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NTSB Finds Manufacturing and Oversight Failures Behind Alaska Airlines Door Plug Blowout

Following a 17-month probe, the board will approve safety recommendations with Boeing beginning a redesign of the door plugs to include an additional retention system under enhanced FAA supervision.

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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Overview

  • The NTSB concluded that missing bolts on a replaced door plug panel, removed during rivet repairs and never reinstalled, caused the midair blowout on Flight 1282 in January 2024.
  • Investigators cited multiple system failures, including Boeing’s inadequate training, guidance and oversight of factory workers, and gaps in the FAA’s inspection system.
  • Boeing and Spirit AeroSystems have started redesigning the door plugs to include a backup retention mechanism, slated for FAA certification by 2026 at the earliest.
  • The FAA has overhauled its oversight approach, maintaining a 38-jets-per-month production cap on the 737 Max until Boeing demonstrates consistent quality improvements.
  • The NTSB is expected to publish its final report in the coming weeks and will vote on recommendations aimed at preventing similar incidents in the future.