On April 1, 2024, Boeing disclosed a significant production flaw affecting its 777 aircraft. Historically, the company has faced scrutiny over its 737 MAX model, but the latest revelations concern the larger 777 model, known for its commercial success.

Boeing’s Everett production facility, where the 777 is assembled (photo: Boeing)

During a press conference, Boeing’s chief executive, Dave Calhoun, announced, “A manufacturing anomaly made it past our quality controls on the 777 production line. A few major components of this particular 777-300ER aircraft were installed in the wrong location, and it was only shortly before delivery that those abnormalities were discovered.”

Boeing CEO Dave Calhoun answering questions after today’s press conference

Boeing employees raised concerns about an aircraft where forward fuselage sections were mistakenly placed under the wings instead of housing the engines. Emergency inspections led to further discoveries, including a serious flaw in an Emirates-operated 777.

Faye Kinuse, an aircraft safety expert, remarked, “This was a scary near miss. If the mistake hadn’t been discovered and any pilot attempted to operate the aircraft, who knows what could have happened.”

Images obtained of the affected aircraft.

In contrast, comments from a Boeing representative suggested a silver lining: “While this error is regrettable, on the bright side this aircraft offers unparalleled economics on a per-seat basis.”

Following Boeing’s announcement, various reports unveiled similar assembly issues involving Airbus, highlighting a broader concern in aircraft manufacturing standards.