FAA has doubled the cases it has opened against Boeing

The increase in cases was disclosed Wednesday during a National Transportation Safety Board hearing into the accident, which happened during an Alaska Airlines flight on Jan. 5.

Brian Knaup, who helps manage the FAA’s oversight of Boeing, said one of the open cases involves the removal of parts that have already been installed on airplanes in production.

That is apparently what caused the mistake that led to the Alaska Airlines accident: Bolts that were removed to open the door plug for maintenance workers were not replaced when the panel was closed and the plane left a Boeing factory near Seattle.

Knaup’s comment came near the end of a two-day hearing that included discussion of Boeing’s poor tracking of parts-removal jobs. The company failed to document who opened the door plug, and the missing bolts were never found.

Another FAA official overseeing Boeing, Bryan Kilgroe, said he is kept awake at night wondering “especially considering all that has happened since Jan. 5, is why is it so difficult to sustain a corrective action for the long term?”

Boeing said it had no comment.

The safety board released released testimony by Boeing employees who said they were pressured to build planes too quickly and not raise safety concerns.

NTSB Chair Jennifer Homendy cited two employees who worked on aircraft doors where the Alaska Airlines plane was assembled and claimed they were moved to other areas — “Boeing prison” and “a cage” — after the door-plug blowout.

“What sort of impression does that give your employees if you sideline them …? It is retaliation,” Homendy said. She said “sidelining” the two workers runs against Boeing’s policy, which is not to retaliate against workers for unintentional mistakes.

Homendy said the NTSB will survey workers at Boeing’s factory in Renton, Washington, where the Alaska Airlines plane was produced, about the company’s safety culture.

Representatives from Boeing and key supplier Spirit AeroSystems described their “safety management systems,” which encourage employees to voluntarily report safety concerns without fear of punishment. Boeing officials touted their “Speak Up” program for reporting concerns about quality and safety.

However, the…