The Federal Aviation Administration (FAA) recently conducted a six-week audit of Boeing’s production of the 737 Max jet and found dozens of issues throughout the manufacturing process, including problems at both Boeing and its key supplier, Spirit AeroSystems. The audit was initiated after a door panel blew off a 737 Max 9 during an Alaska Airlines flight in early January.

In a slide presentation reviewed by The New York Times, it was revealed that the FAA found “multiple instances” where Boeing and Spirit AeroSystems failed to comply with quality-control requirements. The presentation provided a detailed picture of the audit findings, highlighting 97 instances of alleged noncompliance at Boeing and 7 failing audits at Spirit AeroSystems.

One particularly concerning finding was the observation of Spirit mechanics using a hotel key card to check a door seal, which was not documented in the production order. In another instance, mechanics were seen using liquid Dawn soap as a lubricant for a door seal, with unclear instructions on the proper procedures to follow. Both Boeing and Spirit have stated their commitment to addressing these issues and improving safety and quality standards.

The FAA has given Boeing 90 days to develop a plan for quality-control improvements, in response to which Boeing’s CEO, Dave Calhoun, acknowledged the need for immediate changes. Boeing is also in talks to acquire Spirit AeroSystems, with the goal of reducing defects and errors in the production process to zero.

The FAA’s examination included as many as 20 auditors at Boeing and several at Spirit, covering various aspects of the 737 Max production. Many of the issues found by auditors were related to not following approved manufacturing processes or quality-control documentation. The audit also assessed employees’ understanding of quality-control processes, with an average score of 58 percent among interviewed engineers.

Overall, the audit revealed significant lapses in quality control at both Boeing and Spirit AeroSystems, raising concerns about the safety and reliability of the 737 Max jet. The FAA’s ongoing investigation, along with inquiries by other agencies, underscores the seriousness of the issues uncovered during the audit. Boeing and Spirit have committed to addressing these issues and implementing necessary changes to improve safety and quality standards in their production processes.