator] When asked about its changes,
FAA Administrator Mike Whitaker said-
- We are migrating to a system that is,
I would call audit plus.
So we're gonna have more of a surveillance component
where inspectors are actually on the ground
talking to people and looking at the work that's being done.
- [Narrator] In the weeks following
the Alaska Airlines incident, more loose parts,
misdrilled holes, a federal investigation
and a criminal probe into the blowout
have put more pressure on the plane maker to get this right.
- There's a lot at stake, and this is why we're saying,
you know, "Don't be fooled.
Don't think just because we patched up the Alaska plane,
you know, incident that everything is good.
There's a lot of work that needs to get done."
And the good news is all these things are fixable.
- [Narrator] Boeing's proposed changes
to its quality process remain to be seen.
Boeing CFO said-
- [Brian] We're undertaking comprehensive actions
so that we can move forward to strengthen quality
and build confidence.
- [Narrator] That includes
deliberately slowing down aircraft production
at the factory
as Boeing faces increased scrutiny from regulators.
- We've increased our audit
and our oversight of Boeing pretty significantly
since January 5th.
If we see something that requires us to cease production
or pull something down, we'll do that.
- [Narrator] For now, planes are still rolling off the line,
but the FAA has put Boeing's plan
to increase production here on ice.
- The FAA has choked off Boeing's ability
to produce cash flow until it is satisfied
that Boeing can produce quality, safe aircraft.
(dramatic music)
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