FAA restricts Boeing 737 Max production amid door-plug inquiry

The Federal Aviation Administration (FAA) has directed Boeing to cease any further increases in the production rate of the 737 Max, as the agency conducts a comprehensive investigation to ensure the safety of the aircraft’s production system.

On January 24, the FAA informed Boeing that it will not approve any expansion of the Max production, including the 737-9 Max. This action is in response to the FAA’s ongoing investigation and heightened oversight of Boeing and its suppliers. The move follows the in-flight failure of a mid-cabin emergency exit door plug on an Alaska Airlines 737 Max 9 on January 5, currently under investigation by the FAA and the National Transportation Safety Board.

Unnamed sources from Boeing mentioned in a report that company records indicate workers did not properly secure the plug. Although Boeing had recently stated a production rate of 31 monthly for 737s, this pace had been inconsistent due to various quality and supply chain challenges. The exact production rate limitation imposed by the FAA is unclear. Boeing had previously aimed to reach a production rate of 50 737s monthly in 2025 or 2026.

FAA Administrator Mike Whitaker emphasized that Boeing will not return to business as usual until quality control issues are satisfactorily addressed. Boeing has not yet responded to requests for comment.

The FAA is intensively examining Boeing’s compliance with manufacturing requirements and enhancing oversight of new aircraft, with increased presence at all Boeing facilities. The agency insists on taking additional actions to prevent a recurrence of the January 5 incident, where a mid-air incident caused a significant breach in the side of an Alaska 737 Max 9. The FAA has mandated airlines to inspect 737 Max 9 door plugs and related hardware, as well as re-torque fasteners to enhance safety measures.