Boeing Whistleblower on 737 Factory’s Quality Control Process | WSJ

Summary

The 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.