Boeing and FAA Under Fire After Alaska Airlines Door Blowout: “This Never Should Have Happened,” Say Investigators
June 25, 2025 – The alarming incident involving an Alaska Airlines flight last year, where a door plug tore off midair, is now being described as entirely preventable by federal investigators. In a scathing new report, the National Transportation Safety Board (NTSB) has pointed fingers at both Boeing and the Federal Aviation Administration (FAA) for systemic failures that nearly led to a disaster.
What Happened?
In early 2024, an Alaska Airlines Boeing 737 MAX 9 experienced a terrifying midair event: a door panel (called a door plug) blew out, leaving a massive hole in the fuselage. Miraculously, no one was seriously injured. But the chaos and fear onboard — flight attendants trying to secure the area, passengers panicking, and pilots struggling to communicate in a depressurized cabin — revealed something deeper than a single malfunction: a breakdown in aviation safety culture.
NTSB: Boeing and FAA Both to Blame
NTSB Chair Jennifer Homendy didn’t mince words. Opening Tuesday's public hearing, she stated plainly:
“This should have never happened.”
The investigation determined the root causes:
- Boeing failed to provide structured training for its manufacturing employees working on the door plug area. Many workers learned on the job without formal guidance.
- Work tracking at Boeing was inadequate, with missing documentation about who installed key components.
- FAA oversight was weak, lacking the tools or protocols needed to catch major production errors.
Homendy emphasized:
“Aviation accidents aren’t caused by one person. They happen when systems — multiple systems — fail.”
Recommendations (That Can’t Be Enforced)
While the NTSB laid out several clear recommendations — improved employee training, better work verification, and more robust tracking — the agency has no legal authority to force compliance.
Still, Boeing claims it has already begun implementing changes. A company spokesperson said it’s committed to “strengthening safety and quality” and is reviewing the NTSB’s findings.
The FAA’s “Last Line of Defense” Questioned
The FAA also received heavy criticism during the hearing. Homendy pointedly asked:
“Where was the FAA during all of this?”
The agency admitted it had been “too hands-off” in its supervision of Boeing, especially during the 737 MAX’s production. Since the incident, the FAA has tightened oversight:
- Imposed a cap on 737 MAX production.
- Temporarily grounded the MAX 9 fleet for inspections.
- Sent more inspectors into Boeing facilities.
- Required weekly updates from the company.
Transportation Secretary Sean Duffy made it clear:
“The FAA won’t lift the 737 production cap until Boeing can consistently meet rigorous safety standards.”
Behind the Scenes: Whistleblowers and Safety Concerns
The situation at Boeing is more troubling than just a one-off incident. Multiple whistleblowers have testified in congressional hearings, accusing the company of prioritizing speed over safety. One engineer told the Senate he was told to “shut up” when he raised concerns. Others described a corporate culture where safety warnings were ignored or buried.
The NTSB echoed this in their findings, criticizing Boeing for not properly documenting who installed the door plug and for failing to ensure the bolts that secured it were even in place.
Human Impact: A Mother’s Fear
Though no one was killed, the emotional toll was significant. One flight attendant had to comfort a mother who feared her child had been sucked out of the aircraft. Pilots resorted to hand signals because of the noise from cabin depressurization.
Homendy underscored the gravity of the event:
“This put 177 lives in jeopardy. It’s a miracle no one was killed.”
Moving Forward
Despite the crisis, both Boeing and the FAA say they are committed to fixing what went wrong. The NTSB believes that with accountability and action, the U.S. aviation industry can once again lead in safety.
“I believe Boeing, Spirit AeroSystems, and the FAA will take these lessons to heart,” Homendy said.
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