Strengthening Safety & Quality

Introduction

On Jan. 5, 2024, a mid-exit door (MED) plug detached from the left side of a 737-9 carrying 171 passengers and crew, leading to a rapid decompression. The pilots and cabin crew brought the airplane and everyone onboard safely back to the ground.

Boeing continues to fully cooperate with the U.S. National Transportation Safety Board (NTSB) and the Federal Aviation Administration (FAA) in their investigations. 

Our Safety & Quality Plan

Boeing took immediate action last January to ensure the safety of our fleet and production operations for all of our airplanes.

Then, we gathered feedback from our employees, regulator, customers and independent experts to develop a comprehensive plan that strengthens our safety management, quality assurance and safety culture across our production systems.

Boeing’s Safety & Quality Plan generally aligns to four focus areas: investing in workforce training, simplifying plans and processes, eliminating defects, and elevating our safety and quality culture. The plan also sets forth measures to continuously monitor and manage the health of our production system.

We are committed to this plan and to continuous improvement, which has helped make commercial aviation the safest mode of transportation.

Updated: 06/24/2025

Invest in Workforce Training icon
  • Conducted mandatory Product Safety and Quality Training for all employees.
  • Strengthened training for mechanics and quality inspectors with an enhanced support system, including workplace coaches, peer trainers, and skill enhancement centers.
  • Added more than 550 hours of new curriculum to training programs, including quality proficiency, Safety Management System (SMS) Positive Safety Culture, and critical skills.
  • Enrolled more than 2,500 employees in our Foundational Training Center.
  • Digitized the foundational training system to strengthen employee performance tracking and their completion of critical tasks.
  • Deployed revised removals and stamping training for production teammates.
Simplify Plans and Processes icon
  • Instituted random quality audits of documented removals in high frequency areas to ensure compliance to process.
  • Simplified removal process instructions, reducing length of the governing document by 50% while increasing clarity and enabling compliance for employees.
  • Mapped and prepared thousands of governance documents and work instructions for revision.
  • Released more than 1,000 simplified installation plans into 737 production and began launching “how to” videos to supplement instructions.
  • Performed dozens of internal design build audits across airplane programs to determine further opportunities for production improvements and revised standards for inspectors.
  • Updated “stamping” system for mechanics and quality inspectors to display employee names on stamps for completed work.
Eliminate Defects icon
  • Reduced defects in 737 fuselage assembly at Spirit AeroSystems by more than 50% through increasing inspection points at build locations and implementing customer quality approval process.
  • Piloted tool control centralized ownership in targeted 737 and 787 final assembly areas improving compliance and reducing tool loss by 85%.
  • Launched tool control RFID pilot on the 787 program adding unique RFID tags to more than 3,000 tools.
  • Developed embedded management and metrics for FOD (foreign object debris) prevention in critical work areas.
  • Launched work instruction adherence checks as a standard operating rhythm in production to ensure mechanics and inspectors are proficient and resourced.
  • Implemented a new Work in Process (WIP) system and procedure in 737 and 787 final assembly that tracks and secures parts for manufacturing work that is not yet complete to prevent loss or improper use.
Elevate Safety and Quality Culture icon
  • Addressed over 96% of action items in commercial airplane production based on employee feedback during Quality Stand Down sessions.
  • Launched quarterly, manager-led safety and quality events across Commercial Airplane programs to share ideas and strengthen culture.
  • Implemented more than 1,300 Employee Involvement Teams across Airplane Programs and Fabrication, to bring teammates from different work disciplines together to raise and solve issues, ask questions, and offer assistance.
  • Deployed a leadership development training program for all Manufacturing, Quality and Fulfillment managers.
  • Assessed over 2,000 line moves with “move ready” criteria across airplane programs, reducing traveled work by 50% at rollout for the 737 and 787 programs.
Highlighting enhancements throughout 737 MAX Final Assembly

Key Performance Indicators (KPIs)

A significant component of our Safety & Quality Plan is the identification of six key performance indicators (KPIs) focused on safety and production health:

  • Employee proficiency measures share of employees currently staffed who are deemed proficient in core skills.
  • Notice of Escape (NoE) rework hours measures time performing rework due to non-conforming work from Fabrication and suppliers.
  • Supplier shortages measures shortages per day from Fabrication and suppliers.
  • Rework hours per airplane measures time spent performing rework in Final Assembly.
  • Travelers at factory rollout measures unfinished jobs traveling from Final Assembly.
  • Ticketing performance measures quality escapes per ticketed airplane prior to delivery.

Each KPI has defined criteria that help identify areas of potential risk to our operations and trigger corrective action through our Safety Management System (SMS). These metrics have helped Boeing conduct more targeted safety risk assessments in priority areas and maintain production health.

Aircraft Certification, Safety, and Accountability Act (ACSAA)

We have developed detailed plans and deliverables for each recommendation from the FAA’s Expert Review Panel, which was convened per the Aircraft Certification, Safety, and Accountability Act (ACSAA) of 2020. Our actions, which we continue to share with the FAA as they oversee our efforts, fall in the following areas:

  • Launched SMS and Positive Safety Culture training for new Boeing Commercial Airplanes (BCA) Manufacturing and Quality employees.
  • Introduced Leaders in Foundational Training (LiFT) curriculum for managers across BCA, including SMS and Positive Safety Culture material.
  • Improved our Speak Up reporting channel to increase transparency, strengthen confidentiality and create a better user experience for those who report.  

  • Submitted our Commercial Airplanes SMS Implementation Plan to the FAA, which includes actions Boeing will take to transition from its FAA-accepted voluntary SMS.
  • Improved our safety risk management tool to allow those who have identified a potential product safety hazard to enter the data and receive simple and straightforward guidance for how to evaluate the hazard and its risk level. 
  • Deployed required safety and quality training to more than 160,000 employees focused on their role in identifying and reporting potential product hazards – anything that might compromise the ability to deliver safe, compliant and conforming products and services.
  • Enhanced our SMS Champion Program, where employees learn how Boeing’s SMS ensures the safety of our products and services and then help to increase understanding and implementation of the SMS in their work areas.

  • Added ODA unit member capacity and improved the future ODA pipeline to address retirements and to meet current needs.
  • Strengthened the ODA system by completing the re-organization of unit members to give them an independent reporting structure aligned with their functional engineering organizations. This change included the addition of dozens of new senior managers aligned to support the strengthening of the ODA system.
  • Increased technical excellence in our engineering designs and meeting certification requirements through documentation and use of more than 2,700 design practices that incorporate lessons learned and best practices over Boeing’s long history.
  • Benefited from engineering ODA unit members helping create and disseminate design practices and participate in technical design reviews, where frank and transparent discussions are held among engineers and independent expert reviewers. 
  • Saw continued improvement in the percentage of ODA unit members who reported being able to perform their delegated duties free from interference, based on survey results.

  • Created and filled a new position of Human Factors Functional Chief Engineer.
  • Human factors are considered throughout major airplane Technical Design Reviews, including Preliminary Design Review and Critical Design Review, customer introductions, feature development, and airplane development program safety analysis processes.

Examples of Progress

New training strengthens Quality inspectors

Sept. 16, 2025

A new hands-on training program gives Quality inspectors realistic practice before they reach the production floor. By working with actual airplane sections and searching for planted, hidden defects, new-hires build skills and confidence, reducing errors and improving inspection accuracy. The program expands Boeing’s investment in workforce training and supports long-term product quality.

New assessments improve airplane build safety

Aug. 5, 2025

Boeing teams have introduced the Design Build Safety process to identify and address risks during production. More than 40 assessments have been completed, generating 1,300 actions to address potential issues. The process helps improve drawings, inspections and shop aids, leading to clearer instructions and safer, higher-quality builds.

‘Move Ready’ process helps cut traveled work in half

Aug. 4, 2025

Boeing teams have expanded a hazard assessment process that identifies when airplanes can safely move to the next manufacturing position in the factory. The approach has helped cut traveled work – unfinished jobs moving down the production line – by up to 50%. By addressing risks earlier, teams are improving production flow, stability and overall airplane quality.

Transformation of disorganized work area cuts defects by 80%

Jun. 30, 2025

At Boeing Salt Lake, the 737 electrical equipment shelves team redesigned its production area to improve workflow and organization. The new layout cut defects by 80%, shortened order lead time and reduced wasted space. Standardizing the process also boosted efficiency, teamwork and overall product quality.

Employee teams improve factory processes

Jun. 3, 2025

Employee Involvement teams, made up of members from Manufacturing, Quality, Engineering and other areas, meet weekly to solve problems and drive improvements. In Portland, one team introduced a new air-powered tool for cleaning drilled metal holes. The change eliminated defects that led to rework and delays, boosting safety and productivity.

New tool improves quality during airplane design validation

May 20, 2025

A new employee-developed tool streamlines how Boeing tracks and validates airplane configuration changes. By compiling data from multiple systems in real time, the tool reduces errors, improves accuracy and shortens reporting from hours to minutes. The tool helps confirm that airplanes in development meet design requirements while supporting more efficient production.

Using printers to get small 777X parts to the right place

Apr. 15, 2025

New printers have streamlined the way employees label composite shims for the 777X wings. The improved process, inspired by employee feedback, replaces tedious manual labeling, saving hours of work. Each shim now features a QR code for improved traceability, allowing teams to track shims from order placement through installation. This innovation enhances accuracy and improves ergonomics for teammates.

787 team enhances wing tank safety with innovative fittings

Mar. 20, 2025

The 787 program developed a new solution to protect wing tank air hose fittings and reduce fuel tank damage during production. Using 3D-printed components and protective tubing, the fittings stay securely in place and reduce the possibility of tool mark damage. The change enhances safety, reduces rework and supports more efficient production.

777X wings team upgrades fabrication area

Mar. 3, 2025

The 777X team activated a new production area with expanded space and upgraded equipment for composite wing component fabrication. The improvements enhance accuracy, reduce ergonomic challenges and streamline processes for teammates. With increased automation and capacity, the changes are an investment in long-term production stability.

New supply chain initiative improves production support

Feb. 24, 2025

More Boeing supply chain employees are working on the factory floor alongside their manufacturing and maintenance teammates. This approach helps teammates from different disciplines to more proactively address issues, streamline production flow and enhance collaboration.

New process for preventing foreign object debris

Jan. 31, 2025

Boeing introduced new guidelines for eliminating FOD – foreign object debris – in its commercial airplanes and production facilities. With simpler language and expectations, teammates now have daily, specific actions, along with more clearly-marked restricted areas in production.

3D-printed solution eliminates bracket damage

Jan. 20, 2025

Boeing teams resolved a recurring issue in 777X wing assembly by creating 3D-printed covers that protect brackets from minor damage. Previously, disposable tape left the brackets exposed, leaving them vulnerable to scratches. The new protectors are reusable and provide better coverage, resulting in no reported defects so far.

Everett Quality Updates
New wiring process reduces defect risk

Dec. 12, 2024

Boeing has improved how wires are installed in the wings of 777/777X jets by dedicating two electricians work together instead of one. The process of feeding wires through the wings can be difficult to do alone, which increased the risk of damage that could cause delays and rework. Since implementing this team approach, there has been no need for wiring rework in the wings.

Hands-on training goes paperless          

Dec. 9, 2024

Boeing has transitioned to a digital on-the-job training platform for new mechanics and quality inspectors. The digital system offers tailored, role-specific training plans, streamlining the process and reducing administrative tasks, which improves efficiency and ensures readiness for production.

Protective tool prevents scratches on airplane parts

Nov. 13, 2024

Boeing has introduced a new protective tool to address scratches and tool marks on bushings -- round fittings used to join airplane components. This tool covers the bushings during assembly, preventing damage that could require replacements and disrupt production. It is installed as soon as a fuselage enters the factory and removed when the bushings are ready for use.

New nut plates protect wiring during assembly

Nov. 13, 2024

Boeing has improved how panels are installed in the 767 cargo bay. Previously, it was difficult for employees to see or know if screws were pressing into wiring on the back side – causing the potential for chafing and damage. The company now requires capped nut plates to protect the wiring from screws.

Engineering deep-dive improves stowbin installation process

Aug. 9, 2024

During a recent internal audit, engineering teams reviewed documentation related to the stow bin installation process on 737 MAX airplanes. The audit was one of many that examined airplane designs and processes. Over the course of eight weeks, teams identified opportunities to reduce defects, improve ergonomics and ensure safety and quality in stow bin installations.

New employees learn about safety culture during onboarding

July 30, 2024

Boeing Commercial Airplanes has launched a training for new hires that defines a positive safety culture and emphasizes the importance of the company’s Safety Management System. The training includes in-person instruction, videos and discussions that create a personal connection to product safety and encourage employees to report hazards and prioritize workplace safety.

Wiring training introduced on 787 program

July 19, 2024

The 787 Dreamliner has 60-70 miles of wires. Our team introduced a new wire bundle training for incoming 787 teammates to ensure that anyone working in the airplane – regardless of their role – is familiar with the basics of wiring and understand how to safely work with or around them.

Employees prevent repeat defects by updating installation plan

July 10, 2024

When an ill-fitting O-ring was discovered on a P-8 prior to delivery, Boeing engineers, mechanics and factory leaders worked together to identify the root cause of the issue. Our team discovered that two similar O-rings used near each other were easily confused, so they rewrote the installation plan in question to better identify – and keep separate – the two O-rings. There have since been no related defects found.

Fabrication teams improve part protection to minimize damage

July 8, 2024

Boeing's Fabrication teams are making improvements to how they store and transport parts to increase quality and stabilize airplane production. From adjusting cart designs to fortifying part protection measures or working with suppliers on packaging protection, the goal is to reduce damage, create safer working environments and streamline processes.

New guide raises consistency, first-pass quality in drilling process

June 20, 2024

An employee spoke up, triggering a quick improvement that helped standardize the work and inspections for drilling holes in small metallic fillers. These half-inch square pieces known as ‘radius fillers’ have holes drilled in the center to serve as a type of washer, but the task was difficult to execute with precision. A new drill guide was produced, and a new process was documented in the build plan, increasing efficiency, and improving first-time quality.

Additional training reinforces compliance in part removal

June 11, 2024

Boeing has been enhancing the steps employees must take to remove or loosen airplane parts during production. In addition to proficiency testing, a removal history audit and the Quality team’s required approval, mechanics are required to take a new “When and Why” training to initiate a removal and ensure proper documentation.

New tool delivers first-pass quality for interior elements

June 7, 2024

A 3D-printed tool, designed by a Boeing employee, has eliminated scrap and improved first-pass quality on placard installations for airplane interiors. Teammates install placards, which are transparent markers with adhesive that contain directives, onto curtain tracks. A new placard insert tool allows teammates to seamlessly lay the placard down onto the curtain track without needing to touch the adhesive, reducing residue or fingerprints on the adhesive.

New tracking system helps prevent part loss

May 23, 2024

Barcoded labels are part of a pilot project helping the 737 team track parts with greater accuracy, reducing frustrating delays in finding the parts needed to complete jobs on the production line. Since mid-April when the pilot began, teams are able to locate parts in minutes instead of hours. Another advancement is the overhaul of the work-in-progress (WIP) racks where parts are stored. These racks have been made to move along with an airplane as it goes through the assembly process.

Reducing clicks to access build plans

May 22, 2024

Accessing the engineering drawings and installation plans required for our mechanics to build the airplane has gotten much simpler, thanks to the efforts of the Boeing Information Technology (IT)  team acting in response to feedback from employees.  Previously, as many as 10 clicks across multiple programs could be required by a mechanic to access the necessary documents. Implemented improvements have cut that time in half and eliminated the need to access multiple systems.

Paperless program to improve on-the-job training in factories

May 15, 2024

A new digital platform will eliminate the need for paper training records and improve overall training on the 737 program. Individual training packets can be up to 60 pages long and are difficult to keep track of over the course of the roughly 90-day structured on-the-job (SOJT) training program. In the new digital system, an online application helps trainees track and formally document their progress, while leaders can verify who is ready for a particular job and who needs more attention and training.

737 pilot program helps safely manage traveled work

May 29, 2024

Through a safety risk assessment process, Boeing aims to perform more jobs in sequence and keep production lines moving to predictably deliver safe, high-quality jets to customers. As part of this pilot project, new signage is hung in 737 production areas to help teams make sure airplanes have critical jobs completed before they are considered “move ready.”  Boeing is using its Safety Management System (SMS) to identify and mitigate hazards that could be disruptive to production, and employees play a key role by raising their concerns through the Speak Up portal and other means.

New training model provides employes more skills, support

May 9, 2024

To strengthen the training pipeline, Boeing has invested in about 300 hours of new curriculum resulting in new manufacturing and quality employees receiving up to two more weeks of foundational training, followed by enhanced its on-the-job training with more hands-on learning and mentoring from workplace coaches and peer trainers.

Everett flight line teams implement critical inspections

May 11, 2024

Boeing Quality and Engineering teams implemented a new process where they perform additional inspections of nine critical build areas of widebody airplanes during the airworthiness inspection process. The new process is part of an effort to eliminate quality defects and ensure Boeing continues to deliver safe, high-quality airplanes.

Go Deeper

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Safety & Quality Plan Executive Summary
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Employee working inside an airplane
Chief Aerospace Safety Officer Report
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Airplane inspection
Quality
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