On June 12, the 242 individuals aboard Air India flight 171 from Ahmedabad, India, to London had statistics on their side. They were flying on a Boeing 787 Dreamliner, a model that has been in operation since 2011 without a single fatal accident. Boeing reports that over 1,100 Dreamliners are currently in service globally, having transported passengers for over a decade. The specific 787 used for this flight was delivered to Air India in 2014, according to , an aviation analytics company.
Unfortunately, these facts offered no protection. Shortly after takeoff, at a mere 625 feet altitude, the aircraft lost height and crashed into a populated area, resulting in the death of all but one person on board. The cause of the accident is currently unknown.
Boeing’s President and CEO, Kelly Ortberg, stated, “We extend our deepest sympathies to the families and friends of those on Air India Flight 171, as well as to everyone in Ahmedabad affected by this tragedy. I have contacted Air India Chairman N. Chandrasekaran to offer our complete assistance, and a Boeing team is prepared to assist the investigation led by the Aircraft Accident Investigation Bureau of India.”
The investigation will likely extend beyond Flight 171, revisiting the 14 years the 787 has been in service – a period marked by numerous complaints, concerns, and whistleblower reports regarding the safety of this wide-body aircraft. These issues are now being re-examined.
The problems initially surfaced in early 2013, involving belonging to Japanese airlines. One aircraft had just landed at Boston’s Logan Airport, while the other was departing Japan and was forced to return. Both incidents were linked to overheating lithium-ion batteries responsible for powering the planes’ electrical systems. The FAA responded swiftly by grounding the entire global fleet of Dreamliners and temporarily suspending deliveries of new planes. In April 2013, the FAA that included improved battery insulation and a stainless-steel enclosure to contain any potential smoke or flames in the event of a fire. Following the FAA’s decision, the Dreamliners were authorized to resume flights, and Boeing was allowed to continue deliveries within a few weeks.
Another incident occurred in 2019 when John Barnett, a former quality manager who retired in 2017, in an exposé, alleging substandard workmanship concerning the wiring of the plane’s flight control systems. He claimed that metal shavings were left behind during bolt fastening, posing a risk of penetrating the wire insulation, which Barnett warned could have “catastrophic” consequences.
Barnett also claimed that damaged or non-compliant components were being installed in 787s, citing a dented hydraulic tube that a senior manager allegedly retrieved from a scrap bin. The Times reported that the FAA inspected several 787s supposedly free of the shavings reported by Barnett and confirmed their presence. The FAA subsequently mandated that Boeing rectify these issues before delivering the aircraft to customers.
After retirement, Barnett filed a lawsuit against Boeing, of damaging his reputation and hindering his career advancement during his time with the company – accusations Boeing denies. In March 2024, while in North Charleston, S.C., where he had been employed, working on his case, he was from a self-inflicted gunshot.
Barnett’s family stated in a that Boeing’s actions were the “clear cause,” even if “Boeing may not have pulled the trigger.”
Boeing responded to the accusation by stating, “We are saddened by John Barnett’s death and send our condolences to his family,” in a statement.
The previous year proved challenging for Boeing and the Dreamliner, in part due to Barnett’s death. In January , engineer Sam Salehpour reported that the fuselage sections of the Dreamliner were improperly joined, leaving gaps that could lead to the aircraft disintegrating during flight. Salehpour alleged that workers resorted to excessive force when the sections didn’t align.
Salehpour stated, “I literally saw people jumping on the pieces of the airplane to get them to align… By jumping up and down, you’re deforming parts so that the holes align temporarily. I called it the Tarzan effect.”
, Boeing defended the Dreamliner’s structural integrity, stating that “For the in-service fleet, based on comprehensive analysis no safety issues have been identified related to composite gap management and our engineers are completing exhaustive analysis to determine any long-term inspection and maintenance required, with oversight from the FAA.”
Nevertheless, in May, the announced that Boeing was instructed to re-inspect “all 787 airplanes still within the production system and must also create a plan to address the in-service fleet.” This wasn’t the first instance of government intervention regarding the issue of unacceptable gaps in the Dreamliner’s fuselage. From May 2021 to August 2022, the of new Dreamliner deliveries to airlines while the problem was addressed. Deliveries eventually resumed, but, according to Salehpour’s testimony, so did the questionable practices on the factory floor.
Meanwhile, in March 2024, a LATAM Airlines flight from Sydney to Auckland when the pilot’s seat in the 787 suddenly moved forward. The captain regained control, but 10 passengers and three cabin crew members sustained injuries.
Currently, the 1,100 Dreamliners continue to operate. This situation could change depending on the outcome of the Air India investigation. Even a temporary grounding of the aircraft, which is essential for long-distance routes, could create difficulties for airlines and travelers. However, as the grieving families of those on the Air India flight would confirm, loss of life is a far greater tragedy.
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