How ordinary failure could have a seismic effect on an industrial giant

Earlier this year, a Boeing aircraft experienced a significant issue when a door plug fell out during flight. This incident occurred because crucial bolts were missing, highlighting how simple failures can indicate larger problems, according to John Downer, an Associate Professor in Science and Technology Studies. On January 6, Alaska Airlines Flight 1282, a Boeing 737 Max 9, was climbing out of Portland, Oregon, when a large section of the aircraft's structure, a fuselage door plug, broke free. The cabin violently decompressed with a loud boom, causing headrests to be ripped from their moorings. A teenage boy seated near the rupture was almost sucked out. Miraculously, no one died, but it was a close call. If the seats next to the failed fuselage section had not been empty, or if the seatbelt light had not been on, the event could have been deadly. Dangerous failures in modern jetliners are extremely rare, but this incident is particularly concerning. The missing bolts were found in a residential neighborhood, and subsequent inspections revealed more issues. If the missing bolt theory is confirmed, it will be the ordinariness of the failure that sets it apart. Typically, mechanical failures in jetliners are more complex than missing bolts. Making jetliners extremely reliable is challenging, especially in complex technologies that operate in harsh environments. Engineers need to understand the intricacies of the system and its operation to prevent failures. This requires extensive knowledge and effort. For example, building a system that is reliable 99. 99% of the time means understanding how it will behave over 10,000 hours of operation. Engineers use theories, tests, and models to capture potential issues, but the real world is messy, and unexpected problems can arise. As the reliability required increases, the effort needed to achieve it grows exponentially. For instance, increasing reliability from 99. 99% to 99. 999% means accounting for issues that might occur every 100,000 hours. This requires considering even more obscure possibilities. Boeing has faced serious issues with its 737 Max short-haul airliner in recent years. The door plug incident is unusual because it appears to be an avoidable error. Typically, jetliner failures are due to complex issues, but this was a simple mistake. Securing bolts properly is a basic aspect of high-reliability engineering. This kind of mistake should be caught by Boeing's rules and oversight. Some experts believe Boeing has lost its way, cutting corners and not prioritizing safety. Boeing has responded by stating they take reports seriously and act quickly to fix problems. Fixing the missing bolts issue is straightforward, but changing the company's culture is more challenging. It will require significant effort to ensure Boeing focuses on safety. Boeing has been a leader in the aviation industry for decades, but recent problems have put their reputation at risk. The 737 Max has had accidents and near-misses, raising concerns about its future. The 787 Dreamliner has also faced issues, but no catastrophic accidents have occurred. Boeing's reputation for making safe planes is crucial. People trust that planes are safe, and this trust is delicate. If Boeing doesn't address its problems, it could be dangerous for everyone who flies.