Another whistleblower came out on Wednesday with allegations that the Boeing 787 Dreamliner planes were built using substandard components, thereby, possibly leading to “disastrous results.”
Strom’s former contractor Richard Cuevas, a mechanic, has lodged complaints with two US agencies claiming his career suffered as a consequence of raising questions about possible manufacturing defaults in relation to the Boeing 787 Dreamliner.
In March 2024, according to Katz Banks Kumin attorneys, Cuevas was fired for bringing attention to manufacturing deviations in the forward pressure bulkhead – an essential part for managing aircraft’s pressure during flights, says CNN reports.
Who is Richard Cuevas?
Richard Cuevas is another whistle-blower from among those who have emerged from Boeing operations; he adds another twist in this saga. In January, an Alaska Airlines’ plane crashed due to its on-board malfunctioned while flying over Canada and made an emergency landing at Tadoule Lake Airport resulting into deaths of all crew members.
Cuevas worked through Strom which assigned him at Spirit AeroSystems where fuselages for Dreamliner are manufactured.
According to CNN, in October 2023 he filed a complaint with Boeing alleging that Spirit had made changes that went unapproved by implementing different sizes of fastener holes into forward pressure bulkheads of the 787s.
The investigation into his concerns began in October 2023 when Boeing informed Spirit management about the complaints. During this period one time a scientist told me “we’ve got a snitch.” Another time staff member said “don’t trust him,” but never said why. The latter led to discontinuation of my assignment at Spirit AeroSystems Corporation (Spirit).
Richard Cuevas’ lawyers at Katz Banks Kumin said: “Our client saw serious problems with multiple airplanes’ forward pressure bulkhead assembly that departed from what Boeing specified.”
Pointing out the poor craftmanship which raised concern for his own safety but both spirit and Boeing failed to mend the flawed manufacturing process. When an employee complained about these issues, his manager fired him and assumed it was Mr. Cuevas.
What specific problems did Cuevas discover in the airplane?
Cuevas noticed lack of complete sealants on two planes’ forward pressure bulkheads he participated in building that can result to “catastrophe.”
In 2023 at Spirit’s Wichita, Kansas plant, Cuevas saw them drill forward pressure bulkheads improperly in some of their 787s,” which might jeopardize power and air pressure (thus endangering passengers) on those airplanes. In other words he accused them of conducting faulty workmanship by alleging that drilling had been carried out incorrectly resulting in the release of excess air from these holes.
He wrote a report through Boeing ethics hotline telling management that he thought Spirit was hiding these problems from Boeing.
Cuevas saw such a problem with three airplanes that I worked on and believes perhaps up to ten or twelve airplanes are impacted by this issue and at least during production or already supplied for shipment to Boeing
Boeing responded to these allegations by stating that they have previously investigated the claims made by Cuevas and concluded that they did not pose any safety risk.
Bulkhead is an airplane’s critical component which ensures structural integrity while airborne.
Which were previous complaints?
Another whistleblower Sam Salehpour who is a Boeing engineer also noted gaps like this appeared on 787s as well as 777s. The Federal Aviation Administration (FAA) halted shipments of new Dreamliners for nearly two years beginning in 2021 due to these phenomena.
Further, the same attorneys are representing him as they had before he spoke to the Senate in April about concerns on how the 787 was made and punished for exposing it.
According to CNN, more than a dozen whistleblowers have come out against Boeing in recent years. Since January, however, there has been an increase in their number, which was occasioned by a door plug popping off from one of them just moments after takeoff thereby causing a huge hole in one side of the aircraft.
Last week, another present employee at Boeing said that the company hid or lost track of broken or out-of-specification parts for its 737 Max planes fearing these could be on passenger planes.
What did the company say?
“A subcontractor’s employee previously reported concerns to us that we thoroughly investigated as we take seriously any safety-related matter. Engineering analysis determined that the issues raised did not present a safety concern and were addressed.”
“We are reviewing the documents released today and will thoroughly investigate any new claim,”they added.
The allegations have been brought to light by Spirit leadership according to Joe Buccino who serves as a company spokesperson. Spirit “leadership is aware of the allegations and looking into the matter. We encourage all Spirit employees with concerns to come forward, safe in knowing they will be protected.”
In his letter of submission counsel representing Cuevas filled complaints with FAA and OSHA stating: “based on his direct observations of glaring safety issues, that Boeing’s and Spirit’s statements to the public and investors about the safety of 787 Dreamliners are fraudulent.”
The FAA is currently conducting multiple inquiries into Boeing even though it hasn’t ruled out filing charges against it yet if its quality control problems persist further.
“We strongly encourage anyone with safety concerns to report them and we thoroughly investigate every report,” said D.C.-based FAA spokesman Paul Takemoto.
In contrast, five times more reports have been filed with FAA this year than last year.
