FAA Audit Finds Boeing Flaws

A Federal Aviation Administration audit found "systemic" problems with the design and production process at seven Boeing engineering and manufacturing facilities but said there were no immediate safety problems.

The FAA conducted the audit from December to February after what it called a "series of high-visibility production breakdowns" at Boeing last fall. The audit found 107 problems—87 in production and 20 in engineering.

"The findings show that these were not isolated events, that in fact they were systemic issues," John Hickey of the FAA said at a news conference Monday. "They illustrate that design and production systems are not functioning as intended at the Boeing Company."

However, Hickey said the FAA found no immediate safety shortcomings related to the problems. The agency has not decided whether to fine Boeing but is satisfied by the company's response and cooperation, he said.

The FAA studied everything from aircraft engineering to parts receiving and the manufacturing process at Boeing plants in Seattle, Everett, Renton, Auburn, Fredrickson and Spokane, Wash., and in Portland, Ore.

Boeing agreed with the audit findings, said Liz Otis, vice president for quality in the company's commercial airplanes group.

"We stand by the integrity of our quality system, and the excellent safety record of our products clearly validates that," said a statement from Boeing. " The improvements that are being implemented will further enhance the quality of our airplanes. "

Among the incidents last fall that prompted the FAA review:

• An airline told Boeing that two of 16 bolts holding the vertical stabilizer onto the tail of a 767 were not sufficiently tightened.
• Assembly line mechanics at Boeing's Everett plant, where 747s, 767s and 777s are built, reported that fuel tank repairs were being made after the tanks had been inspected and that debris such as sealant tubes and rivet guns were occasionally left behind.
• An adhesive was improperly applied to a condensation barrier that keeps moisture from dripping onto cockpit electronics. The drip shields also did not meet flammability standards, prompting Boeing to briefly halt delivery of 50 airplanes while the part was replaced.

For example, Hickey said engineers who made design changes did not always document their actions, which makes replicating the steps by other engineers more difficult.

FAA officials sid Boeing has worked with them to address the findings and to tighten internal and external controls to ensure products perform to expectations.

Boeing will add 70 inspectors at suppliers' facilities by the end of the year and 300 on Boeing's own production lines and will perform self-audits in its own facilities, the FAA said. Boeing also has set up a board to review design changes on every plane.

In addition, the FAA will add inspectors at Boeing plants and will continue working with the company for the next two years to determine why the problems occurred and make any additional changes needed.

David Stempler, president of the Air Travelers Association, a Washington airline passenger group, said he is satisfied by the audit and the company's response. "I don't think we feel there are any problems," he said.

The government, mostly through the FAA, must approve an airplane's design, manufacture, inspections, testing and certification, along with its materials and parts and the way they are used.

Monday's announcement was the second major safety-related initiative by the FAA and Boeing in as many months.

In September, Boeing announced new emergency procedures and maintenance guidelines for 737s, the world's most popular airliner, and said it was redesigning the rudder in the 737 to prevent problems that may have caused two deadly crashes.

An FAA panel recommended the changes earlier.