Boeing has announced plans to make design changes to its 737 MAX 9 aircraft to prevent future door panel blowouts, following a harrowing incident in January 2024. During an Alaska Airlines flight, a panel blew off the fuselage, causing a rapid decompression and forcing the plane to make an emergency landing. The incident, which thankfully resulted in no serious injuries, highlighted a potential flaw in the aircraft's design.
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The issue stems from the 737 MAX 9's mid-cabin exit door design. Unlike traditional doors, these exit doors are designed as "plugs" that can be removed to accommodate different seating configurations. However, this design feature also means that the door plugs are not as securely fastened as traditional doors. To address this issue, Boeing is working on design changes that will ensure the door plugs cannot be closed if there is any issue until it is firmly secured. Elizabeth Lund, Boeing's senior vice president of quality, explained during a National Transportation Safety Board (NTSB) hearing that the company hopes to implement these changes within the year and then retrofit them across the fleet.
The NTSB hearing also revealed that the Alaska Airlines incident was the result of a series of errors and oversights. Four bolts that helped secure the panel were not replaced after a repair job in a Boeing factory, but the work was not documented, according to the NTSB. The pilots quickly landed the aircraft back in Portland, Oregon, and the door plug was later found in a backyard in Cedar Hills, Oregon. The incident has had far-reaching consequences for Boeing. The company has faced a criminal investigation and the departure of several key executives. Boeing has also agreed to a plea deal with the US Department of Justice over the 737 MAX crashes in 2018 and 2019, and it has been working to improve its quality control and safety procedures.
In addition to the design changes, Boeing has also been increasing its quality inspections and adding more internal checks to prevent similar incidents in the future. The company is also expanding its training programs and simplifying its processes and procedures. The 737 MAX 9 door panel blowout has been a wake-up call for Boeing, and the company is taking steps to ensure that such an incident does not happen again. The design changes and the increased focus on quality and safety are part of Boeing's efforts to regain the trust of its customers and the flying public.