Inside Boeing factories, a persistent narrative of pressure, fatigue, and rising defects continues to emerge, raising concerns about the aerospace giant's safety culture and production quality. Recent reports and interviews with whistleblowers paint a picture of an environment where meeting deadlines sometimes takes precedence over rigorous safety protocols, leading to potential compromises in aircraft integrity.
These concerns have been amplified by the testimony of current and former Boeing employees, who have come forward with allegations of safety lapses and retaliation for raising concerns. Sam Salehpour, a quality engineer at Boeing, testified before a Senate subcommittee, claiming that Boeing is "putting out defective airplanes" and that he faced threats after raising safety concerns about the 787 and 777 aircraft. He alleged that the company rushed production and overlooked safety standards, potentially leading to premature fatigue failure in some areas of the 787 Dreamliner. Specifically, Salehpour claimed that Boeing failed to adequately "shim," or fill tiny gaps in manufactured products, a practice he believes is critical for preventing structural weaknesses. He also stated that he witnessed workers jumping on fuselage panels to align them.
Another whistleblower, Ed Pierson, a former senior Boeing manager, has repeatedly stated that Boeing's production culture placed intense pressure on workers to meet deadlines, contributing to errors across critical aircraft systems. Quality control reports, according to Pierson, have flagged issues in flight controls, electrical wiring, hydraulics, and pressurization systems.
These allegations are not new. In fact, Boeing has been under increased scrutiny since the two fatal 737 MAX crashes in 2018 and 2019, which claimed 346 lives. The subsequent investigations revealed a series of issues, including quality control lapses, safety protocol deficiencies, and a lack of transparency. The FAA conducted an audit of Boeing's manufacturing processes for the 737 MAX in March 2024 and found that Boeing failed 33 of 89 product audits. In addition, the door plug blowout on an Alaska Airlines 737-9 MAX in January 2024 further intensified concerns about Boeing's manufacturing processes.
Boeing has acknowledged the need for improvement and has taken steps to address the issues. The company submitted a safety improvement plan to the FAA in May 2024, focusing on elevating safety culture, investing in workforce training, simplifying manufacturing processes, and eliminating defects. Boeing also released its 2025 Chief Aerospace Safety Officer Report, highlighting a 220% increase in reports through the anonymous "Speak Up" tool from 2023 to 2024. Hector Silva, Vice President of Regulatory Compliance & Quality Core for Boeing Commercial Airplanes, stated that increased supplier oversight has contributed to a reduction in defects by as much as 40 percent.
Despite these efforts, challenges remain. FAA Administrator Mike Whitaker stated that the company needs a "fundamental cultural shift". Moreover, some critics remain skeptical of Boeing's progress. Rich Plunkett, the director of strategic development for SPEEA, acknowledged Boeing's investment in safety training but noted that it fell short, citing reports of managers leaving training sessions to focus on aircraft delivery.
The ongoing concerns about pressure, fatigue, and rising defects inside Boeing factories highlight the critical importance of a robust safety culture, rigorous quality control, and transparent communication. As investigations continue and Boeing works to implement its safety improvement plan, the aviation industry and the flying public will be closely watching to see whether the company can truly restore its reputation and ensure the safety of its aircraft.
