In a nutshell: The Boeing 737NG (NG= Next Generation) is the latest and most modern version of the long lived (and up to now) very reliable line of the 737 twin engine passenger aircraft. As per the aircraft type certificate approved by the FAA, some critical parts of the 737NG's assembly have to be built by computer control, ie. CNC processes. This was to maintain extremely precise tolerances in the way the parts were fitted together. In turn these precise tolerances meant the airframe was significantly stronger and more robust than if it had been built to less precise standards using more hand built components and traditional parts manufacturing techniques.
The whistleblowers claim, ignored for years by Boeing and the US regulatory authorities, is that one of the Boeing subcontractors supplying parts for the fuselage were not using CNC machines (very expensive to buy and maintain) to fabricate the components as required by the type certificate, but were building many of the parts partly or entirely by hand. This meant that they were not meeting the design specs, and when the parts got to the Boeing plant for final assembly into airplanes the Boeing workers found the parts were not fitting together correctly. Instead of rejecting the parts and insisting that the subcontractor meet its obligations to supply parts within specifications, Boeing management had their assembly line workers force fit and perform on the spot modifications on the out of spec components to force the parts into place even though this would introduce unplanned for stresses into the components and fuselage assembly and lead to an overall weakening of the end product.
When the whistleblowers brought their concerns to the attention of Boeing's management and later the FAA they were basically ignored. The whistleblowers were concerned that these faulty parts could lead to catastrophic failures in flight and a consequent loss of an aircraft. Independent aviation experts have confirmed that they believe these concerns on the part of the whistlblowers are very valid. The impression left on those involved in pursuing this matter was that this jury rigging of faulty parts to make them work had been so widespread and common that if action was taken to check all the 737NGs in operation which might have been affected it would be enormously expensive (can you imagine the lawsuits?) and also do significant damage to Boeing's reputation.
Read more at the link below. The article also contains two embedded videos. The 2nd video is a 52 minute Al Jazeera TV report on the problem and well worth watching (also posted in the DU videos forum).
Al Jazeera has conducted an investigation into claims that more than 1,500 of the world's most commonly-used passenger planes, the Boeing 737NG, were built with ill-fitting and illegal parts. Two whistleblowers who used to work for Boeing spoke to Al Jazeera's People & Power programme. Al Jazeera has also uncovered internal Boeing documents which seem to support the claims - and others which appear to show that the US government itself has been helping Boeing to cover up the problems.
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The parts in question were some of the most crucial elements of an aircraft fuselage - parts known as "chords" and "bear-straps".
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So vital are these parts to the safety of an aircraft, that Boeing's own 737NG Structural Repair Manual - obtained by Al Jazeera in the course of its investigation - lists them as "Primary Structural Elements" and warns: "The failure of PSE's could result in the catastrophic failure of the airplane."
According to lawyer Bill Skepnek - who for the last six years has become intimately acquainted with almost every nook and cranny of the 737NG design - when Boeing talks of the potential for these parts to cause "catastrophic failure", it means exactly what it says.
http://dailybail.com/home/boeing-in-massive-safety-cover-up-report.html
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