In a recent investigation, The Wall Street Journal revealed long-standing concerns within Boeing regarding its manufacturing practices, which led to a series of quality issues that culminated in the Alaska Airlines plane accident on January 5. The current second.
The incident highlighted the challenges associated with Boeing’s overall strategy of outsourcing its aircraft manufacturing, and raised new concerns regarding oversight of its manufacturing operations.
External sources raise concerns
According to the newspaper, the roots of Boeing’s manufacturing challenges go back to a controversial white paper presented by aerospace engineer John Hart Smith in 2001 warning of the dangers associated with excessive outsourcing, and emphasizing the importance of on-site quality and technical support from the main manufacturer.
Despite the logical approach taken by this paper, it did not receive full attention to the concerns raised, according to the Wall Street Journal.
The newspaper continues that after more than two decades, Boeing is facing the repercussions of its outsourcing strategy, as evidenced by a series of quality issues, including fatal accidents involving the 737 Max 8 aircraft in 2018 and 2019, explaining that the Alaska Airlines incident Airlines’ recent case involving an explosion in the cabin of a Max 9 plane mid-flightHintensified scrutiny of Boeing’s manufacturing operations.
battlefield
The newspaper indicates that one of the important aspects of Boeing’s manufacturing chain is Spirit Aerosystems, the sole supplier of the fuselage for many Boeing models, as the relationship between them was marred by battles over costs and quality issues, and the shutdown of the “MAX” model and the Corona virus epidemic led to a strain on financial resources. For Spirit, which led to a large number of layoffs and a shortage of expertise when demand picked up again.
Complaints from Spirit employees reveal production problems and internal quality concerns, raising questions about the safety of Boeing aircraft around the world.
According to the newspaper, Cornell Byrd, chapter president of the International Association of Machinists and Aerospace Workers, claims that pressure on Spirit employees to meet tight deadlines has led to undetected defects in the planes now spread around the world.
Both Boeing and Spirit confirm their commitment to safety and cooperation with investigators. However, the Federal Aviation Administration announced that it would step up oversight of Boeing’s aircraft manufacturing, announcing a review of Max 9 production.
FAA Administrator Mike Whitaker said manufacturing problems, not design flaws, were the root cause of the Alaska accident.
It is noteworthy that the Federal Aviation Administration had grounded 171 Max 9 aircraft from flying last week after the explosion.
recognition
In a watershed moment, Boeing CEO David Calhoun admitted he and his company were responsible for the latest safety blunder during an all-hands meeting at the Renton plant in Washington.
While Calhoun did not specify the origin of the problem, he stressed Boeing’s ultimate responsibility to ensure the safety of planes leaving its factories. This admission represents a departure from previous attempts to shift blame for the Max 8 crashes, signaling a new era of accountability, according to what the Wall Street Journal said.
However, concerns remain about Boeing’s ability to correct its manufacturing problems. Stan Deal, head of Boeing’s commercial airline business, in an interview with the Wall Street Journal, stressed the need to “own” the entire aircraft construction process, noting that the company has not succeeded during Calhoun’s tenure since 2020 in completely solving manufacturing challenges, Which left her grappling with her tarnished reputation.
Challenges of outsourcing a factory
Boeing’s outsourcing strategy reflects a broader trend in modern manufacturing, where components are produced by different companies before final assembly. While this approach aims to reduce costs and enhance flexibility, it exposes companies to increased risks, as the end product is only as reliable as the often less efficient supplier.
The complexities of overseeing a disparate supply chain and manufacturing have increased the complexity of Boeing’s manufacturing operations, according to engineers the newspaper spoke to.
Airbus, Boeing’s main competitor, takes a similar approach, outsourcing components globally. However, Airbus CEO Guillaume Faury stressed the importance of “oversight” of suppliers to ensure quality, acknowledging the risks inherent in these manufacturing methods.
Lessons from history
The newspaper concludes that the problems facing Boeing are not new to the present, but they reflect the mistakes of the past, especially the extensive outsourcing strategy used in developing the “787 Dreamliner” aircraft in the first decade of the 21st century.
Although this approach was aimed at reducing costs and risks, it led to delays in production and unplanned costs. The newspaper pointed out that the “Max” model, although it did not come with a new design, faces continuing challenges, with more than 11,000 737 aircraft delivered. Since its inauguration in 1968.
The Max model, which was introduced in 2017, has suffered downtime after fatal accidents, further highlighting the complexities of managing a distributed manufacturing system, especially during disruptions such as the Covid-19 pandemic, says the Wall Street Journal.
