Yesterday's Aviation Catastrophe Involved the Same Aircraft Warned About by a Previous Deceased Boeing Insider
The Boeing 787 Dreamliner, launched in 2011 with the promise of more affordable production, has been embroiled in a series of controversies due to persistent safety and quality-control issues.
At the heart of the controversy are allegations of improper fuselage assembly, defective parts, and systemic quality control breakdowns. Multiple whistleblowers, including former Boeing engineer Sam Salehpour, have reported that sections of the Dreamliner’s fuselage were improperly fastened, a practice known as the "Tarzan effect" that risks deforming parts and potentially compromising the aircraft's structural integrity and lifespan.
A notable scandal involved an Italian supplier, MPS, providing titanium structural parts made from a lower-strength alloy than specified, affecting nearly 500 in-service Dreamliners. Issues with fuselage gaps filled improperly with shims, defects in horizontal stabilizers, and internal quality lapses across Boeing’s facilities have persisted.
Regulatory bodies, including the Federal Aviation Administration (FAA), have conducted multiple investigations into these problems. In response, Boeing halted 787 deliveries from May 2021 to August 2022 to address fuselage gap issues, and as of May 2025, the FAA ordered Boeing to reinspect all 787s still in production and develop plans for the in-service fleet.
Safety incidents linked to manufacturing defects have also come to light. In March 2024, a 787 flight experienced a sudden plunge due to a pilot seat lurching forward unexpectedly, injuring passengers and crew. The recent Air India Flight 171 crash is also under investigation with respect to the 787’s safety.
Critics have long expressed concern about the 787's overly complicated assembly process, which involves a convoluted network of contractors offering limited transparency. Analysts point to Boeing's failed corporate culture prioritizing fast production over proper testing and quality controls, as well as the extensive outsourcing model for the 787 production, contributing to delays, quality problems, and higher costs.
Former quality manager at Boeing, John Barnett, warned last year that the factory producing the 787 Dreamliner had shoddy work practices and poor oversight. Barnett, who refused to fly on the Dreamliner and was involved in a legal dispute with the company at the time of his death, ruled an apparent suicide, accused Boeing of using sub-standard parts and building planes with a mandate of speed and efficiency that endangered lives.
Salehpour accused Boeing of being involved in a "criminal cover-up" and implied that something could "happen" to him due to his outspoken criticism. Another whistleblower who spoke out also died. Boeing admitted to other potential misconduct at the company.
In sum, the Boeing 787 Dreamliner controversy is driven by persistent quality and safety concerns rooted in flawed assembly practices, supplier fraud, inadequate regulatory compliance, and a corporate culture that pushed production at the expense of thorough quality assurance and employee concerns. These issues continue to attract regulatory enforcement and industry criticism, raising questions about the aircraft’s long-term reliability and passenger safety.
The Boeing 787 Dreamliner's controversies revolve around improper assembly, defective parts, and systemic quality control breakdowns, as reported by whistleblowers like Sam Salehpour. For instance, the "Tarzan effect" was found to be a practice involving the improper fastening of fuselage sections. The aviation industry and even finance, as Boeing's corporate culture has been criticized for prioritizing fast production over proper testing and quality controls. Critics also caution against the overly complicated assembly process, which involves a network of contractors offering limited transparency. Additionally, regulatory bodies have ordered Boeing to reinspect all Dreamliners still in production and develop plans for the in-service fleet due to safety incidents linked to manufacturing defects. The future of the Boeing 787 Dreamliner remains uncertain, with questions about its long-term reliability and passenger safety persisting.
