A new issue on some Boeing 737 fuselages will slow production and require re-work on about 50 airplanes, Boeing said.
The problem stems from work done at Spirit AeroSystems in Wichita. Two rivet holes do not meet Boeing’s specifications and must be re-worked on affected airframes. Boeing is developing specific re-work instructions, including the length of time each repair will require.
“While this issue could delay some near-term 737 deliveries, this is the only course of action given our commitment to deliver perfect airplanes every time,” Boeing Commercial Airplanes President Stan Deal said in a Feb. 4 internal message. “The days we are setting aside in the 737 program will allow time for our teams to complete the inspections and, if needed, perform the necessary rework.”
Boeing learned of the new issue Feb. 1, Deal’s message said, citing an employee of the supplier—which Deal did not identify—who flagged the problem.
The issue will not freeze 737 deliveries but will likely lead to reduced monthly production and fewer near-term customer handovers due to the added work. Boeing’s current notional monthly production rate is 38 aircraft per month—a figure it has voluntary agreed to hold at while the FAA conducts stepped-up oversight of the program.
The FAA’s added surveillance is focused on Boeing’s Renton, Washington, 737 MAX production facilities, FAA Deputy Associate Administrator for Aviation Jodi Baker said during a Feb. 5 media briefing. Specific tasks include full aircraft inspections as well as examinations of Boeing’s quality system, employee training, and basic procedures. Any lessons learned will be applied to other Boeing sites, including possibly suppliers such as Spirit, Baker said.
“We’re still pretty early on with what we’ve seen, and we will address any concerns as they come up,” she continued.
An FAA team is reviewing all findings and will issue specific recommendations, Baker said, adding the agency “is estimating this to be a six-week process.”
Meanwhile, the FAA said that 135 of 144 737-9s grounded for door plug inspections have been cleared to return to revenue service. Eight of the remaining nine to be cleared are in Alaska Airlines’ fleet, while the other is a United Airlines aircraft.
The FAA ordered the checks following the Jan. 5 inflight loss of a door plug from an Alaska 737-9. The NTSB is investigating the occurrence and has not issued a preliminary report. Statements from Boeing and the FAA point to a production mistake or combination of mistakes at Spirit and Boeing as playing key roles.
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