The recent crash of Air India Flight 171, a Boeing 787-8 Dreamliner, has revived global concern over Boeing’s quality control processes, as investigators from both India and the United States begin looking into what caused the fatal accident.

The aircraft, en route from Ahmedabad to London Gatwick, crashed shortly after takeoff on Thursday, killing 241 out of the 242 passengers and crew members on board. This is the first fatal incident involving the Boeing 787 since it entered commercial service in 2009.

US Team Joins Indian Probe

In response to the tragedy, the U.S. National Transportation Safety Board (NTSB) has dispatched experts to India to support the investigation being conducted by the Aircraft Accident Investigation Bureau (AAIB). “The NTSB will be leading a team of U.S. investigators travelling to India to assist the Aircraft Accident Investigation Bureau with its investigation into the crash of an Air India Boeing 787 in Ahmedabad, India, Thursday,” the agency announced on X (formerly Twitter).

Though the cause of the crash remains unknown, the incident has raised questions over the Dreamliner’s build quality and past oversight, especially as similar safety issues have surfaced in earlier cases involving the aircraft model.

Boeing’s Troubled Track Record With the 787

While Boeing touts the 787-8 Dreamliner as the most popular widebody aircraft ever produced, it has not been free from controversy. Prior incidents involving cockpit seating failures and auto-pilot malfunctions have led to targeted inspections by the U.S. Federal Aviation Administration (FAA).

In one such case, a pilot’s seat shifted unexpectedly during flight, disengaging the autopilot system and causing the aircraft to nosedive—prompting the FAA to issue formal checks of cockpit components.

Moreover, whistleblower accounts have continually highlighted concerns around Boeing’s manufacturing practices. Sam Salehpour, a Boeing quality engineer, told the FAA last year that “he observed shortcuts taken by Boeing” in assembling the Dreamliner, which included “drilling debris left in interfaces and deformation of composite material,” according to CBS News.

John Barnett: The Whistleblower Who Warned the Industry

The latest crash has also put the spotlight back on John Barnett, a former Boeing quality manager and prominent whistleblower who long criticised the Dreamliner program. Mr. Barnett alleged widespread negligence at Boeing’s South Carolina plant between 2010 and 2017, where he claimed pressure was mounting on employees to prioritize production speed over safety.

He specifically pointed out that metallic debris was frequently left near electrical wiring, risking in-flight hazards, and warned that about 25% of the aircraft’s oxygen masks might fail in an emergency. Barnett also noted that some critical parts lacked proper tracking during assembly—evidence, he said, of flawed oversight.

“Grave concerns about safety were routinely ignored in favor of meeting quotas,” Barnett had stated in interviews.

Regulatory Response and Retaliation Allegations

In 2017, Barnett reported his findings to both the FAA and OSHA. The FAA acknowledged some issues and directed Boeing to implement fixes, but OSHA ruled in favour of the company in 2021—a decision Barnett challenged. He also accused Boeing of retaliating against him by denying promotions and isolating him from work teams, which he said contributed to a toxic workplace environment.

Despite retiring in 2017 due to health issues, Barnett remained vocal. He appeared in the Netflix documentary Downfall: The Case Against Boeing and raised fresh alarms after the Alaska Airlines door plug incident in early 2024.

A Mysterious and Tragic Death

On March 9, 2024, Barnett was found dead in a truck parked outside a Charleston, South Carolina hotel. He had been staying there while preparing to testify in a whistleblower retaliation case against Boeing. When he missed a scheduled legal deposition, authorities performed a welfare check and discovered his body with a gunshot wound to the head. A handwritten note inside the vehicle read: “I can’t do this any longer. F**k Boeing. I pray Boeing pays.”

Officials concluded the death was a suicide, though some supporters continue to question the circumstances.

Boeing’s Safety Record Under Renewed Fire

According to Boeing’s own April 2024 report on commercial aviation safety, the airline industry saw a spike in accidents last year. The data shows 47 accidents occurred globally in 2024, including 12 classified as “hull losses”—meaning aircraft were destroyed or beyond repair—and 187 total fatalities.

Boeing explained that a “hull loss” can also mean the aircraft is missing and unrecovered. Though the report claims long-term improvements in aviation safety, the recent crash and whistleblower claims have intensified public and regulatory scrutiny.

No Official Cause Yet Determined

Authorities have not yet confirmed what led to the Air India crash. However, the combination of historical complaints, regulatory findings, and past whistleblower allegations has placed Boeing at the center of international attention once again.