By Andrew Tangel, Andy Pasztor and Alison Sider
Boeing Co. has found debris inside the fuel tanks of about
two-thirds of undelivered 737 MAX jets inspected so far, according
to federal and aviation-industry officials, indicating a bigger
production-related problem than the company previously
suggested.
The revelation comes as the plane maker struggles to restore
public and airline confidence in the grounded fleet.
A Boeing spokesman said Friday the plane maker has found debris
in fuel tanks of about 35 jets.
While Boeing disclosed the debris problem publicly earlier this
week, the latest details shed more light on the scale of the issue.
Industry officials said Boeing has so far inspected about 50 of
roughly 400 MAX planes awaiting delivery once regulators allow the
jet back in the air. Materials left behind include tools, rags and
boot coverings, according to industry officials familiar with the
details.
The problem marks the latest in a string of setbacks stretching
over many months that have delayed the return of the MAX to
commercial service while raising questions about the plane maker's
safety and engineering culture.
Boeing's initial comments on Tuesday indicated it came across
evidence of such assembly-line lapses in several MAX jets, without
disclosing the precise number or the total that had been inspected.
Boeing executives have recently pledged greater transparency
following a series of belated disclosures to regulators, airlines
and the public.
On Friday, the Boeing spokesman said inspections first found the
fuel-tank debris in late November and immediately notified the
Federal Aviation Administration. He said the manufacturer has added
safeguards to prevent workers from leaving materials inside fuel
tanks at its 737 factory in Renton, Wash., and beefed up efforts
across the company.
"Boeing is taking it very, very seriously," the spokesman
said.
The FAA earlier this week said that once Boeing informed it
about the problems, the agency moved to step up surveillance and
plans further action as appropriate based on additional inspection
findings. On Friday, an agency spokesman reiterated the voluntary
inspections are "part of the company's ongoing efforts to ensure
manufacturing quality."
Boeing has also broadened its debris inspections to cover other
interior spaces and compartments inside the MAX besides fuel tanks,
according to industry and government officials.
Industry officials cautioned that the percentage of planes with
problems may decline as inspections progress, depending on the time
period in which they were assembled and other factors.
The inspections have raised red flags, some of the officials
said, because Boeing's commercial-airplane unit traditionally has
been recognized as a leader in devising systems to combat such
production lapses. All tools used inside aircraft are supposed to
be logged and tagged, with employees double-checking each other to
verify each piece of equipment is removed. The Boeing spokesman
said the company has ramped up such checks to prevent future
problems.
Regulators have grounded the aircraft since March 2019,
following the second of two fatal crashes that killed a total of
346 people.
Boeing has assigned a team to look after the parked planes, many
of them already painted in the colors of the airlines buying them,
conducting regular checks to prepare for their eventual delivery
when regulators give the green light.
Unwanted tools and debris left inside finished airplanes can
pose various operational risks. In fuel tanks, such debris can clog
fuel lines and damage sensors, pumps or interior linings.
The emergence of so-called foreign object debris, known in the
industry as FOD, comes as Boeing and regulators have been grappling
with much more complicated technical issues for more than a year:
fixing a flight-control system implicated in both fatal crashes and
overhauling related pilot training.
Boeing has said it doesn't expect checking planes and removing
any debris to delay the MAX's clearance from regulators to return
to service, which it currently expects to start midyear. But the
new problem raises fresh questions about Boeing's ability to
resolve lingering lapses in quality-control practices and presents
another challenge to Chief Executive David Calhoun, who took charge
in January.
MAX operators and customers said they became aware of the issue
with the undelivered MAX jets earlier this week.
Some airlines said they were taking steps to ensure that there
wasn't any debris in planes that have already been delivered and
were operational before the grounding. Southwest Airlines Co. said
it had already been planning to inspect the fuel tanks of the 34
stored MAX planes it operated prior to the grounding before they
return to service. A spokesman for American Airlines Group Inc.
said the airline conducts its own inspections before and after
taking delivery of new planes. American said it would perform
additional inspections on its 24 grounded MAX jets before they
return to service, though there have been no signs of problems with
debris in those planes. United Airlines Holdings Inc. also said it
plans to inspect its MAX planes, including the fuel tanks, before
they resume flying.
In addition, FAA inspectors will check every MAX individually
for required maintenance, various inspections and suitable
readiness before allowing it to carry passengers.
The 737 MAX is the latest Boeing jet to face such problems. Last
year, debris was found on some 787 Dreamliners, which Boeing
produces in Everett, Wash., and North Charleston, S.C.
Boeing also twice had to halt deliveries of the KC-46A military
refueling tanker to the U.S. Air Force after tools and rags were
found in planes after they had been delivered from its Everett
factory north of Seattle.
Pentagon leaders said last March that it could take a year for
Boeing to rebuild trust in the program.
"It does not take a rocket scientist to deliver an airplane
without trash and debris on it," Air Force procurement chief Will
Roper said in an interview last June. "It just merely requires
following a set of processes, having a culture that values
integrity of safety above moving the line faster for profit. And
Boeing has certainly conveyed they're serious [about] restoring
that culture."
Later that year, in October, Boeing ousted its
commercial-airplane division chief, Kevin McAllister, as the MAX
crisis dragged on. In December, the company's board -- then headed
by Mr. Calhoun -- removed then-CEO Dennis Muilenburg and installed
Mr. Calhoun as his successor.
Boeing has said it had put in place new procedures to keep
debris out of finished airplanes. It halted MAX production in
January amid the prolonged grounding.
Boeing's general manager for the 737 program, Mark Jenks, in a
message to employees earlier this week, said: "FOD is absolutely
unacceptable."
With MAX production halted, Boeing's Renton, Wash., factory
still produces military versions of the 737 for the U.S. Navy and
some international customers, including the U.K.'s Royal Air
Force.
The Navy, which started receiving the P-8A Poseidon jets in
2012, hasn't found any debris in the aircraft's fuel tanks, a
spokeswoman said. Government inspectors have for years conducted
their own checks along with Boeing personnel, she added.
Doug Cameron contributed to this article.
Write to Andrew Tangel at Andrew.Tangel@wsj.com, Andy Pasztor at
andy.pasztor@wsj.com and Alison Sider at alison.sider@wsj.com
(END) Dow Jones Newswires
February 21, 2020 22:18 ET (03:18 GMT)
Copyright (c) 2020 Dow Jones & Company, Inc.
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