A six-week audit conducted by the Federal Aviation Administration (FAA) reportedly uncovered “dozens of problems” at Boeing facilities.

The audit was initiated following an alarming incident in early January when a door panel blew off a 737 Max 9 flight operated by Alaska Airlines, prompting heightened scrutiny of Boeing’s quality-control practices.

The NYT report provided insights into the findings of the audit, based on an internal FAA slide presentation.

Auditors identified numerous issues, with many falling under the categories of failure to adhere to approved manufacturing processes and inadequate documentation of quality control measures.

Out of 89 product audits conducted, Boeing reportedly passed 56 tests but failed 33 of them, indicating a significant number of deficiencies in the production process.

Similarly, of the 13 product audits focused on Spirit AeroSystems, a key supplier responsible for manufacturing fuselages for the 737 Max, only six resulted in passing grades, while seven audits ended in failure.

Hotel key card

Some of the troubling practices uncovered during the audit included mechanics at Spirit reportedly using a hotel key card to check a door seal and applying liquid Dawn soap as a lubricant during the fit-up process.

In response to the findings, a spokesman for Spirit stated that the company is reviewing all identified nonconformities for corrective action.

This latest development comes on the heels of the FAA’s directive to Boeing to develop a plan for quality-control improvements within 90 days.

Additionally, an expert panel’s report highlighted a concerning “disconnect” between Boeing’s senior management and employees regarding safety culture.

The backdrop of these investigations is the tragic history of the Boeing 737 Max, with two fatal crashes in 2018 and 2019 claiming the lives of 346 passengers and crew members.

In light of these incidents, Boeing emphasized its commitment to implementing immediate changes and developing a comprehensive action plan to strengthen safety and quality.