Federal authorities have launched an investigation into Boeing after a whistleblower, identified as Sam Salehpour, raised concerns about manufacturing shortcuts in two of the company's widebody jet models. The whistleblower, a Boeing engineer, alleged that the shortcuts taken during the manufacturing process of the Boeing 777 and 787 Dreamliner jets could pose catastrophic risks as the airplanes age.

The New York Times first reported on Salehpour's complaint, which was filed with the Federal Aviation Administration (FAA) in January and made public on Tuesday. Although the complaint is not specific to the newer 737 Max jet, which has been grounded twice by the FAA, it raises concerns about "two quality issues that may dramatically reduce the life of the planes."

Speaking to reporters on a conference call, Salehpour emphasized that his intention was not to see Boeing fail but rather to ensure its success and prevent potential crashes. He stated, "The truth is Boeing can keep going the way it is. It needs to do a little bit better, I think."

In response to the whistleblower complaint, the FAA confirmed that it is investigating the allegations. Salehpour has been interviewed by the FAA as part of their ongoing investigation. The agency stressed the importance of voluntary reporting without fear of reprisal, stating that it is a critical component in ensuring aviation safety.

Concerns about the manufacturing of the widebody jets will also be addressed in an upcoming hearing by a Senate subcommittee next week. While Boeing has not commented on the claims made about the 777, the company disputed Salehpour's concerns regarding the 787 Dreamliner. Boeing stated, "These claims about the structural integrity of the 787 are inaccurate and do not represent the comprehensive work Boeing has done to ensure the quality and long-term safety of the aircraft."

Boeing's 787 Dreamliner, which entered service in 2011, is claimed to have a potential 50-year lifespan, with around 44,000 flights per aircraft. However, Salehpour's complaint alleges that improper filling of tiny gaps when joining separate parts of the fuselage could lead to increased wear and a shorter lifespan, potentially resulting in "catastrophic" failures.

These allegations are not entirely new, as the FAA and Boeing previously halted deliveries of the Dreamliners for nearly two years starting in 2021 to investigate similar gap issues. Boeing claims to have made changes in its manufacturing process, and deliveries resumed. The company maintains that the 787 Dreamliners are safe to fly.

According to Salehpour's attorneys, the FAA expressed surprise when they discovered through the whistleblower's complaint that the gap issues were still a concern. Salehpour himself described witnessing workers jumping on airplane pieces to temporarily align the gaps, stating, "By jumping up and down, you're deforming parts so that the holes align temporarily... and that's not how you build an airplane."

In addition to the manufacturing concerns, Salehpour alleged retaliation by Boeing after raising another issue related to the 787 and a different plane model. Following this, he claimed to have been transferred out of the 787 program to the 777 program. In his new role, Salehpour reportedly found subpar work in aligning body pieces and pressure on engineers to approve work that had not been properly inspected.

Salehpour estimates that over 400 777s and 1,000 787s are affected by these issues. The news of the investigation led to a temporary decline of 2% in Boeing shares before recovering later in the day.

This is a developing story, and updates will be provided as the investigation progresses.