A former quality manager at Spirit AeroSystems has come forward with serious allegations against the company, claiming that defective 737 Max fuselages were knowingly delivered to Boeing for years. Santiago Paredes, who worked at Spirit AeroSystems’ Wichita, Kansas factory, shared his concerns with CBS News, detailing his experiences inspecting 737 fuselages before they were sent to Boeing. Spirit AeroSystems, which was spun off from Boeing in 2005, is responsible for building most of the 737 Max line. Paredes, who spent a decade with Spirit before leaving in 2022, stated that it was rare to inspect a job without finding defects and that he was often instructed to downplay any issues he discovered.
“Working at Spirit, I almost grew a fear of flying,” Paredes said. “Knowing what I know about the 737, it makes me very uncomfortable when I fly on one of them.” He further alleged that Boeing was aware of the defective fuselages being delivered by Spirit and suggested that it was only a matter of time before a significant incident occurred. He referenced a blown-out door plug aboard a 737 Max 9 in January as an example. CBS News also received several images from current and former Spirit workers showing dented fuselages and missing fasteners.
In response to Paredes’ claims, a Spirit spokesperson told CBS News that the company encourages all employees with concerns to come forward, assuring them that they will be protected. “We remain committed to addressing concerns and continuously improving workplace safety standards,” the spokesperson added.
These allegations come nearly a month after another whistleblower, Sam Salehpour, stepped forward with claims that fuselages for Boeing 787 Dreamliners were not fastened together correctly, putting the planes at risk of breaking apart over time. On May 7, the Guardian reported that the Federal Aviation Administration (FAA) was investigating whether Boeing completed inspections for 787 Dreamliners to confirm that fuselages were correctly attached and if employees might have falsified records.
The issue of using defective parts in aircraft assembly is not new. The aviation industry has long grappled with the challenge of ensuring the integrity of parts used in manufacturing. The reuse of parts from scrapyards in factory assembly lines has been a topic of concern, as it raises questions about the safety and reliability of the aircraft.
Scrapyards, or “boneyards,” are where decommissioned aircraft are stored, often in arid desert climates that inhibit rust and erosion. These facilities, such as the Mojave Air and Space Port in California and the Davis-Monthan Air Force Base in Arizona, store thousands of commercial and military planes. While many of these aircraft are beyond repair, some are eventually returned to active service after undergoing maintenance and reconfiguration.
The Mojave Air and Space Port, for example, is one of the world’s top destinations for retired aircraft. It boasts ideal environmental conditions, including an arid desert climate, high elevation, low pollution levels, and alkaline soils. These factors help preserve the aircraft and prevent rust from forming. The facility stores a variety of aircraft, including those manufactured by Boeing, Airbus, McDonnell Douglas, and Lockheed Martin.
Similarly, the Davis-Monthan Air Force Base in Arizona is the largest aircraft storage and preservation facility in the world. The base, officially known as the 309th Aerospace Maintenance and Regeneration Group (AMARG), was set up after World War II and is now the only repository of decommissioned military and government aircraft in the country. The base is used for both short and long-term storage and for salvaging usable parts from aircraft. In total, the boneyard returns hundreds of millions of dollars worth of spare parts to military, government, and allied clients.
The reuse of parts from these boneyards in factory assembly lines raises significant safety concerns. While the practice can be cost-effective, it also poses risks if the parts are not properly inspected and certified. The allegations made by Paredes and Salehpour highlight the potential dangers of using defective or improperly fastened parts in aircraft manufacturing.
The aviation industry is under increasing pressure to ensure the safety and reliability of its aircraft. The FAA’s investigation into Boeing’s practices is a step in the right direction, but more needs to be done to address the root causes of these issues. Companies must prioritize safety over cost-cutting measures and ensure that all parts used in manufacturing meet the highest standards of quality and reliability.
In conclusion, the allegations made by Santiago Paredes and Sam Salehpour underscore the importance of rigorous quality control in the aviation industry. The reuse of parts from scrapyards in factory assembly lines can be a cost-effective practice, but it must be done with the utmost care to ensure the safety and reliability of the aircraft. The aviation industry must take these concerns seriously and work to address the underlying issues to prevent future incidents and maintain public trust in air travel.
Source: CBS News, The Guardian, The New York Times
