Boeing discloses new quality problem on 787 Dreamliner jets

The company made its disclosure as Michael Whitaker, head of the Federal Aviation Administration, was preparing for a Friday visit to the South Carolina factory where the 787 is built, part of the agency’s stepped up oversight of Boeing.

While a midair door panel blowout aboard an Alaska Airlines’ jet earlier this year brought scrutiny of Boeing’s manufacturing practices, it also renewed long standing questions of the FAA’s oversight of the company.

Whitaker has been praised for his quick decision to ground 737 Max 9 aircraft in the wake of the Jan. 5 blowout until inspections could be completed. But on Thursday, in an appearance before the Senate’s Commerce, Science and Transportation Committee, he was grilled about the FAA’s response to the crisis.

“We are counting on you to be that agent of change. We know that this begins by taking a hard look at the agency itself,” Sen. Maria Cantwell (D-Wash.), chair of the committee said, noting that Whitaker was overwhelmingly confirmed to lead FAA by the Senate last October.

Added Sen. Ted Cruz (Tex.), the committee’s ranking Republican: “The FAA must guarantee that not only are they certifying an aircraft is safely designed but that the manufacturer is building them to that safe design. Clearly, that was not happening at Boeing.”

Whitaker told members of the panel that the door panel blowout made it clear that the agency’s oversight of Boeing has been “too hands off,” and that a more aggressive approach was needed. The agency has put more inspectors on Boeing factory floors where they can interact with front-line employees, he said.

Thursday’s hearing took place just weeks after Boeing submitted a plan to the FAA to address shortcomings identified by the agency. The company’s chief executive David Calhoun is expected to testify next week before the Senate’s permanent subcommittee on investigations.

In a statement, Boeing said Thursday the latest issue involving its 787 jets, first reported by Reuters, was identified as part of the company’s quality management system. The company found that some fasteners were torqued incorrectly and are being studied to determine whether they will require repairs.

“We are taking the time necessary to ensure all airplanes meet our delivery standards before delivery,” Boeing said in a statement. “We are working closely with our customers and the FAA and keeping them updated.”

This is only the latest issue to impact production of the 787 jetliner. Last month, the FAA said it had launched an investigation into whether Boeing employees skipped key inspection of certain 787 aircraft and falsified reports to say the work was completed.