New Delhi, July 21 - A leading aviation expert recently disclosed that the Boeing 787 Dreamliner's automated systems can independently shut off fuel to its engines, an event that has reportedly happened on two separate occasions, sending ripples through the aviation industry. This revelation comes in the context of ongoing investigations into the tragic crash of Air India Flight AI171, which killed 260 people in Ahmedabad, India, on June 12, 2025. The preliminary report from India’s Aircraft Accident Investigation Bureau (AAIB) highlighted that the fuel control switches on the Boeing 787-8 Dreamliner transitioned from the “RUN” to “CUTOFF” position shortly after takeoff, leading to a catastrophic dual-engine failure. The incident has raised critical questions about the reliability of the Dreamliner’s automated systems and the potential for software malfunctions to override human control.
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The expert, Mary Schiavo, a former U.S. Department of Transportation Inspector General and aviation attorney, has pointed to the Thrust Control Malfunction Accommodation (TCMA) system as a key area of concern. This system, mandated by the U.S. Federal Aviation Administration (FAA), is designed to assess whether the aircraft is on the ground or airborne and can autonomously reduce engine thrust under certain conditions. Schiavo cited a 2019 incident involving an All Nippon Airways (ANA) flight NH-985, a Boeing 787 (Reg. JA825A) flight from Tokyo to Osaka, where the TCMA system erroneously interpreted the plane as being on the ground during its final approach. This misjudgment triggered an automatic fuel cutoff, causing both engines to flame out. Fortunately, the incident occurred during landing, allowing the aircraft to glide to the runway without crashing. The Japanese authorities and Boeing later attributed the event to a software glitch, not pilot error.
A second incident involved a United Airlines Dreamliner flight from Washington, D.C., to Nigeria, where automated systems reportedly caused the aircraft to enter a nose dive due to thrust and engine issues. While details of this event remain less clear, it underscores the potential for software-driven systems to interfere with critical flight operations. In the case of Air India Flight 171, the AAIB report noted a cockpit voice recorder exchange where one pilot asked the other, “Why did you cut off the fuel?” to which the response was, “I didn’t.” This conversation, combined with the rapid transition of both fuel switches to the cutoff position within a second, suggests the possibility of an automated system acting independently. The Boeing 787’s Full Authority Digital Engine Control (FADEC) system, which manages engine functions like fuel flow and is integrated with the TCMA, is now under scrutiny.
Experts suggest that a malfunction in FADEC, potentially triggered by faulty sensor data or a software bug, could have caused the fuel switches to move without pilot input. The 2018 FAA Special Airworthiness Information Bulletin, which flagged issues with fuel control switch locking mechanisms on Boeing aircraft, including the 787, adds further complexity. Although advisory, Air India did not inspect the switches on the crashed aircraft, raising questions about whether a mechanical or electronic flaw could have contributed. This issue is particularly alarming given the Dreamliner’s reliance on advanced automation, a hallmark of its design since entering service in 2011. With over 1,100 Boeing 787s operating worldwide, the implications of a systemic software issue are profound. Schiavo has emphasized that premature blame on pilots, as seen in approximately 75% of aviation incidents, often oversimplifies complex technical failures. The ongoing investigation, involving experts from Boeing, General Electric, and international regulators, is expected to take months to analyze millions of lines of flight data recorder code. As the aviation community awaits a final report, due by June 2026, the focus remains on ensuring that software systems, designed to enhance safety, do not become unforeseen risks in the skies.