In a recent development, Boeing finds itself grappling with multiple safety issues in its commercial aircraft programs, resulting in repercussions such as certification delays for the 737 MAX 7 and 737 MAX 10 models. These setbacks have not only dampened plans to increase production but also necessitated inspections and maintenance procedures for aircraft already in service.

The Federal Aviation Administration (FAA) has set a 90-day deadline for Boeing to devise a turnaround plan for its safety management system. This directive comes in the wake of an Expert Review Panel's findings, which identified 27 areas of concern regarding Boeing's engineering and manufacturing capabilities and made 53 recommendations for improvement.

One of the specific concerns raised by the FAA involves a design flaw in the new 737 MAX, relating to the potential disablement of the engine anti-ice system in rare circumstances. A review conducted by Boeing discovered a single point of failure in the standby power system control unit design, which could result in the loss of control and indication of both engine anti-ice systems. The FAA deems this as a safety risk that could lead to the loss of thrust on both engines and compromise the continued safe flight and landing of the aircraft. Although this issue has not occurred during service, the FAA has proposed an Airworthiness Directive to address the potential risks, with estimated costs per affected aircraft amounting to $5,290.

Additionally, Boeing has withdrawn its request for an exemption from the FAA concerning another design flaw in the MAX's engine inlet de-icing system. This flaw involves the use of carbon composite material, which may overheat and cause the inlet to break up, potentially resulting in debris impacting the fuselage during flight. Although no incidents have been reported regarding this issue, the FAA's proposed advisory circular aims to eliminate any potential safety risks.

Furthermore, a separate de-icing issue has been identified in Boeing's 787 Dreamliner program, affecting the 787-8, 787-9, and 787-10 model aircraft in service. This issue revolves around missing seals between various ducts within the engine inlet, which allows air to leak and exposes inlet components to high temperatures. If left unaddressed, this condition can lead to structural damage and the detachment of the inlet from the airplane, endangering the safety of the aircraft and its occupants.

The cumulative effect of these issues raises concerns about Boeing's engineering decisions on its aircraft programs. The findings of the Expert Panel suggest that Boeing needs to improve its mechanisms for knowledge exchange to develop capable engineers for its next-generation aircraft. Additionally, the panel highlighted the importance of maturing Boeing's safety management system to avoid quality failures in manufacturing, including increased oversight of suppliers like Spirit AeroSystems.

Spirit AeroSystems, a critical supplier for multiple Boeing programs, has encountered its fair share of issues in collaboration with Boeing. The National Transportation Safety Board (NTSB) reported missing bolts on an Alaska Airlines 737 MAX mid-exit door plug, which were allegedly removed during a repair process conducted by Spirit AeroSystems staff. In another incident, Boeing was forced to rework 50 undelivered 737 MAX aircraft after Spirit AeroSystems discovered mis-drilled holes on the window frame. In light of these ongoing challenges with their supplier, Boeing is currently engaged in talks to reverse the spin-off of Spirit AeroSystems, believing that the reintegration of their manufacturing operations would enhance aviation safety, improve quality, and align with the interests of customers, employees, and shareholders.

As Boeing strives to address these safety concerns and implement necessary measures, the industry and stakeholders will closely monitor the company's progress in restoring trust and confidence in its aircraft programs.