FAA Investigates Claims of Fuselage Issues in Boeing 777 and 787 as Whistleblower Testifies

The Federal Aviation Administration (FAA) is actively investigating allegations by Boeing engineer and whistleblower Sam Salehpour regarding quality concerns in the fuselages of Boeing 777 and 787 aircraft. Salehpour’s claims, which suggest significant gaps in fuselage panels that could potentially compromise aircraft safety, have led to a forthcoming US Senate inquest scheduled later this month.

According to Salehpour, during his time on the 787 production line, he witnessed improper assembly practices, including personnel physically jumping on aircraft parts to align them. This method, he argued in statements reported by CNN, could deform parts and does not adhere to standard aerospace engineering practices.

Boeing previously halted 787 deliveries for 14 months from 2021 to 2022 after discovering similar issues, later resuming with assurances that production adjustments had been made to meet safety specifications. However, Salehpour contends that ongoing problems persisted and were also evident in the 777 line, to which he was reassigned after raising initial concerns. He expressed fears that the integrity issues could reduce the lifespan of the aircraft, potentially leading to catastrophic failures, affecting over 1,400 aircraft across both models.

Boeing has publicly denied these claims, describing them as “inaccurate” and reaffirming their commitment to the safety and quality of their aircraft. The company also indicated that it is conducting thorough studies to address long-term fatigue concerns which they claim would not affect the current fleet for many years, if at all.

The US Senate Permanent Subcommittee on Investigations has summoned Boeing CEO Dave Calhoun and Salehpour to testify on April 17. Senators Richard Blumenthal (D-CT) and Ron Johnson (R-WI) have expressed their intentions for the hearings, stating they aim to scrutinize Boeing’s engineering and assembly processes thoroughly. They emphasized the need for Boeing to demonstrate why the public should remain confident in its aircraft amidst these severe allegations, and to detail measures to prevent future safety compromises.