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.
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    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:

    Examples of Progress

    New training strengthens Quality inspectors

    New assessments improve airplane build safety

    ‘Move Ready’ process helps cut traveled work in half

    Transformation of disorganized work area cuts defects by 80%

    Employee teams improve factory processes

    New tool improves quality during airplane design validation

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

    787 team enhances wing tank safety with innovative fittings

    777X wings team upgrades fabrication area

    New supply chain initiative improves production support

    New process for preventing foreign object debris

    3D-printed solution eliminates bracket damage

    Everett Quality Updates
    New wiring process reduces defect risk

    Hands-on training goes paperless          

    Protective tool prevents scratches on airplane parts

    New nut plates protect wiring during assembly

    Engineering deep-dive improves stowbin installation process

    New employees learn about safety culture during onboarding

    Wiring training introduced on 787 program

    Employees prevent repeat defects by updating installation plan

    Fabrication teams improve part protection to minimize damage

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

    Additional training reinforces compliance in part removal

    New tool delivers first-pass quality for interior elements

    New tracking system helps prevent part loss

    Reducing clicks to access build plans

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

    737 pilot program helps safely manage traveled work

    New training model provides employes more skills, support

    Everett flight line teams implement critical inspections

    Go Deeper

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