The Big List of Boeing Problems

By Brian Wang

Here's a summary of the major problems associated with various Boeing aircraft models and projects, based on the information available up to August 2024. Boeing has serious problems with is commercial planes, space programs and military planes and programs. They also plausibly killed one or two whistleblowers.

Boeing 737 MAX

Crashes: Two fatal crashes (Lion Air Flight 610 in 2018 and Ethiopian Airlines Flight 302 in 2019) led to the grounding of the entire fleet due to issues with the MCAS (Maneuvering Characteristics Augmentation System) software.

The Boeing 737 MAX passenger airliner was grounded worldwide between March 2019 and December 2020 – longer in many jurisdictions.

Quality Control Issues: Post-crash, numerous quality control issues surfaced, including problems with door plugs, loose bolts, and installation issues, leading to further scrutiny and grounding of some models.

Jan 2024, Alaska Airlines Boeing 737 MAX 9 lost a door plug in flight.

Incident Overview: A door plug, essentially a cover for an emergency exit that isn't used in certain aircraft configurations, detached mid-flight from a Boeing 737 MAX 9, creating a large hole in the fuselage. This incident led to immediate grounding of similar aircraft models by the FAA for inspections. A review of more planes found more poorly assembled door plugs with missing bolts.

FAA Audits: Failed over 37% of FAA audits, highlighting significant non-compliance in quality control for the 737 MAX program.

Boeing 787 Dreamliner

Manufacturing Flaws: Issues with the fuselage, including improperly torqued fasteners, leading to halted deliveries.

Battery Fires: Early in its service, there were incidents of battery fires leading to groundings.

Quality and Production Delays: Significant production issues in South Carolina, with numerous flaws found in quality assurance checks.

Boeing 777 and 777X

As of May 2024, the 777 had been involved in 31 aviation accidents and incidents, including a total of eight hull losses (five in-flight accidents), resulting in 542 (including one fatality due to ground casualties) fatalities along with three hijackings.

2014, Kuala Lumpur to Beijing Malaysia flight 370 crashed in the Indian Ocean. US officials believe the most likely explanation to be that someone in the cockpit of Flight 370 re-programmed the aircraft's autopilot to travel south across the Indian Ocean.

2014, Malaysia Airlines Flight 17 (MH17), was shot down by an anti-aircraft missile while flying over eastern Ukraine.

As of 2024, the Boeing 777, particularly the 777X variant, has encountered several significant issues:

Engine-Related Structural Component Failure: The 777-9, part of the 777X family, experienced a setback when a structural component between the engine and the airplane structure failed, leading to a halt in flight tests. This component, unique to the 777-9, was described as a "severed thrust link," which is critical for engine operation. This incident has raised concerns about the aircraft's readiness for certification and delivery, which were already delayed.

Delays in Certification and Delivery: The 777X program, which includes the 777-9 model, has been plagued by numerous delays. Initially expected to enter service in 2020, it's now aiming for 2025, highlighting significant challenges in design, manufacturing, and certification processes. These delays are not only costly but also affect Boeing's reputation and customer trust.

Boeing has confirmed a temporary halt in flight testing of its entire 777-9 fleet following the discovery of a failed engine-related structural component.

Quality Control and Safety Concerns: Following previous issues with other models like the 737 MAX, the 777X's problems add to the narrative of Boeing's broader quality control and safety oversight challenges. The company has faced scrutiny for its production processes, leading to a comprehensive review by the FAA and internal restructuring.

Impact on Boeing's Operations and Market Position: These issues, combined with other Boeing aircraft problems, have led to a significant financial impact, including a drop in stock value and a loss of market confidence. The delays and quality issues have also given competitors like Airbus an advantage in the market, particularly with models like the A350.

Customer and Regulatory Backlash: The recurring issues have not only delayed deliveries but also led to increased scrutiny from regulators and dissatisfaction among airlines, which have been forced to manage fleet planning uncertainties. This situation underscores a broader crisis in trust towards Boeing's ability to deliver safe, reliable aircraft on schedule.

These problems with the Boeing 777, especially the 777X, reflect deeper systemic issues within Boeing concerning quality control, engineering oversight, and regulatory compliance, which have been exacerbated by the intense competition in the aerospace industry and the high expectations set by previous model

Boeing Starliner (CST-100):

Technical Failures: Multiple issues including propellant system valves, flammable tape, parachute issues, helium leaks, and design vulnerabilities in the propulsion system, delaying crewed flights. It had problems on the first manned mission to the Space Station. It will return empty and will not return the astronauts. It was deemed not safe enough for the manned return flight.

It is many years late and billions over budget.

Space Launch System (SLS)

Delays and Cost Overruns: While not directly a commercial or military aircraft, the SLS project has faced significant delays and cost overruns, though specific in-flight anomalies like those with Artemis I have been noted, indicating ongoing technical challenges.

It is many years late and tens of billions over budget.

Major problems with Boeing's military plane programs

Cost Overruns and Fixed-Price Contract Challenges: Programs like the KC-46A Pegasus, designed for aerial refueling, have seen significant cost overruns, totaling billions in losses for Boeing due to fixed-price contracts. These contracts require Boeing to absorb any additional costs beyond the agreed price, leading to financial strain.

Delays in Delivery and Production: Multiple programs, including the T-7A Red Hawk jet trainer, have faced substantial delays. For instance, the T-7's critical design review was pushed back by nearly two years due to funding and design issues, affecting planned production schedules.

Quality and Safety Concerns: The V-22 Osprey has experienced fatal crashes, highlighting ongoing safety and design issues. Similarly, the KC-46A had to redesign its remote vision system due to visibility problems that could affect stealth aircraft refueling.

Since its introduction, the V-22 Osprey has been involved in accidents that have resulted in at least 62 fatalities. This figure includes incidents from the 1990s through to recent years.

General Issues Across Models

FAA Oversight and Boeing's Self-Certification: The relationship between Boeing's self-certification processes and FAA oversight has come under intense scrutiny, with critics pointing to a cozy relationship that might have overlooked safety for speed in production.

Deaths of Whistle Blowers

John Barnett: A former Boeing quality inspector who raised concerns about safety flaws, was found dead from what was initially reported as a self-inflicted gunshot wound in March 2024. Despite the police investigation concluding it as a suicide, there was public skepticism and calls for further investigation due to the timing and context of his legal actions against Boeing.

Joshua Dean: Worked for Spirit AeroSystems, a Boeing supplier, and highlighted manufacturing defects on the Boeing 737 MAX. He died in May 2024 from complications due to a fast-spreading infection. His death, following closely after Barnett's, fueled conspiracy theories despite medical explanations.

Public and Legal Scrutiny:

Whistleblower Testimonies: Multiple whistleblowers, including Sam Salehpour and others, have come forward with concerns over quality control and safety issues, leading to Senate hearings and increased regulatory oversight. These testimonies have painted a picture of systemic issues within Boeing's production processes.