Allegations made by John Barnett — a former quality control manager at Boeing’s 787 factory in North Charleston, SC — paint a troubling picture of the safety of the 787 Dreamliner. This aircraft has been repeatedly lauded as one of the safest in the skies. Barnett’s allegations have launched investigations and discussions among aviation regulators and industry experts since they first made headlines.
Barnett alleged that Boeing’s manufacturing processes were so inadequate that defective parts could slip through the cracks. He first brought these concerns to the attention of the Federal Aviation Administration (FAA), which ruled in his favor on some of his claims. These concerns emerged as the 787 Dreamliner became known for its innovative design, being the first commercial aircraft primarily constructed from composite materials like carbon fiber to reduce weight. This exciting novel approach brought about unforeseen strains that have made safety an issue of concern.
The 787 Dreamliner was blasted, deservedly, with a litany of bad press after the aircraft experienced a cascade of highly-publicized safety crises. In 2013, lithium-ion batteries on a 787 caught fire while the aircraft was stationary at Boston’s Logan International Airport. This incident was serious enough to lead to a temporary grounding of the entire fleet. A week later, another 787 had to make an emergency landing due to overheating batteries during an internal flight in Japan. Since then, the FAA has mandated regular inspections for airlines operating the 787, following reports of undetected leaks and other potential hazards.
Barnett’s allegations indicated that workers at Boeing’s factory failed to adhere to strict procedures designed to track components throughout the production process. In fact, he predicted that many aircraft already in service may harbor the types of hidden defects that could lead to catastrophic accidents. That rings particularly true as it appears the factory’s abusive practices haven’t stopped in the wake of the explosion. The probe revealed that at least 53 “non-conforming” parts have disappeared from the production line.
In a 2019 interview with the BBC, Barnett stated, “I believe it’s just a matter of time before something big happens with a 787.” His tragic death in early 2024 has added fuel to an already fiery criticism of Boeing and its adherence to safety procedures.
The saga of the787 Dreamliner debacle is still playing out. Now, industry experts are weighing in with what this means for Boeing, and the future of commercial aviation. Sam Salehpour, a quality engineer, warned lawmakers that “the safety problems I have observed at Boeing, if not addressed could result in a catastrophic failure of a commercial aeroplane that would lead to the loss of hundreds of lives.”
Richard Aboulafia, an aviation analyst, acknowledged that despite the Dreamliner’s impressive record—over a billion passengers flown and no crashes until recently—there remain valid concerns regarding production practices. “You know. It’s been 16 years of operations, 1,200 jets and over a billion passengers flown, but no crashes until now,” he noted. He remarked, “I really think production problems are more of a short-term concern.”
The FAA’s oversight of these issues has ramped up in the last few years. Aboulafia stated, “For the past few years, there’s been far greater oversight of 787 production.” He noted that some notable production issues stemmed from Boeing’s unprecedented decision to establish a production line outside its traditional Puget Sound area.
Boeing’s innovative approach to aircraft design is what has distinguished the Seattle manufacturer from its competitors. Airbus has targeted the largest hubs in air travel. Aboulafia pointed out that Boeing’s strategic decisions reflect an understanding of market demand: “Boeing said ‘no, people want to fly point to point.’”
Though the 787 program has had its share of woes, it continues to be a leader in the global aviation. Today, there are more than 1,100 Boeing 787 jets flying around the globe. The company has worked diligently to address past issues and assure stakeholders about the Dreamliner’s safety.