Boeing defended its 787 Dreamliner aircraft program amid safety concerns raised by a whistleblower ahead of a U.S. Senate hearing. The whistleblower, Boeing quality engineer Sam Salehpour, claimed that the company failed to properly shim certain areas of the aircraft, potentially causing premature fatigue failure. Salehpour is set to testify at the hearing on Boeing’s safety culture, with his allegations currently under investigation by the FAA. Boeing officials stated that they have not found any fatigue cracks in the nearly 700 in-service Dreamliner jets that have undergone heavy maintenance inspections after six and twelve years.
Boeing’s reputation has been tarnished by safety issues, including a mid-air panel blowout on a 737 MAX plane earlier this year. The company halted deliveries of the 787 aircraft for over a year while the FAA investigated quality problems and manufacturing flaws. In 2021, Boeing acknowledged that some 787 airplanes had shims that were incorrect in size and areas that did not meet skin-flatness specifications. However, they stated that reports of workers jumping on plane parts to align them were not part of their standard process.
Steve Chisholm, Boeing’s chief engineer for mechanical and structural engineering, assured reporters that all inspection findings had been shared with the FAA. The 787 Dreamliner, launched in 2004, has a tight specification of a five-thousandths of an inch gap allowance within a five-inch area, likened to the thickness of a human hair. Lisa Fahl, vice president of Boeing Commercial Airplanes airplane programs engineering, reiterated that the allegations of workers jumping on airplane parts were not reflective of Boeing’s official procedures.
The FAA is currently investigating Salehpour’s claims, which have raised concerns about Boeing’s safety culture and manufacturing practices. The company has faced scrutiny over its handling of safety issues, particularly following the 737 MAX crisis. Boeing has been working to address quality problems and manufacturing flaws within the 787 program, including issues with shims and skin-flatness specifications. The company’s efforts to address these concerns and uphold safety standards will be closely monitored as the investigation continues.
Boeing’s senior officials highlighted the company’s commitment to safety and the rigorous inspection process conducted on in-service Dreamliner jets. The lack of fatigue findings in these inspections provides some reassurance regarding the aircraft’s structural integrity. Boeing’s collaboration with the FAA and transparency in sharing inspection results demonstrate its dedication to addressing safety concerns within the 787 program. However, ongoing investigations and the upcoming Senate hearing will likely continue to test Boeing’s efforts to restore confidence in its aircraft manufacturing processes and safety culture. The company’s ability to address and resolve these issues will be crucial in rebuilding trust with regulators, customers, and the public.
