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Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

bbc.com

11–20 of 188 posts

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#11

The headline is missing an important bit. Boeing knew of the flaw, and sent a letter to airlines about it. In 2011.

Well yes but Boeing also said it "would not result in a safety of flight condition." There's a lot of gray going on here.

The FAA has not determined that this flaw did lead to a safety of flight condition. Investigation is still ongoing.

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#12

The headline is missing an important bit. Boeing knew of the flaw, and sent a letter to airlines about it. In 2011.

Well yes but Boeing also said it "would not result in a safety of flight condition." There's a lot of gray going on here.

A former air accident investigator who works as an aviation safety consultant said "It's extraordinary that Boeing concluded that a failure of this part would not have safety consequences," and said the report was "disturbing"

Doesn't seem like gray to me. It seems a company who has a history of cutting corners and ignoring or downplaying safety problems did exactly that in this case too which resulted in the deaths of many people. UPS made an error here as well in trusting Boeing when they said it wasn't a safety issue and they should have installed the revised bearing assembly out of an abundance of caution, but I don't know much they would have known back in 2011 about the changes at Boeing that prioritized profit over safety following the merger with McDonnell Douglas

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#14

Every five years feels too infrequent. These are planes that are 30 years old and have done 100,000 hours of flying. Apparently UPS policy is to keep them around for about 35 years to maximize the ROI. But maybe once they hit a particular age they need to be inspected deeply every few months. I am not an expert, however. Can metal fatigue be detected with such infrequent inspection?

Sounds like it is included as part of standardized airplane checks based on age of aircraft + hours flown. [1]: https://en.wikipedia.org/wiki/Aircraft_maintenance_checks#AB... On things like D check, the aircraft is essentially completely taken apart and inspected at that level typically taking 50,000 man hours and 6 month-1 year of time.

Thanks for this post. I’m blown away by that 50,000 hours figure.

The article mentions the cost and that Boeing underestimates it. When you divide the cost by the number of hours, it seems very reasonable. Parts and materials being included. I’m surprised any job that extensive isn’t even more expensive.

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#15

I’m guessing that manufacturers know of lots of flaws in the parts they make.

Hopefully they don't usually downplay the risks of dangerous known flaws in critical parts like Boeing seems to have done in this case.

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#16

The headline is missing an important bit. Boeing knew of the flaw, and sent a letter to airlines about it. In 2011.

FWIW, the MD-11 was designed by McDonnell Douglas, and manufactured by McDonnell Douglas in 1991, before the Boeing merger. A McDonnell Douglas DC-10 failed in a similar way in Chicago in 1979, so it the issue may go way back.

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#17

The headline is missing an important bit. Boeing knew of the flaw, and sent a letter to airlines about it. In 2011.

Well yes but Boeing also said it "would not result in a safety of flight condition." There's a lot of gray going on here.

Apparently they expected it to blow up on the ground, so technically the plane wasn't flying yet ...

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#18

Insane that we can have places like the skunk works create the sr71 and operate on shoe string budgets but the largest passenger plane company in the world can’t accurately assess risk on planes far under the former planes Mach 3 record

I don't see that as a valid comparison. SR-71s could operate with a much higher level of risk than commercial passenger planes. IIRC, SR-71s leaked fuel on the ground, and their wings dragged on the ground without special attachments. Pilots needed special pressure suits, etc.

I also expect that they were much less complex than an aircraft that provides a comfortable, pressurized cabin; the high level of safety mentioned above; freight capacity; etc.

Also, despite Boeing's recent problems, I would guess that commerical passenger planes are far more safe than they were decades ago when the SR-71 was developed. Accidents were much more common despite many fewer flights, iirc.

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#19
Some are forgetting how risk in technology works: No technology is designed or operated without flaws; that's an absurd approach and impossible to implement.

To reduce negative outcomes, we use risk management: assessing the likely lifetime cost of the flaw, and taking cost-effective measures to reduce the risk to an acceptable level. As a familiar example, redundant mass storage drives are much more cost-effective than high-reliability mass storage drives.

Re: Boeing knew of flaw in part linked to UPS plane crash, NTSB report says

#20
post #18

Insane that we can have places like the skunk works create the sr71 and operate on shoe string budgets but the largest passenger plane company in the world can’t accurately assess risk on planes far under the former planes Mach 3 record

I don't see that as a valid comparison. SR-71s could operate with a much higher level of risk than commercial passenger planes. IIRC, SR-71s leaked fuel on the ground, and their wings dragged on the ground without special attachments. Pilots needed special pressure suits, etc. I also expect that they were much less complex than an aircraft that provides a comfortable, pressurized cabin; the high level of safety menti…

12/32 SR71s were lost in the 33 years they were flying. 11/200 MD-11s have been hull-lost from 1988-2025. Not to mention that passenger/cargo planes will put on a lot more flight hours than the SR71s did in a given year.
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