Dishwashing liquid to install a door… an audit overwhelms the design process of Boeing’s 737 Max

Doors torn off, tires that failpieces of wings that are dislocating… For several weeks, the aircraft manufacturer Boeing experiences repeated problems with their devices. The group now has a little more lead in aid: the damning report delivered by the Federal Aviation Administration (FAA), finalized at the end of February, after six weeks of investigation and revealed Tuesday by the New York Times.

Boeing, according to this report, failed 33 of 89 audits. Its subcontractor Spirit Aero Systems responsible for the design of the fuselage and body of the 737 Max failed on seven of the 13 checks carried out. “A slap in the face” for the manufacturer, according to Gérard Feldzer, former airline pilot and president of aviation without borders. “Boeing is not virtuous. They will pay dearly for their mistakes,” analyzes the expert.

Mistakes that send shivers down your spine. According to the American newspaper, the American authority found that Spirit mechanics used a hotel card to check the seals of a door. But it gets worse: dishwashing liquid was used as lubricant to install this same door! “For years, the FAA has relied on Boeing’s technical resources. She is now discovering things that she had no idea of ​​before,” breathes Gérard Feldzer.

“A company run by financiers”

For Bertrand Vilmer, former test pilot and member of the Icare consulting firm, these dysfunctions arise from three difficulties: “There are three levels of problems: Boeing management, compliance with quality control processes and the role of the FAA. »

Complications that Gérard Feldzer also denounces: “Boeing was originally an engineering company. Today it is a company run by financiers who put pressure on engineers. In their haste, they make significant mistakes. » “This financial management is not up to date on flight safety, certification criteria…” adds Bertrand Vilmer.

Regarding the quality control process, Boeing engineers themselves judge that it is deficient. The FAA, which surveyed six engineers at the company, says the overall average rating given by employees on understanding quality controls amounts to only 58%. But the FAA is also responsible for certain failures, according to Bertrand Vilmer. “The culprit is Boeing but also the FAA. She delegated tests on the flight controls, on certain crucial functionalities that did not fulfill her role as policeman correctly,” slips the former pilot.

The two experts interviewed by Le Parisien, however, welcome the creation of such a report, reinstating a climate of confidence within aeronautical circles. “The markets and specialists are reassured by this audit. Boeing will respond with a serious plan,” underlines Bertrand Vilmer.

Ongoing investigations

The American company now has three months to redress the situation and offer solutions. “We used your feedback, along with that of our regulator and our customers, to take immediate actions to strengthen our safety and quality,” Stan Deal, head of Boeing’s commercial aviation arm, wrote in a statement on Tuesday. a message to employees. “These actions are at the center of the comprehensive plan that we will soon submit to the FAA,” he added. Spirit for its part promised to “examine all non-conformities identified with a view to corrective measures”. The solutions presented by the two entities will be examined and submitted for validation by the FAA.

In parallel with this audit, the manufacturer is still targeted by two investigations carried out after failures on Alaska Airlines. One is run by the National Transportation Safety Board, the other by the U.S. Department of Justice.