Boeing will be delaying delivery of new 787s because of new safety issues.

Once again, Boeing’s MBA driven culture has led to it cutting corners, and the FAA has called foul.

It appeared that faith based safety procedures are not looked upon favorably by the regulatory authorities:

Boeing Co. has halted deliveries of its 787 Dreamliners, adding fresh delays for customers following a recent five-month suspension in handing over the aircraft due to production problems, people familiar with the matter said.

Federal air-safety regulators have requested more information about Boeing’s proposed solution to address the previously identified quality lapses, these people said.

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A Boeing spokesman said the company was working in a timely and transparent manner to provide regulators with more information related to undelivered 787s. The Federal Aviation Administration on Friday confirmed that Boeing had halted Dreamliner deliveries, saying that the plane maker needs to demonstrate that its proposed inspection method complies with federal-safety regulations.

There are statistical methods to validate these procedures, it’s just that Boeing couldn’t be bothered to take the time, because there were union members to be laid off.

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The FAA launched a review of Boeing’s Dreamliner production last year and has increased scrutiny of its 737 MAX manufacturing operations following earlier factory slip-ups.

As part of its Dreamliner scrutiny, the agency has recently requested more information about the plane maker’s proposed method for addressing quality issues using a system that would allow for targeted checks of newly produced aircraft, rather than broader inspections of more areas, people familiar with the matter said. Boeing’s proposed method is based on a statistical analysis of data.

Until Boeing can satisfy the FAA’s requests, the agency is requiring Boeing to perform the broader inspections, which are more time-consuming and labor-intensive, these people said.

Many of the 787 quality lapses involve tiny gaps where sections of the jet’s fuselage, or body of the plane, join together. Problems have emerged in other places, too, including the vertical fin and horizontal stabilizer at the tail. Such gaps could lead to eventual premature fatigue of certain portions of the aircraft, potentially requiring extensive repairs during routine, long-term maintenance.

This is a problem with composite structures.  Unlike aluminum, things need to fit exactly, since you there is very little flexing to accommodate tolerance stack-up.

You have to get these shims right, or you get point loads, which are death to composites.

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Boeing has reduced output of the Dreamliner to five a month after shuttering assembly at its Everett, Wash., plant near Seattle and focusing production at North Charleston, S.C. It had built up a backlog of around 100 finished planes by the end of April, and had hoped to deliver most of them by the end of the year.

Yes, the South Carolina plant, which (by their own admission) they opened just to punish and weaken the union, which has poor training, poor morale, and poor safety procedures.

The management at Boeing does not know how to make airliners, and holds the people who do in deep disdain, and it shows.

When do the crashes start?  

My bad, they already have.