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December  5, 2024


Federal Aviation Administration Oversight of Boeing


Commercial  air travel is one of the safest forms of
transportation, and fatal crashes are extremely rare.
Between  2013 and 2022, U.S. air carriers flew more than
175 million cumulative flight hours and experienced six
fatal crashes resulting in 15 total fatalities. The
International Air Transport Association found that global
airline safety performance improved by 61% over the past
decade. Although design flaws and manufacturing defects
have seldom played a significant role in commercial
aviation crashes, two fatal mishaps and additional serious
incidents involving Boeing airplanes have brought its
design and manufacturing processes under global scrutiny.
As the sole producer of large transport airplanes in the
United States, Boeing is a major focus of Federal Aviation
Administration (FAA) oversight. In the wake of these
events, FAA has increased oversight and inspections of
Boeing aircraft development and manufacturing, and
Congress has scrutinized both Boeing and FAA. Some
ongoing challenges to effective FAA oversight of Boeing
include production pressures spurred by continued global
demand;  the complexity of a distributed and diverse supply
network; challenges at FAA to recruit, retain, and train its
inspector workforce; and heavy reliance on delegated
aircraft design and production certification functions.

  Boeing  Commercal Arpanes
Boeing Commercial  Airplanes (BCA) is a business unit of
the Boeing Company,  a global aerospace conglomerate.
BCA  employs  about 48,000 workers, primarily at facilities
in Washington State and South Carolina. Boeing produces a
number  of commercial airliners, including the narrow-body
737 and three wide-bodies: the 767, 777, and 787
Dreamliner. In 2023, it ended production of the iconic 747
jumbo jet. More than 10,000 Boeing jetliners are in service
around the world, and more than 5,400 of its airplanes are
currently on order. In 2023, Boeing delivered 528 airplanes,
a 10% increase over 2022. However, production caps
imposed by FAA  in early 2024 amid concerns over quality
assurance along with a 2-month machinist strike have
slowed deliveries by about 20%, compared with 2023.

Long-standing Safety Concerns
For over a decade, FAA has been raising concerns about
Boeing aircraft. In 2015, Boeing entered into a settlement
agreement with FAA  following multiple failures to take
corrective actions regarding observed deficiencies in quality
assurance. As part of the agreement, Boeing committed to
implementing a Safety Management  System (SMS),
adopting a regulatory compliance plan, and stepping up
audits and verification processes to oversee suppliers and
component  parts. Despite these actions, concerns over the
quality and safety of Boeing airplanes and the adequacy of
FAA  oversight of Boeing design and manufacturing
practices have persisted. These concerns have primarily
focused on Boeing's two most modem  commercial


airplanes: the Boeing 737 Max and the Boeing 787
Dreamliner.

Trouble with the Max
The 737 is considered Boeing's narrow-body stalwart.
Boeing has delivered almost twelve thousand 737s since the
model's initial introduction in 1967. The most recent
iteration, the Boeing 737 Max, made its debut in 2016,
offering more quiet, fuel-efficient engines and other
performance improvements. However, two catastrophic
passenger airline crashes overseas-Lion Air Flight 610 on
October 29, 2018, and Ethiopian Airlines Flight 302 on
March  10, 2019-led to a 20-month worldwide grounding
of all 737 Max airplanes and halted deliveries until
November  2020. Broader concerns over the certification of
the 737 Max prompted intense scrutiny of FAA's
delegation of certification responsibilities to Boeing,
culminating in legislation requiring sweeping reforms to the
aircraft certification process and FAA's oversight of aircraft
manufacturers and their certification units. The 2020
Aircraft Certification, Safety, and Accountability Act
(Division V of P.L. 116-260) required FAA to reform
policies and practices related to aircraft certification and
mandated industry-wide implementation of FAA-approved
SMS  programs.

On January 5, 2024, a Boeing 737 Max airplane operated
by Alaska Airlines experienced an in-flight separation of a
door plug, a covering for an emergency exit opening that is
installed when a door is not required. Following the mishap,
which caused some injuries and no fatalities, FAA launched
an investigation of Boeing manufacturing processes and
ordered a comprehensive audit of the 737 Max production
lines and supply chain to evaluate compliance with FAA-
mandated quality procedures.

A February 2024 incident, where the rudder controls of a
United Airlines Boeing 737 Max became stuck during
landing at Newark Liberty Airport, prompted a National
Transportation Safety Board (NTSB) investigation. NTSB
found that incorrectly assembled rudder actuator bearings in
an automated control unit are susceptible to freezing,
possibly limiting rudder movement in cold weather. A
similar incident involving an Aeromexico 737 Max in
March 2023  prompted Boeing to issue a notice to operators.
In September 2024, NTSB  urged FAA and Boeing to take
immediate corrective action. In October 2024, FAA issued
a safety alert advising operators of affected aircraft to carry
out rudder system checks before landing and to follow
stuck-rudder procedures if a jam is suspected.

Boeing had previously experienced rudder system issues
with its 737 jets. In the 1990s, design flaws in 737 rudder
control systems resulted in two fatal crashes in the United
States. NTSB concluded that under certain conditions,