NTSB Urges 737 Max Retrofit After Door Blowout

The National Transportation Safety Board (NTSB) concluded that the January 2024 door plug blowout on an Alaska Airlines Boeing 737 Max 9 resulted from systemic failures in Boeing's manufacturing and oversight, as well as insufficient FAA inspections. Investigators determined that four bolts securing the door plug were removed during assembly and never replaced, and the accident could have been avoided if even one bolt had been reinstalled. The incident caused minor injuries but no fatalities, thanks to the crew's response. The NTSB highlighted a rushed and error-prone factory environment, with workers reporting pressure to perform tasks for which they were unqualified. Boeing and Spirit AeroSystems are redesigning the door plug with additional safety backups, and both the company and FAA have taken some steps to improve procedures. The NTSB recommended retrofitting all 737 Max planes with the new design once certified and called for stronger risk identification and safety oversight to prevent future accidents.