Airline safety expert questions Boeing door plug installation and inspection process

Summary

The NTSB is investigating a serious incident involving a 737 aircraft, where a door plug blew out mid-flight at 16,000 feet. This has raised concerns over Boeing's manufacturing and inspection processes. Experts like former NTSB board member John Goolia suggest that the installation of the door plug, a part commonly used on domestic aircraft, may have been faulty or missed during inspection. Airlines, including United and Alaska, have discovered similar issues with loose hardware in their fleets, indicating potential flaws in the manufacturing process. Boeing has not yet commented on these concerns as the investigation continues.

Takeaways

• 😀 Investigators from the NTSB are focusing on a hole in the 737 where the door plug blew out at 16,000 ft, landing in a Portland teacher's yard.
• 😀 The incident raises questions about Boeing’s aircraft manufacturing and inspection processes, particularly regarding missed installation steps.
• 😀 John Goolia, a former NTSB board member, highlights that there should be inspection requirements for components that could lead to a potential crash.
• 😀 Door plugs, which seal optional doors on planes for airlines with fewer passengers, have been in use for decades in domestic aircraft.
• 😀 These plugs are lighter than emergency doors and do not require maintenance or escape slides, as they are not meant for emergency use.
• 😀 The failure could be tied to the manufacturing process, as loose hardware has been found during inspections of grounded 737 Max9 aircraft by Alaska Airlines and United Airlines.
• 😀 United Airlines mechanics have found at least five aircraft with loose attachments of door plugs, suggesting the issue may stem from how the planes were assembled.
• 😀 Boeing’s spokesman declined to comment on whether the door plugs were inspected or removed during the assembly process, citing NTSB policy on ongoing investigations.
• 😀 Goolia stresses that any failure involving a single point of failure in a critical part of an aircraft needs to be thoroughly inspected during manufacturing.
• 😀 The NTSB is continuing its investigation into the cause of the blowout, with questions surrounding both manufacturing and inspection procedures that may have been overlooked.

Q & A

What is the focus of the NTSB investigators regarding the 737 incident?

The NTSB investigators are primarily focused on the hole in the 737 where the door plug blew out at 16,000 feet, as well as the manufacturing and inspection process of the aircraft.

What concerns did FAA-certified airplane mechanic John Goolia raise about the manufacturing process?

John Goolia raised concerns about the potential flaws in the manufacturing process, noting that the failure of a critical component like the door plug should have been checked during inspection, especially since such a failure could lead to a potential crash.

What role do door plugs play in domestic aircraft?

Door plugs are used to seal optional extra doors on aircraft, typically when airlines choose to carry fewer passengers. They are secured by bolts and stop fittings and are lighter than emergency doors, with no requirement for maintenance or an escape slide.

How does the failure of a door plug impact the safety of the aircraft?

If a door plug fails, it could lead to serious structural issues, as the door is supposed to remain securely attached to the aircraft. A failure in the attachment points could compromise the safety of the flight.

What is the significance of the diagram from the NTSB shown in the script?

The diagram from the NTSB illustrates the attachment points around the door that are supposed to secure the door plug to the airframe. The failure of these attachments is a key area of investigation in the case.

What have Alaska Airlines and United Airlines discovered during their inspections of 737 Max 9 fleets?

Alaska Airlines has found loose hardware during inspections of its grounded 737 Max 9 fleet, and United Airlines mechanics have identified at least five aircraft with loose attachments, suggesting a potential manufacturing issue.

What does United Airlines believe is the cause of the loose attachments?

United Airlines believes that the loose attachments are the result of a manufacturing issue, which could stem from improper installation or missed steps in the production process.

What did Boeing refuse to comment on regarding the door plug issue?

Boeing refused to comment on specific questions about who inspected the door plug, whether it was inspected at all, or whether the door plugs are ever removed during assembly, citing NTSB policy that prevents discussion of the case while it is under investigation.

How does the age of the 737 in question relate to the investigation?

The age of the 737 is significant because the aircraft had only been in operation since October, suggesting that any issues with the door plug were likely due to recent manufacturing or assembly processes.

What is the primary concern raised by John Goolia in regard to the quality control in aircraft manufacturing?

John Goolia's primary concern is the quality control in the aircraft manufacturing process. He emphasizes that any single point of failure, like the door plug, should be thoroughly checked to prevent safety hazards.