The Wall Street Journal, in a recent investigatory report, has revealed long-standing concerns within Boeing regarding its manufacturing practices which have led to a series of quality-related issues, culminating in an incident involving an Alaska Airlines plane on January 5th of this year.
This incident has highlighted the challenges associated with Boeing’s overarching strategy of outsourcing the manufacturing of its aircraft and has revived questions about oversight of its manufacturing processes.
Outsourcing Raises Concerns
According to the newspaper, the roots of Boeing’s manufacturing challenges go back to a controversial white paper presented by aeronautical engineer John Hart-Smith in 2001. It warned of the risks associated with excessive outsourcing, emphasizing the importance of onsite quality and technical support from the primary manufacturer.
Despite the logical approach this paper took, it did not receive full attention regarding the raised concerns, says The Wall Street Journal.
The newspaper continues, mentioning that after more than two decades, Boeing is facing the consequences of its outsourcing strategy, as shown by a series of quality issues, including fatal incidents involving the 737 MAX 8 in 2018 and 2019. The latest incident with Alaska Airlines, which entailed a mid-flight explosion in the cabin of a MAX 9, has intensified scrutiny on Boeing’s manufacturing operations.
The Battlefield
The paper points to “Spirit AeroSystems” as a significant factor in Boeing’s manufacturing chain, the sole supplier of the fuselage for many Boeing models. The relationship has been marred by battles over costs and quality issues. The MAX shutdown and the COVID-19 pandemic strained Spirit’s financial resources, leading to mass layoffs and a shortage of expertise once demand rebounded.
Complaints from Spirit employees reveal production problems and internal quality issues, raising questions about the safety of Boeing’s aircraft worldwide.
The International Association of Machinists and Aerospace Workers’ branch president, Cornell Beard, claims that the pressure on Spirit’s employees to meet tight deadlines has led to undetected defects in planes that are now deployed globally.
Both Boeing and Spirit assert their commitment to safety and cooperation with investigators. However, the Federal Aviation Administration has announced increased oversight over Boeing’s manufacturing, along with a review of the MAX 9 production.
FAA Administrator Mike Whitaker has stated that manufacturing issues, not design flaws, were the root cause of the Alaska incident.
It is noted that the FAA had grounded 171 MAX 9 aircraft last week following the explosion incident.
Admission
In a pivotal moment, Boeing CEO David Calhoun took responsibility for the recent safety error during a comprehensive meeting at the Renton factory in Washington.
While Calhoun did not specify the problem’s origin, he underscored Boeing’s ultimate responsibility for ensuring the safety of aircraft leaving its factories. This acknowledgment marks a departure from previous attempts to deflect blame for the MAX 8 crash incidents, signaling a new era of accountability, according to The Wall Street Journal.
The executive president of Boeing admitted his responsibility for the recent safety error related to the company’s aircraft incident (Al Jazeera)
Nonetheless, concerns remain about Boeing’s ability to correct its manufacturing problems. In discussion with The Wall Street Journal, Stan Deal, president of Boeing’s commercial airline business, emphasized the need to “own” the entire airplane building process, noting the company has not fully solved the manufacturing challenges under Calhoun’s leadership since 2020, leaving it grappling with a tarnished reputation.
Challenges with Outsourced Manufacturing
Boeing’s outsourcing strategy reflects a broader trend in modern manufacturing. Components are produced by various companies before final assembly, aiming to reduce costs and enhance flexibility. However, this approach exposes companies to increased risks as the final product’s reliability depends heavily on the least efficient supplier.
The complexities of overseeing a fragmented supply and manufacturing chain have increased Boeing’s manufacturing operations’ intricacy, according to engineers interviewed by the paper.
Airbus, Boeing’s main rival, follows a similar approach, sourcing components globally. However, Airbus CEO Guillaume Faury emphasizes the importance of “control” over suppliers to ensure quality, acknowledging the inherent risks in these manufacturing methods.
Lessons from History
The newspaper concludes that Boeing’s current problems reflect past mistakes, particularly the intensive outsourcing strategy used in developing the “787 Dreamliner” in the early 21st century. Although this approach aimed to reduce costs and risks, it resulted in production delays and unplanned expenses. The “MAX” model, despite being not a new design, continues to face ongoing challenges, with more than 11,000 737 aircraft delivered since its debut in 1968.
The MAX model, introduced in 2017, has faced grounding after fatal accidents, highlighting the complexities of managing a distributed manufacturing system, especially during disruptions such as the COVID-19 pandemic, according to The Wall Street Journal.
