Washington——

The head of the Federal Aviation Administration said on Wednesday that Boeing Co. must develop a comprehensive plan to address “systemic quality control issues” within 90 days after an in-flight emergency last month reignited safety concerns.

The head of the Federal Aviation Administration (FAA) issued a statement criticizing the plane maker after an all-day meeting with Chief Executive Dave Calhoun on Tuesday calling for the plan.

“Boeing must commit to real and profound improvements,” FAA Administrator Mike Whitaker said in a statement. “Achieving fundamental change will require a sustained effort from Boeing leadership, and we will hold them accountable every step of the way.” accountability and set mutually understood milestones and expectations.”

Calhoun said in a statement that Boeing’s leadership team is “fully committed” to addressing the FAA’s concerns.

“We know exactly what needs to be done,” Calhoun said in a statement. “Boeing will develop a comprehensive action plan with measurable criteria to demonstrate the profound changes required by Administrator Whitaker and the FAA. “

On January 5, a door panel of a brand-new Alaska Airlines 737 Max 9 passenger plane fell off during a flight, forcing the pilot to make an emergency landing and leaving passengers exposed in a large hole 16,000 feet above the ground. Boeing urgently explained and strengthened safety procedures .

Boeing’s production rates have been capped by regulators and closely scrutinized by lawmakers and customers following the Jan. 5 incident, and the new announcement raises new questions about how long the production pause will last.

Whitaker said Boeing’s plan must incorporate the findings of an upcoming FAA audit of the production line and an expert review panel report released earlier this week.

The report, commissioned in early 2023, was highly critical of the company’s safety management processes, saying Boeing suffered due to “inadequate and confusing implementation of various components of a proactive safety culture.”

Boeing abruptly fired Ed Clark, head of the troubled 737 Max program, last week as part of a management shakeup.

Shares rose 2.3% on Wednesday.

‘systemic change’

The FAA said on Wednesday that Boeing must take steps to improve its safety management system (SMS) program, which it committed to in 2019, and integrate it with its quality management system to “achieve measurable and systematic performance in manufacturing quality control.” change”.

On February 12, Whitaker visited Boeing’s factory in Renton, Washington, where the 737 Max series is produced. Two people familiar with the matter told Reuters that Whitaker expressed concerns about some of the things he saw during the tour.

Sources said the FAA’s meeting with Calhoun lasted more than seven hours, with much of it focusing on a series of quality issues at the plane maker.

“Boeing must reexamine every aspect of its quality control process and ensure safety is the company’s guiding principle,” Whitaker said.

The Alaska Airlines accident is Boeing’s second major crisis in recent years, following Max crashes in 2018 and 2019 that killed 346 people. This resulted in a 20-month grounding of the 737 Max and damaged Boeing’s reputation.

The FAA panel’s report cited the recent issues, saying they had heightened concerns that “safety-related information or actions are not being implemented throughout Boeing.”

Aviation executives expressed frustration with Boeing’s quality controls. France’s Airbus, the only major commercial plane maker, reported a record annual aircraft order in January and confirmed an 11% increase in deliveries for 2023, retaining its position as the largest manufacturer alongside Boeing Co for the fifth consecutive year.

The FAA grounded the Max 9 for several weeks in January and restricted Boeing Max production after a series of quality issues while it conducted an audit of the manufacturing process.

A door panel that flew off a Max 9 appears to be missing four key bolts, according to a preliminary report from the National Safety Transportation Board this month. The panel on some 737 Max 9s is a plug, not an additional emergency exit.

The door jam in question was reportedly removed to repair rivet damage, but the NTSB has found no evidence that the bolts were reinstalled.

The disclosure angered Boeing’s airline customers. Some companies, including Alaska Airlines, have announced they will conduct enhanced quality oversight of planes before they leave Boeing plants.