Federal authorities are investigating Boeing after a whistleblower, Sam Salehpour, a Boeing engineer, raised concerns about shortcuts taken in manufacturing its 777 and 787 Dreamliner jets, which could pose catastrophic risks as the planes age. Salehpour’s formal complaint to the FAA, filed in January and made public recently, is not specific to the newer 737 Max jet that has been grounded twice.
Salehpour claims that the quality issues he raised in his complaint may dramatically reduce the life of the planes and increase the likelihood of crashes. He told reporters that he raised these concerns not to see Boeing fail but to ensure that the company succeeds in preventing accidents. The FAA has interviewed Salehpour as part of its investigation into the matter and they encourage all aviation industry personnel to share information without fear of reprisal.
Boeing has denied Salehpour’s concerns about the 787 Dreamliner, stating that the claims about the structural integrity of the plane are inaccurate and do not represent the extensive work Boeing has done to ensure the quality and long-term safety of the aircraft. The company has disputed the allegations made by Salehpour and maintained that the 787 Dreamliners are safe to fly.
Salehpour’s complaint specifically focuses on the 787 Dreamliner planes, which could have a 50-year lifespan, according to Boeing. He alleges that crews assembling the plane failed to properly address tiny gaps when joining separately manufactured parts of the fuselage, leading to increased wear on the plane and the risk of catastrophic failure. Boeing had previously halted deliveries while investigating these gaps and made changes to its manufacturing process before resuming deliveries.
Salehpour also claims that he faced retaliation from Boeing after raising concerns about quality control issues on the 787 and a separate plane model. He pointed out drilling issues with the 787 and was subsequently transferred out of the program. In his new role, Salehpour discovered subpar work with aligning body pieces and pressure on engineers to approve work that had not been inspected. These issues reportedly extend to more than 400 777s and 1,000 787s. Following the news of Salehpour’s complaint, Boeing’s shares fell 2%.
