A recent six-week audit conducted by the Federal Aviation Administration (FAA) on Boeing's production of the 737 Max jet has revealed a plethora of problems throughout the manufacturing process, according to information obtained by The New York Times. This scrutiny was initiated after an incident where a door panel detached from a 737 Max 9 during an Alaska Airlines flight in January.

The audit identified "multiple instances" where both Boeing and its supplier, Spirit AeroSystems, failed to meet quality-control requirements, though specific details were not disclosed by the agency. However, a presentation reviewed by The Times sheds more light on the findings.

For Boeing's part, the FAA conducted 89 product audits, out of which 33 resulted in failure, indicating 97 instances of noncompliance. Similarly, Spirit AeroSystems underwent 13 product audits, with seven failing grades reported.

Among the concerning observations during the examination, FAA officials witnessed Spirit mechanics using a hotel key card to check a door seal, a practice not documented in the production order. Additionally, mechanics were seen using liquid Dawn soap as lubricant during the assembly process, with unclear instructions regarding proper procedures.

Boeing and Spirit AeroSystems have yet to comment on these findings. However, in response to the audit, Boeing's CEO, Dave Calhoun, acknowledged the need for improvement and mentioned ongoing efforts to address the issues highlighted.

As discussions for Boeing to acquire Spirit unfold, the latter has expressed its commitment to working with Boeing to rectify the deficiencies outlined by the regulator. Meanwhile, the FAA refrained from disclosing specifics of the audit due to ongoing investigations, including one by the National Transportation Safety Board into the Alaska Airlines incident and another by the Justice Department, which has initiated a criminal investigation.

The audit, involving up to 20 auditors at Boeing and several at Spirit, covered various aspects of the 737 Max, including its wings and systems. Many of the flagged issues pertained to deviations from approved manufacturing processes and insufficient documentation on quality control.

In one audit focusing on the problematic door plug component, Boeing faced failure, indicating concerns over inspection and documentation procedures. Similarly, Spirit failed audits related to the installation of the door plug, cargo door, and cockpit windows, raising questions about technicians' knowledge and adherence to process requirements.

The findings underscore the ongoing challenges facing Boeing as it seeks to address safety concerns and regain trust in its aircraft manufacturing processes.

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