Boeing Whistleblower Alleges Faulty Plane Parts May Be on New Aircraft

A recent report from the Senate subcommittee has brought to light fresh allegations from a Boeing whistleblower, raising serious concerns about the safety and quality of the company’s aircraft. Sam Mohawk, a quality assurance investigator at Boeing, claims that the 737 program has lost track of hundreds of faulty parts.

Released on Monday, the 204-page report details various accusations from whistleblowers who have firsthand knowledge of Boeing’s practices at its Washington facilities. The Senate subcommittee stated that these allegations “paint a troubling picture of a company that prioritizes speed of manufacturing and cutting costs over ensuring the quality and safety of aircraft.”

One of the prominent voices in this report is Sam Mohawk, based in Renton, Washington. In a complaint to the Occupational Safety and Health Administration (OSHA) dated June 11, Mohawk alleged that the 737 program was losing “hundreds” of “non-conforming” parts. He further claimed that Boeing’s Renton factory ordered staff to move “improperly stored” aircraft parts to “intentionally hide” them from Federal Aviation Administration (FAA) inspectors.

“There were approximately 60 parts being stored outdoors, including 42 rudders alone, plus flaps, winglets, ailerons, stabilizers, and vertical fins,” Mohawk’s OSHA complaint read. He added that those parts, which were hidden from the FAA inspection, had been moved back outside or lost completely.

The report also highlights allegations from Merle Meyers, a former Boeing quality manager. Meyers claimed that Boeing’s manufacturing team often tried to retrieve faulty parts from a “reclamation” area, even after they were designated for disposal. Meyers further alleged that manufacturing staff had forms to justify moving parts from reclamation back into the production line, with examples dating back to 2002, involving parts like “787 leading edge slats,” “landing gear fitting,” “787 nacelle forgings,” and “wire bundles.”

These new accusations add to the growing list of concerns about Boeing’s practices. The report mentions two whistleblowers who died before its release: Joshua Dean, a former Spirit AeroSystems employee, and John Barnett, a former Boeing manager. Dean, who testified against Spirit AeroSystems in a shareholder lawsuit, died suddenly in May. Barnett died in March from what the Charleston County coroner’s office described as “a self-inflicted gunshot wound.”

The Senate subcommittee’s document was released just before Boeing CEO Dave Calhoun’s testimony before a Senate panel on Tuesday. During the hearing, lawmakers questioned Calhoun about the series of high-profile safety incidents involving Boeing. Calhoun defended the company’s safety record, stating, “I am proud of every action we’ve taken,” in response to Sen. Josh Hawley.

In response to the new allegations, a Boeing spokesperson said, “We continuously encourage employees to report all concerns as our priority is to ensure the safety of our airplanes and the flying public.” Boeing is currently reviewing the whistleblowers’ claims after receiving the document late Monday evening.