Amid Whistleblower Complaints, Boeing Buys Spirit, Ending Outsourcing of Key Work on Planes

Monday Boeing announced plans to acquire its key supplier, Spirit AeroSystems, for $4.7 billion, according to the Associated Press — 'a move that it says will improve plane quality and safety amid increasing scrutiny by Congress, airlines and the Department of Justice. Boeing previously owned Spirit, and the purchase would reverse a longtime Boeing strategy of outsourcing key work on its passenger planes.'

But meanwhile, an anonymous reader shared this report from Newsweek:

More than a hundred Boeing whistleblowers have contacted the U.S. aviation watchdog since the start of the year, Newsweek can reveal. Official figures show that the Federal Aviation Administration's (FAA) whistleblowing hotline has seen a huge surge of calls from workers concerned about safety problems. Since January the watchdog saw a total of 126 reports, via various channels, from workers concerned about safety problems. In 2023, there were just 11....

After a visit from FAA Administrator Mike Whitaker to a Boeing factory earlier in the year, Boeing CEO Dave Calhoun agreed to share details of the hotline with all Boeing employees. The FAA told Newsweek that the number of Boeing employees coming forward was a 'sign of a healthy culture'.... Newsweek also spoke to Jon Holden, president of the 751 District for the International Association of Machinists, Boeing's largest union which represents more than 32,000 aerospace workers. Holden said that numerous whistleblowers had complained to the FAA over Boeing's attempt to cut staff and reduce inspections in an effort to 'speed up the rate' at which planes went out the door...

Holden's union is currently in contract negotiations with Boeing, and is attempting to secure a 40% pay rise alongside a 50-year guarantee of work security for its members.

CNN also reports on new allegations Wednesday from a former Boeing quality-control manager: that 'for years workers at its 787 Dreamliner factory in Everett, Washington, routinely took parts that were deemed unsuitable to fly out of an internal scrap yard and put them back on factory assembly lines.'
In his first network TV interview, Merle Meyers, a 30-year veteran of Boeing, described to CNN what he says was an elaborate off-the-books practice that Boeing managers at the Everett factory used to meet production deadlines, including taking damaged and improper parts from the company's scrapyard, storehouses and loading docks... Meyers' claims that lapses he witnessed were intentional, organized efforts designed to thwart quality control processes in an effort to keep up with demanding production schedules. Beginning in the early 2000s, Meyers says that for more than a decade, he estimates that about 50,000 parts 'escaped' quality control and were used to build aircraft. Those parts include everything from small items like screws to more complex assemblies like wing flaps. A single Boeing 787 Dreamliner, for example, has approximately 2.3 million parts...

Based on conversations Meyers says he had with current Boeing workers in the time since he left the company, he believes that while employees no longer remove parts from the scrapyard, the practice of using other unapproved parts in assembly lines continues. 'Now they're back to taking parts of body sections — everything — right when it arrives at the Everett site, bypassing quality, going right to the airplane,' Meyers said.

Company emails going back years show that Meyers repeatedly flagged the issue to Boeing's corporate investigations team, pointing out what he says were blatant violations of Boeing's safety rules. But investigators routinely failed to enforce those rules, Meyers says, even ignoring 'eye witness observations and the hard work done to ensure the safety of future passengers and crew,' he wrote in an internal 2022 email provided to CNN.

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