FAA Opens Investigation Into Boeing Over In-Flight Door Plug Blowout and Other ‘Discrepancies’

The damaged part of an Alaska Airlines Boeing 737 Max 9, Flight 1282, which was forced to return to Portland International Airport on Jan. 5, 2024. The Oregonian via AP

Boeing says it’s fully cooperating with an investigation launched by federal aviation authorities to determine if the planemaker failed to ensure completed products adhered to approved designs and met safety standards after an emergency door plug blew off in mid-flight.

The Federal Aviation Administration (FAA) announced on Jan. 11 that it had launched an investigation to determine if Boeing “failed to ensure completed products conformed to its approved design and were in a condition for safe operation” in compliance with federal regulations.

The probe comes after a Boeing Model 737 Max 9 aircraft operated by Alaska Airlines lost a door plug—a panel covering an unused emergency door on the jetliner—blew out in-flight, leaving a gaping hole and leading to rapid cabin decompression.

‘It Cannot Happen Again’

While no one was seriously hurt and the plane made a safe emergency landing, the incident has prompted increased scrutiny of the planemaker by federal authorities, who ordered the Max 9 model planes grounded for inspection.

“This incident should have never happened and it cannot happen again,” the FAA said in the statement, adding that it had formally notified Boeing of the investigation, which was prompted by the door plug blowout and “additional discrepancies.”

Alaska Airlines and United Airlines (the only two U.S. carriers operating the Max 9) both grounded their Max 9 fleets and have been carrying out the FAA’s newly mandated “enhanced inspections,” which include both left and right cabin door exit plugs, door parts, and fasteners such as bolts.

United Airlines, which operates 79 of the Max 9 jets, told The Epoch Times in an earlier statement that it had found issues related to the installation of door plugs, including loose bolts.

The FAA said it’s taking the matter seriously and passenger safety is its top priority as the agency proceeds with its probe.

“Boeing’s manufacturing practices need to comply with the high safety standards they’re legally accountable to meet,” the FAA said. “The safety of the flying public, not speed, will determine the timeline for returning the Boeing 737-9 Max to service.”

Boeing said in a statement obtained by The Epoch Times that it “will cooperate fully and transparently with the FAA and the NTSB on their investigations,” while Boeing President and CEO Dave Calhoun told an all-employee safety meeting on Jan. 9 about the company’s approach to the grounding and the FAA’s order for ”enhanced inspections” of the jets.

“We’re going to approach it with 100% complete transparency every step of the way,” Mr. Calhoun said.

The FAA’s investigation is the latest development in an air safety saga that began when the door plug blew off an Alaska Airlines flight on Jan. 5, forcing the pilot to make an emergency landing.

The fuselage plug area of Alaska Airlines Flight 1282 Boeing 737-9 MAX, which was forced to make an emergency landing with a gap in the fuselage, is seen during its investigation by the National Transportation Safety Board (NTSB) in Portland, Ore., on Jan. 7, 2024. NTSB/Handout via Reuters

The Incident

Alaska Airlines Flight 1282 was about six minutes into its flight en route to Ontario, California, from Portland, Oregon, when the harrowing incident occurred.

The door plug blowout took place when the aircraft reached an altitude of about 16,000 feet. The pilot declared an emergency, notifying air traffic control of a depressurization issue.

Social media footage showed a window and a portion of a side wall panel missing on the airplane and oxygen masks deployed.

None of the 171 passengers or six crew members were seriously injured.

National Transportation Safety Board (NTSB) Chair Jennifer Homendy said the two seats next to the part that tore off were unoccupied.

The new Boeing 737 MAX 9 was delivered in late October to Alaska Airlines and certified in early November, according to FAA data.

The door plug from Alaska Airlines Flight 1282 in Portland, Ore., on Jan. 8, 2024. National Transportation Safety Board via AP

The door plug incident prompted the FAA to issue an emergency directive requiring immediate inspections of Boeing 737 Max 9 planes before they can be returned to service because the agency determined the unsafe condition “is likely to exist or develop in other products of the same type design.”

Besides mandating the enhanced inspections of the Max 9 planes, the FAA also required carriers to fix any issues they discover before the aircraft can be returned to service.

United told The Epoch Times on Monday that it found bolts that needed additional tightening while inspecting its Max 9 planes.

The carrier added that its technicians would remedy the problems and “safely return the aircraft to service,” adding that it was still waiting for final approval from the FAA on the full inspection process.

Alaska Airlines, which operates 65 of the Max 9 planes, expressed regret for the incident and for the disruption to travel (both it and United were forced to cancel hundreds of flights).

“We have made the decision to cancel all flights on 737-9 MAX aircraft through Saturday, Jan. 13 while we conduct inspections and prepare fully for return to service,” Alaskan Airlines said in a statement.

The cancellation equates to roughly 110–150 flights per day.

“My heart goes out to those who were on this flight—I am so sorry for what you experienced,” Ben Minicucci, CEO of Alaska Airlines, said in a statement.