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NTSB Finds Boeing and FAA Failures Led to Door Plug Blowout on 737 Max

Missing bolts plus oversight failures are blamed for the January 2024 blowout prompting redesigned plugs under stricter safety protocols

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, Oregon, U.S. January 7, 2024.  NTSB/Handout via REUTERS/File Photo
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TOPSHOT – US President Donald Trump addresses the nation, alongside US Secretary of State Marco Rubio (R) from the White House in Washington, DC on June 21, 2025, following the announcement that the US bombed nuclear sites in Iran. President Donald Trump said June 21, 2025 the US military has carried out a “very successful attack” on three Iranian nuclear sites, including the underground uranium enrichment facility at Fordo. “We have completed our very successful attack on the three Nuclear sites in Iran, including Fordow, Natanz, and Esfahan,” Trump said in a post on his Truth Social platform. (Photo by Carlos Barria / POOL / AFP) (Photo by CARLOS BARRIA/POOL/AFP via Getty Images)
National Transportation Safety Board chairman Jennifer Homendy speaks during a meeting about Alaska Airlines Flight 1282, Tuesday, June 24, 2025. (AP Photo/Julia Demaree Nikhinson)

Overview

  • The NTSB’s 17-month probe concluded that missing bolts plus insufficient FAA oversight triggered the midair blowout of a door plug panel on Flight 1282 in January 2024.
  • Boeing factory workers reported that production speed pressures and insufficient training led to four securing bolts being omitted during a rivet repair at the Renton plant.
  • NTSB Chair Jennifer Homendy criticized Boeing’s safety culture plus FAA audit gaps as systemic failures that should have been identified pre-delivery.
  • CEO Kelly Ortberg has launched new safety reforms plus appointed a senior vice president of quality, overseeing a redesigned door plug with a redundant backup system due for FAA approval in 2026.
  • The FAA has capped 737 Max output at 38 jets per month, regulators are enforcing tougher manufacturing standards plus Boeing faces passenger lawsuits and a Justice Department probe.