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    Boeing Says It’s Changing Type of Panel That Blew Off Alaska Airlines Jet

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    The company told regulators the changes in design and production of the door plugs would allow its warning systems to detect malfunctions.Boeing officials told regulators on Tuesday that the aircraft maker would make changes to how it designed and produced the type of panel that blew off an Alaska Airlines jet shortly after takeoff in January.Boeing told regulators that it was redesigning its door plugs — the panels that replace emergency-exit doors in certain design configurations that create more seats — so that its warning systems could detect any malfunctions.The design changes are expected to be “implemented within the year,” said Elizabeth Lund, a senior vice president for quality at Boeing, who testified on Tuesday at an investigative hearing held by the National Transportation Safety Board, an independent government investigative agency.The hearing on Tuesday revealed that Boeing employees removed a door plug from what would later be the Alaska Airlines jet to repair damaged rivets, but without any required internal authorization or paperwork detailing the removal of the panel — a critical structural element. The safety board’s investigation found earlier this year that the plane, a 737 Max 9, left the Boeing factory in Renton, Wash., missing bolts that should have held in place the door plug that blew off midair.The safety board’s chairwoman, Jennifer Homendy, suggested at the hearing that the work culture at Boeing prioritized meeting production schedules over safety standards, and led to an overtaxed work force and lapses in the production process.On Tuesday, Ms. Homendy read quotes from the board’s interviews with mechanics who have worked at the Boeing facility for years. The workers testified to board investigators that they were regularly pressured into working 10 to 12 hours a day, six to seven days a week, Ms. Homendy said.We are having trouble retrieving the article content.Please enable JavaScript in your browser settings.Thank you for your patience while we verify access. If you are in Reader mode please exit and log into your Times account, or subscribe for all of The Times.Thank you for your patience while we verify access.Already a subscriber? Log in.Want all of The Times? Subscribe. More

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      FAA Audit of Boeing’s 737 Max Production Found Dozens of Issues

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      The company failed 33 of 89 audits during an examination conducted by the Federal Aviation Administration after a panel blew off an Alaska Airlines jet in January.A six-week audit by the Federal Aviation Administration of Boeing’s production of the 737 Max jet found dozens of problems throughout the manufacturing process at the plane maker and one of its key suppliers, according to a slide presentation reviewed by The New York Times.The air-safety regulator initiated the examination after a door panel blew off a 737 Max 9 during an Alaska Airlines flight in early January. Last week, the agency announced that the audit had found “multiple instances” in which Boeing and the supplier, Spirit AeroSystems, failed to comply with quality-control requirements, though it did not provide specifics about the findings.The presentation reviewed by The Times, though highly technical, offers a more detailed picture of what the audit turned up. Since the Alaska Airlines episode, Boeing has come under intense scrutiny over its quality-control practices, and the findings add to the body of evidence about manufacturing lapses at the company.For the portion of the examination focused on Boeing, the F.A.A. conducted 89 product audits, a type of review that looks at aspects of the production process. The plane maker passed 56 of the audits and failed 33 of them, with a total of 97 instances of alleged noncompliance, according to the presentation.The F.A.A. also conducted 13 product audits for the part of the inquiry that focused on Spirit AeroSystems, which makes the fuselage, or body, of the 737 Max. Six of those audits resulted in passing grades, and seven resulted in failing ones, the presentation said.At one point during the examination, the air-safety agency observed mechanics at Spirit using a hotel key card to check a door seal, according to a document that describes some of the findings. That action was “not identified/documented/called-out in the production order,” the document said.We are having trouble retrieving the article content.Please enable JavaScript in your browser settings.Thank you for your patience while we verify access. If you are in Reader mode please exit and log into your Times account, or subscribe for all of The Times.Thank you for your patience while we verify access.Already a subscriber? Log in.Want all of The Times? Subscribe. More

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      Boeing Reinstalled Panel That Later Blew Out of 737 Max Jet

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      Employees at its Washington State factory are said to have removed the door plug for further work before the plane was delivered to Alaska Airlines.Nearly three weeks after a hole blew open on a Boeing 737 Max 9 during an Alaska Airlines flight, terrifying passengers, new details about the jet’s production are intensifying scrutiny of Boeing’s quality-control practices.About a month before the Max 9 was delivered to Alaska Airlines in October, workers at Boeing’s factory in Renton, Wash., opened and later reinstalled the panel that would blow off the plane’s body, according to a person familiar with the matter.The employees opened the panel, known as a door plug, because work needed to be done to its rivets — which are often used to join and secure parts on planes — said the person, who asked for anonymity because the person isn’t authorized to speak publicly while the National Transportation Safety Board conducts an investigation.The request to open the plug came from employees of Spirit AeroSystems, a supplier that makes the body for the 737 Max in Wichita, Kan. After Boeing employees complied, Spirit employees who are based at Boeing’s Renton factory repaired the rivets. Boeing employees then reinstalled the door.An internal system that tracks maintenance work at the facility, which assembles 737s, shows the request for maintenance but does not contain information about whether the door plug was inspected after it was replaced, the person said.The details could begin to answer a crucial question about why the door plug detached from Flight 1282 at 16,000 feet, forcing the pilots to make an emergency landing at Portland International Airport in Oregon minutes after taking off on Jan. 5. The door plug is placed where an emergency exit door would be if a jet had more seats. To stay in place, the plug relies primarily on a pair of bolts at the top and another pair at the bottom, as well as metal pins and pads on the sides.We are having trouble retrieving the article content.Please enable JavaScript in your browser settings.Thank you for your patience while we verify access. If you are in Reader mode please exit and log into your Times account, or subscribe for all of The Times.Thank you for your patience while we verify access.Already a subscriber?  More