NTSB hearing investigates Boeing 737 Max critical door failure, sheds light on manufacturing issues

Officials examined a serious malfunction involving a door mechanism on a nearly new Boeing 737 Max 9 at a major federal safety hearing Tuesday. The investigation, led by National Transportation Safety Board (NTSB) chair Jennifer Homendy, was held at NTSB headquarters in Washington, D.C. The focus was on a distressing incident on Alaska Airlines Flight 1282 on Jan. 5, 2024, that prompted urgent discussions about aviation safety and manufacturing practices.

The hearing revealed that Boeing is actively developing design changes to improve the reliability of the 737 Max 9 following the door failure. Elizabeth Lund, Boeing’s commercial airplane safety manager, said the changes are designed to prevent the door from closing unless it is securely latched, with implementation expected this year.

More than 3,000 pages of documents were released by the NTSB prior to this detailed two-day investigation. These documents include interviews with Boeing staff and insights into the problems of Spirit AeroSystems, which has been associated with several manufacturing issues. Preliminary findings suggest that the bolts intended to secure the door were improperly tightened, although fortunately the incident did not cause serious injuries.

“This is strictly an investigation; it is not a platform for Boeing to improve its public image,” Chairman Homendy stressed during the proceedings.

The fallout from the door failure has been severe for Boeing, prompting a reshuffle of its leadership, including the appointment of Robert “Kelly” Ortberg, a veteran aerospace executive from Rockwell Collins, as its new CEO. The shakeup is intended to steer the company through its current challenges, including delayed aircraft deliveries and strained relationships with airlines and regulators.

Further complicating Boeing’s situation is the ongoing problem of “traveled work,” in which defects in airplane parts require out-of-sequence repairs before the aircraft is delivered. In response, Boeing has moved to acquire Spirit AeroSystems, a strategy aimed at tightening control over production quality.

During the hearing, a Boeing employee testified about the frequency of door replacements, comparing it to “changing underwear,” highlighting the routine nature of such critical maintenance on airplanes.

The NTSB intends to continue its rigorous examination of these safety and manufacturing defects to ensure that similar near-catastrophic failures are avoided in the future.