A former National Transportation Safety Board (NTSB) member has expressed concerns over potential failures in the manufacturing and inspection process of Boeing's 737 Max 9 aircraft. The worries arise after a near-disaster occurred on an Alaska Airlines flight last Friday when a "door plug" blew out of the aircraft at 16,000 feet.

John Goglia, a former NTSB member and FAA certified mechanic, highlighted possible shortcomings in the installation process of the door plug, questioning whether the process itself or human oversight was to blame. With the 737 Max 9 being a relatively new aircraft, having rolled off the assembly line in October, Goglia raised doubts about the level of oversight and inspections carried out during the manufacturing and installation processes at Boeing's plant and its subcontractor in Wichita, Kansas.

Goglia emphasized the importance of inspection requirements for critical components like the door plug, stating that any potential single point of failure must be thoroughly checked by both the installers and an independent set of eyes. He expressed concern over the lack of inspection requirements for the door plug installation, calling for a more robust oversight system.

The Federal Aviation Administration (FAA) has initiated an investigation into Boeing's 737 Max 9 aircraft, looking into whether Boeing failed to ensure the aircraft conformed to its design and operated safely in compliance with FAA regulations. The FAA is determined to prevent a recurrence of the incident, stating that it should have never happened.

Boeing expressed its commitment to cooperate fully and transparently with both the FAA and the NTSB during their investigations into the incident.

The door plug, commonly used to seal optional extra doors when airlines choose to reduce passenger seats, is secured in place by bolts and fittings. These plugs are lighter than emergency doors, cannot be opened or closed, and do not require additional maintenance or an escape slide.

The NTSB is focusing its investigation on the precise cause of the door plug failure and whether any of the attachment points or installation procedures were at fault. The incident on Alaska Airlines Flight 1282 resulted in a severe depressurization that caused a teenager's shirt to be ripped off and the flight deck door to forcefully open. The pilots declared an emergency and were able to safely return to Portland, avoiding serious injuries.

NTSB Chair Jennifer Homendy emphasized the fortunate outcome of the incident occurring at a lower altitude, stating that if it had happened during cruise altitude (typically between 30,000 and 40,000 feet), the consequences might have been catastrophic.

During a meeting with employees, Boeing's President and CEO, Dave Calhoun, acknowledged the company's mistake and pledged to work closely with the NTSB to determine the cause of the incident. Calhoun expressed confidence in the NTSB's capabilities and expertise as they investigate the accident.

The investigations into the Alaska Airlines incident will shed light on potential flaws in the manufacturing and inspection processes, raising important questions about safety practices and oversight within the aviation industry.