The Boeing 787: Broken Dreams l Al Jazeera Investigations

No matter how you may feel about (all) nation-state sponsored media outlets, AlJazeera deserves respect for this excellent footage they got from inside the factory. It's a few years old, but should have raised more alarm by now: ▶ this video

Another worrisome development: link Al-Jazeera has really been on fire digging into Boeing. This video (though from 2014) was remarkable: ▶ this video

The MCAS is what brought Boeing issues into the zeitgeist, but I was aware of issues at Boeing ~ 18 years ago from friends who had worked there and Al Jazeera did a great investigation ~ 9 years ago ( ▶ this video ). Boeing used to be the gold standard and as someone who researches such gold standards it was disheartening to see them give that up. But that happened very slowly and started a long time ago. Clearly diluting focus away from safety is an issue for whatever the reason especially when the safety of airplanes is declining. This should also be taken in context that many aspects of manufacturing have improved greatly over the past 20 years so even if everything else stayed the same the general safety should have been greatly improved. So the drag on safety by the culture is bad enough to overcome these 'free' gains and end up with even less safe planes should highlight just how bad that effect is.

Al Jazeera has a long report on YouTube [0] covering the allegations around Charleston, I know that they can be biased against the US but this report is quite eye opening. Even more given the interview with a VP (or director, can't remember exactly the position) being cut short by the PR person involved, the reports from workers inside the factory stating they wouldn't fly a plane built there, etc. [0] ▶ this video

Check out this documentary on Boeing's sketchy manufacturing & QA process back in the days of the 787 release. It seems that the company has been toxic for a while now. ▶ this video

It's worth watching Al Jazeera's series on the production of the 787 Dreamliner, and related cultural issues at Boeing after their merger with McDonnell Douglas [1]. Personally, I think it's worth taking with a grain of salt as it appears quite one-sided, but the interviews with Boeing ex-employees and head engineers are enlightening, and could go some way to explaining the lack of redundant systems (i.e. cost and time). [1] ▶ this video

You're referring to The Boeing 787: Broken Dreams published in 2014 by Al Jazeera ▶ this video This revealed a host of problems with the 787 Dreamliner, mainly that its battery packs catch fire (which is why it was grounded by the FAA from January to April 2013 to revise the battery design). This is the plane relevant to this latest whistleblower, but not the same plane as the 737 MAX, the one with the MCAS system and the door plugs missing bolts

It describes how it used providers instead of internalization to push down on the prices. However, to anyone who might expect it, it doesn’t tell that Boeing has fired 900 QAs out of 3000 back in 2021. This documentary is not as damning as Al Jezeera’s documentary on the 2013 airframe mishaps: ▶ this video Maybe it’s a European bias, but I’d like to see more shame (and jail time) upon the Boeing management, down to the guy at the bottom who signed off the bolt work without even looking at the plane, which is criminal. But I’m fair, I’d also enjoy the management of Volkswagen going to jail, like that manager who went to holidays through a USA connection and was intercepted by the US border and is still rotting in jail.

> I love flying on the Boeing 787 Dreamliner Then you really shouldn't watch this video: ▶ this video TLDW: Critical Dreamliner fuselage parts didn't fit together because workers at the subcontractor (Ducommun) traced a template with magic marker onto the material and cut and drilled the part by hand. Officially, the parts were manufactured by high precision CNC machinery with extremely small tolerances. At Boeing, if drill holes didn't match up in parts A and B, workers were told to just put the parts together and re-drill the hole in part B through the hole in part A, or hammer the parts into place. Internal Boeing investigators who found out and documented the issues were threatened to be sued if they spoke up. They were later fired, after the US government allegedly leaked their identities to Boeing. Here, a Boeing employee speaks about the work culture in the manufacturing plant: ▶ this video

There are reports about the SC plant making the 787 from Al Jazeera [1] where they investigate exactly that. And the unionisation helps a lot in the Washington plant to allow employees to speak up with no fear of reprimands. I do believe being unionised impacts a lot the work environment psychological safety, allowing employees of the plant to halt production if they don't think work is being performed up to their standards, in NC there is no such provision and the employees themselves are caught on video stating "I wouldn't fly on a plane made here". [1] ▶ this video

According to this newer documentation, many workers of the South Carolina plant would never fly a 787. Because they know how they are being made. ▶ this video

Interestingly I found out about Boeing's N.C. plant quality control issues from an Al-Jazeera report on the 787 [0] way back in 2014. The part about the plant has an interview with an employee recording other employees worried about safety, training and other issues. There is a Q&A with a Boeing VP that is interrupted by some PR/legal aide when questions about quality issues in Charleston start. It's an ongoing issue for quite a long time... [0] ▶ this video (I've timestamped to the relevant part about the Charleston plant)