We now have a good picture of why the door of the Alaska Airlines 737 blew off mid-flight. The answer is speed and sloppiness every step of the way. Here are the details.

Out of Sequence Production
Out of sequence production to keep production lines moving and sloppy work procedures and Behind the Alaska Blowout.
Months before a piece of a Boeing 737 blew out midflight, leaving a door-sized hole in its side, the plane spent nearly three weeks shuffling down an assembly line with faulty rivets in need of repair.
Workers had spotted the bad parts almost immediately after the plane’s fuselage arrived at the factory. But they didn’t make the fix right away and the 737 continued on to the next workstation. When crews completed the repair 19 days later, they failed to replace four critical bolts on a plug door they had opened to do the job, leading to the Jan. 5 accident on an Alaska Airlines flight.
At Boeing, there is a term for situations such as this one, when work is completed out of the production line’s ordinary sequence: traveled work. Four years ago, in the aftermath of a pair of fatal MAX crashes, Boeing laid out five values central to improving safety. Number three on the list: eliminate traveled work.
Traveled work emerged as a problem during a review of Boeing’s safety culture on behalf of the Federal Aviation Administration.
Employees are told that safety is the top priority “but then they see airplanes being pushed out with work not being finished,” said Javier de Luis, who was part of an independent panel that conducted the review.
Spotting Bad Parts
“Workers had spotted the bad parts almost immediately after the plane’s fuselage arrived at the factory.”
Questions Abound
- Why is it that no one can spot bad parts and rivets before a fuselage arrives at the factory?
- Why was the door removal not properly logged?
- Who is it that is supposed to double or triple check everything done out of sequence?
- If it takes 19 days to do a repair what else is suspect on the plane?
- Is there no quality control in building the fuselages?
Spirit AeroSystems makes fuselages for Boeing’s 737 Max jets.
If Boeing can spot the bad parts immediately, why couldn’t or didn’t Spirit AeroSystems spot bad rivets?
Is there no one at Boeing on sight at Sprit checking anything?
Boeing is in Talks to Buy Back Fuselage Maker Spirit AeroSystems
On March 1, CNBC reported Boeing is in Talks to Buy Back Fuselage Maker Spirit AeroSystems After Spate of Quality Defects
Boeing in 2005 spun off operations in Kansas and Oklahoma that became the present-day Spirit AeroSystems. About 70% of Spirit’s revenue last year came from Boeing, and roughly a quarter came from making parts for Boeing’s main rival, Airbus, according to a securities filing.
“We believe that the reintegration of Boeing and Spirit AeroSystems’ manufacturing operations would further strengthen aviation safety, improve quality and serve the interests of our customers, employees, and shareholders,” Boeing said in a statement on Friday. “Although there can be no assurance that we will be able to reach an agreement, we are committed to finding ways to continue to improve the safety and quality of the airplanes on which millions of people depend each and every day.”
Explaining Quality Control at Spirit AeroSystems
Spirit has struggled financially, and was last profitable in 2019, before the pandemic. In October, Spirit appointed Pat Shanahan, who spent about three decades at Boeing, as its new, interim CEO.
Spirit has lost money since 2019. That explains why Spirit AeroSystems would rush things. In turn, Boeing rushed things.
Boeing Door Blowout Reveals Cockpit Security Problems As Well
Also recall Boeing Door Blowout Reveals Cockpit Security Problems As Well
The jet cockpit door is designed to open during decompression. This is a mistake for two reasons. The door blowoff incident at Alaska airlines exposed both issues.
How Doors Blow Off Mid-Flight
Everyone is rushing things, doing things out of order, not properly logging things done out of order, and not rechecking things done out of order.
In short, speed is the #1 priority.
That is the bottom line story of how airplane doors (where there isn’t even supposed to be a door), blow off mid-flight.
https://mishtalk.com/economics/at-boeing-speed-not-safety-is-the-companys-top-concern/







