Dreamliner Safety Is the "Safest Plane" Title Up in the Air?

How Safe is the Boeing 787 Dreamliner, Really?

The recent tragic Air India crash, claiming the lives of at least 270 people, has understandably cast a shadow over the aviation industry. While the investigation is still underway, the incident has brought renewed scrutiny to the aircraft involved: the Boeing 787 Dreamliner. Until now, this plane was considered one of Boeing's safest.

For nearly a decade and a half, the 787 has operated without a major accident or any fatalities. According to Boeing, it has carried over a billion passengers across the globe. With over **1,100 currently in service worldwide**, the Dreamliner has become a mainstay of modern air travel. But is its reputation truly deserved?

This post delves into the safety record of the Boeing 787, examining its history, design innovations, and the controversies that have plagued its production.

A Revolutionary Design Born from Crisis

The Dreamliner's story began in the early 2000s, amidst rising oil prices. Boeing sought to create a fuel-efficient, long-haul aircraft. Aviation historian Shea Oakley explains that Boeing initially focused on speed with the "Sonic Cruiser," but the 9/11 attacks shifted airline priorities to fuel economy. Airlines wanted something like the Sonic Cruiser, but more economical.

The 787 emerged as a radical departure from conventional designs:

• Composites over Aluminum: It was the first commercial plane built primarily with lightweight carbon fiber composites, reducing weight and fuel consumption.
• Aerodynamic Advancements: Enhanced aerodynamics minimized drag.
• Efficient Engines: Modern engines from General Electric and Rolls Royce maximized fuel efficiency.
• Electrical Systems: Lighter electrical systems replaced many mechanical and pneumatic components.

Boeing claimed that these innovations would make the 787 **20% more efficient than the Boeing 767**, with a significantly smaller noise footprint.

Early Troubles and Production Woes

Despite the initial excitement, the 787 faced early hurdles. In 2013, battery fires on parked and in-flight 787s led to a global grounding of the aircraft. Boeing implemented a solution, but the incident raised serious questions about the plane's reliability.

Production problems also surfaced, partly attributed to the establishment of a second assembly line in North Charleston, South Carolina. Analyst Richard Aboulafia noted "serious development issues" related to this decision.

Whistleblower Allegations: A Persistent Shadow

Perhaps the most concerning aspect of the 787's safety narrative is the consistent stream of whistleblower allegations. Former and current employees have raised serious concerns about production standards and quality control.

The late John Barnett, a former quality control manager, claimed that pressure to speed up production compromised safety. He alleged:

• Workers failed to follow procedures to track components.
• Substandard parts were deliberately fitted to aircraft.
• Defective fixings were used, creating metal shavings near wiring.

The FAA partially upheld Barnett's claims, confirming that at least 53 "non-conforming" parts had gone missing.

More recently, Sam Salehpour, a current Boeing employee, testified before Congress about shortcuts in assembly processes that could lead to "a catastrophic failure." He highlighted improperly rectified gaps in fuselage joints, which could result in "premature fatigue failure." Boeing denies these claims, asserting that the 787's structural integrity is sound and the issues have been rigorously examined under FAA oversight.

A Mixed Verdict: Safety Record vs. Lingering Concerns

Despite the controversies, the Boeing 787 has flown for 16 years, transported a billion passengers, and had no crashes until now, which speaks volumes. Richard Aboulafia argues that any major issues would likely have surfaced by now.

However, the Foundation for Aviation Safety has expressed concerns, particularly regarding water leaks from washrooms into electrical equipment bays. The FAA has instructed airlines to conduct regular inspections in response to these reports.

The recent Air India crash serves as a stark reminder of the importance of rigorous safety standards and thorough investigations. While the cause remains unknown, it is crucial to address any potential vulnerabilities in the 787, whether related to the aircraft, the airline, or other factors.

For now, the 787's safety record remains statistically strong. Scott Hamilton of Leeham Company stated, "Based on what we do know about the plane, I would not hesitate to get on board a 787."

Ultimately, the safety of the Boeing 787 Dreamliner is a complex issue. While its operational history suggests a high level of safety, the persistent whistleblower allegations and recent tragedy underscore the need for constant vigilance and a commitment to the highest standards of quality control. The ongoing investigation into the Air India crash will be crucial in determining the path forward and ensuring the continued safety of air travel.

Source: https://www.bbc.com/news/articles/cwyq7vgq2e5o