Introduction to the Boeing 787 Dreamliner Controversy

A former quality manager at Boeing, John Barnett, had previously warned about the poor work practices and inadequate oversight at the factory producing the 787 Dreamliner. Barnett, who had extensive experience working for the airplane manufacturer before becoming a vocal critic, claimed that Boeing was using sub-standard parts in the construction of the planes, prioritizing speed and efficiency over safety. This warning was made despite being involved in a legal dispute with the company, which ultimately ended with his death in an apparent suicide.

Recent Tragedy and Renewed Scrutiny

Yesterday, a Boeing 787 Dreamliner crashed in Ahmedabad, India, resulting in the loss of nearly all lives on board. This devastating incident has reignited scrutiny of the controversial manufacturer. Although the cause of the crash is still unknown, if it is discovered to be related to a technical design flaw, it will not be entirely unexpected. Barnett was among many critics who had long expressed concerns about Boeing’s manufacturing practices, and his death had sparked conspiracy theories due to his involvement in a legal case against his former employer.

History of Concerns with the 787 Dreamliner

The 787 Dreamliner was launched in 2011, with the promise of being a more affordable aircraft to manufacture. However, from its inception, the plane was criticized for its overly complex assembly process. One critic noted that the plane was assembled through a convoluted network of contractors, some of whom lacked transparency. Another commentator stated that Boeing seemed to have abandoned its established methods, instead opting for an unproven approach. Critics argued that the company had outsourced too many parts to various contractors, posing a risk that the components might not fit together properly during assembly.

Technical Issues and Safety Concerns

Upon its launch, the 787 Dreamliner was plagued by technical issues. In 2013, a series of battery-related fires in aircraft cabins led the FAA to ground all 787s in the US until the safety concerns could be addressed. In 2015, a software bug was discovered that could have resulted in a "loss of control" by the pilots. The plane also experienced fuel leaks and other problems. In 2019, The New York Times reported on the South Carolina plant where the Dreamliner was manufactured, highlighting allegations of shoddy production and weak oversight that compromised safety. Barnett, who had already left the company by then, was quoted in the article, stating that he had not seen a single plane produced in Charleston that he would consider safe and airworthy.

Whistleblowers and Criticisms

After Barnett’s death, another whistleblower, Sam Salehpour, a former Boeing engineer, claimed that the deficiencies in the 787’s assembly could cause the aircraft to "break apart" in midair. Salehpour testified before Congress, accusing Boeing of being involved in a "criminal cover-up." He also implied that he might face consequences for speaking out. Other Boeing whistleblowers emerged, offering similar critiques, and another whistleblower died. During this time, Boeing admitted to falsifying documents about the 787, including failing to complete required inspections and potentially engaging in other misconduct.

Conclusion

Boeing did not respond to a request for comment on these allegations. The recent crash of the 787 Dreamliner has raised fresh concerns about the company’s manufacturing practices and the safety of its aircraft. As the investigation into the cause of the crash continues, it remains to be seen whether the warnings and criticisms from Barnett and other whistleblowers will be vindicated.