Boeing Faces Scrutiny After Whistleblower Alleges Flaws in 787 Dreamliner Manufacturing

April 9, 2024 – A Boeing engineer, Sam Salehpour, has raised serious concerns about the manufacturing processes of the company’s 787 Dreamliner and 777 jets, alleging that Boeing took shortcuts that could compromise safety. According to Salehpour, these issues pose a risk of “catastrophic” consequences as the aircraft age, potentially affecting the structural integrity of over 1,000 planes in service.

Salehpour’s allegations, detailed in a complaint filed with the Federal Aviation Administration (FAA), claim that Boeing overlooked quality control issues during the production of the 787, including misaligned parts and inadequate inspections. He also raised concerns about similar issues in the 777 production line, warning that these shortcuts could lead to significant safety risks over time. The whistleblower, who has since faced reported retaliation from Boeing, called for the grounding of the 787 fleet for further inspections.

The FAA has confirmed it is investigating these claims, emphasizing its commitment to ensuring aviation safety. Boeing issued a statement acknowledging the allegations and asserting that it remains confident in the 787’s safety, citing rigorous quality assurance processes. However, the company is cooperating with the FAA’s investigation.

This development adds to Boeing’s ongoing challenges, following other whistleblower reports and incidents that have drawn public and regulatory scrutiny. Salehpour’s testimony is expected to be reviewed by federal panels, with calls for transparency growing louder within the aviation industry.

As the investigation unfolds, the aviation community and passengers await further details on the potential implications for the 787 Dreamliner fleet and Boeing’s broader manufacturing practices.