Alaska Airlines’ Max 9 left Boeing factory without key ‘retention hardware’

An Alaska Airlines’ Boeing 737 Max 9 left the Boeing factory without bolts to secure a door plug, the NTSB reveals.

A preliminary report on the Alaska Airlines’ door plug blowout has found four bolts meant to secure the feature were missing. Picture: NTSB/AFP

An investigation into the shocking Alaska Airlines’ door blowout has found four bolts that should have secured the plug on the Boeing 737 Max 9 were missing before it left the factory.

The National Transportation Safety Board has released its preliminary report on the incident over Portland, Oregon on January 5, in which the door plug blew out as the plane ascended through 16,000ft.

The report detailed how the flight crew heard a “loud bang” and felt their ears pop.

“The captain said his head was pushed into the heads-up display and his headset was pushed up, nearly falling off his head,” said the NTSB report.

“The first officer said her headset was completely removed due to the rapid outflow of air from the flight deck. Both flight crew said they immediately donned their oxygen masks. They added that the flight deck door was blown open and that it was very noisy and difficult to communicate.”

There were 177 people on board, and seven passengers and a flight attendant suffered minor injuries as the aircraft returned to Portland.

Days later the plug was retrieved from a Portland backyard.

The NTSB report pointed to photographic evidence provided by Boeing, showing the door plug in question after work was carried out to replace damaged rivets on the new Max 9 in September 2023.

“Photo documentation obtained from Boeing shows evidence of the left-hand plug closed with no retention hardware (bolts) in the three visible locations,” said the NTSB report.

The fourth site was covered with insulation and could not be seen in the photo, noted the report.

“This image was attached to a text message between Boeing team members on September 19, 2023. These Boeing personnel were discussing interior restoration after the rivet rework was completed during second shift operations that day.”

The door plug from the Alaska Airlines Boeing 737 Max 9. Picture: NTSB/AFP

The NTSB made no determinations in the preliminary report and was continuing to investigate.

A statement from Boeing CEO Dave Calhoun said whatever final conclusions were reached, Boeing was “accountable for what happened”.

“An event like this must not happen on an aeroplane that leaves our factory,” said Mr Calhoun. “We simply must do better for our customers and their passengers. We are implementing a comprehensive plan to strengthen quality and the confidence of our stakeholders. It will take significant, demonstrated action and transparency at every turn – and that is where we are squarely focused.”

The Boeing 737 Max 9 was grounded for three weeks after the incident, resulting in over 1000 flight cancellations by Alaska Airlines and United.

Several airlines were insisting on greater oversight of Boeing’s manufacturing processes as a result, including Emirates which has a huge order for 777-9s.

On a recent visit to Australia, Emirates president Tim Clark said if Boeing had any sense they “would turn their undivided attention to sorting out the quality issues of all aircraft coming off the line”.

“They must expect there’ll be a high degree of regulator rigour in all of this as well as people like ourselves who now insist we have more access to the construction processes and timelines of the aircraft coming down the line for us,” said Sir Tim.

“I don’t think Boeing would object to that but at the same time it’s up to them to put their house in order. There’ve been too many shocks recently to suggest other than that’s what they need to be doing and I think they’ll get on with that.”

No Boeing Max 9 aircraft operate in Australia, with Virgin Australia and Bonza flying Max 8s which were grounded for almost two years from early 2019.

Virgin Australia has 25 Max 10s on order with the first due to be delivered by the end of next year.