Years of Safety Warnings Surround Boeing 787 Dreamliner
The Boeing 787 Dreamliner, recently involved in a tragic crash near Ahmedabad, had been under scrutiny for its safety features for years, thanks to internal whistleblowers who raised early alarms about potential risks.
A Veteran Quality Manager Sounds the Alarm
John Barnett, a former Boeing quality manager with over three decades at the company, had voiced serious concerns as early as 2019 regarding the assembly of the 787 Dreamliner. Stationed at Boeing’s North Charleston plant, Barnett claimed that workers, pressured to meet tight production schedules, deliberately installed substandard parts on aircraft to avoid delays—actions he warned compromised safety standards.
After retiring in 2017, Barnett pursued legal action against Boeing, asserting that his warnings to management went ignored. In the final week before his untimely passing in March 2024, from what was reported as a self-inflicted gunshot wound, he was actively providing testimony in a whistleblower lawsuit against the company.
He also exposed critical faults with the oxygen delivery systems, revealing that as many as one in four breathing masks could fail during emergencies—highlighting a potentially deadly flaw in safety protocols.
Concerns Over Rushed Production and Salvaged Parts
Barnett recounted that soon after joining the South Carolina facility, it became clear that the drive to accelerate aircraft production often took precedence over thorough quality assurance. Disturbingly, he alleged that defective parts had even been reclaimed from scrap bins and reused, a claim Boeing categorically denies.
Current Engineer Warns of Premature Structural Failures
Adding weight to these concerns, Boeing engineer Sam Salehpour spoke out in April 2024, urging that all 787 Dreamliners worldwide should be grounded immediately due to risks of premature structural failure. Salehpour highlighted poor workmanship, specifically pointing to inadequate sealing of tiny fuselage gaps where separate sections are joined, which accelerates wear and threatens the aircraft’s longevity and integrity.
Despite his decade-long service at Boeing, Salehpour alleged retaliation for his revelations, including exclusion from crucial meetings. His claims are now part of an ongoing investigation by the Federal Aviation Administration (FAA).
Ongoing Investigations and Boeing’s Response
The FAA also launched an inquiry following Boeing’s April 2024 disclosure that certain 787 Dreamliners might have skipped mandated inspections verifying appropriate bonding and grounding at wing-fuselage joints. The probe is examining whether Boeing employees falsified records during these checks.
The aircraft involved in the recent Ahmedabad crash was an 11-year-old Boeing 787-8, marking the first significant accident involving this model.
In response, Boeing stated: “We are in contact with Air India regarding Flight 171 and stand ready to support them. Our thoughts are with the passengers, crew, first responders and all affected.”
