Side Panel

Expand side panel

Discussions List View Topic

Boeing announced plans to eliminate up to 900 quality-inspector positions as part of a sweeping transformation of its manufacturing system. The idea is to move away from reliance on inspections by a second set of eyes to find any defects after a mechanic does a job. Instead, Boeing is redesigning tasks to make it easier for mechanics to get things right first time, and deploying smart tools and digital technology to track and monitor quality. Boeing is also using sampling rather than inspecting every job for accuracy.

But recently, a Boeing system called Process Monitoring revealed a breakdown in quality, reports The Seattle Times (Feb. 1, 2019). In one job category, an audit found only 93% of tasks were done correctly. To maintain this form of quality control in one important job category on the 747, 767 and 777 planes, Boeing set the requirement of a 95% pass rate.

One work task that recently fell short is called Bond and Ground, which means ensuring that all the components in the airplane are electrically grounded and that the connections between the components provide a continuous grounded electrical pathway through the metal airframe. (This is important to safely dissipate any buildup of static electricity. If a lightning strike were to hit an improperly grounded component, it could explode or start a fire).

As a result of the failed audit, Boeing must now revert to the former system using quality inspectors to check bonding jobs once work is complete. This much more labor-intensive regime must continue until 10 consecutive airplanes move through the system and meet the required quality standard. This will take months, since mechanics currently build a new 747 only once every 40 work days, a new 767 every 8 work days and a new 777 every 6 work days.

Inspectors are unhappy. One, referring to the failed audit, said the changes mean that safety is going to be put at risk in favor of lower costs.

1. After reading the section The Role of Inspection in Chapter 6, please comment on Boeing's new quality control program. 2. Philip B. Crosby (1926 - 2001) was a legend in the discipline of quality management. A noted quality professional, consultant, and author, he is widely recognized for promoting the concept of "zero defects" and for defining quality as conformance to requirements. Quality Is Free was Crosby's attention-getting book published in 1979. It has been credited with playing a large part in beginning the quality revolution in the United States and Europe. Why would Crosby say "quality is free"? Please comment in relation to the case of Boeing or your personal experience