Investigators Say the Incident ‘Never Should Have Happened’

The National Transportation Safety Board has published its findings on an incident in 2024 involving a door panel flying off of an Alaska Airlines B737 MAX 9. Investigators all seem to agree that the event was completely preventable, citing poor training at Boeing and insufficient FAA oversight.

The incident involved a door panel detaching mid-flight, leaving a gaping hole in the fuselage but, miraculously, no injuries. Faulting both the FAA and Boeing for overlooking multiple red flags, NTSB Chair Jennifer Homendy was not scared to say that the accident “never should have happened” during a recent public hearing.

The NTSB explained that Boeing lacked structured training for workers tasked with removing and reinstalling door plugs, which are critical components to cabin pressurization. Instead, employees learned through informal, on-the-job methods. Investigators also found Boeing’s work documentation process to be flawed, with no clear record of who performed maintenance on the failed aircraft.

Meanwhile, the FAA was criticized for ineffective audits, oversight gaps, and a failure to detect or correct Boeing’s quality control lapses. Homendy added that she had “lots of questions about where the FAA was during all of this.”

The NTSB recommended improvements to Boeing’s training and documentation systems. While these comments cannot be enforced, Boeing and fuselage supplier Spirit AeroSystems have already begun implementing changes, including a new door plug retention system. This is now undergoing FAA certification.

The FAA responded by noting it has since increased its on-site presence at Boeing facilities, capped 737 MAX production, and required more audits and inspections. But even former FAA leadership admitted the agency had been “too hands off” in its regulatory role.

FMI: www.ntsb.gov