Following the tragic crash of Air India Flight AI171, a Boeing 787-8 Dreamliner, on June 12, 2025, in Ahmedabad, India, whistleblower allegations about Boeing’s manufacturing practices have resurfaced. The crash, which killed 241 of the 242 people on board and several on the ground, was the first fatal incident involving a 787 Dreamliner since its debut in 2011. Here’s a breakdown of the key whistleblower claims and their relevance to the incident:
Whistleblower Claims
- Sam Salehpour’s Allegations (2024):
- Structural Flaws: Boeing engineer Sam Salehpour filed a formal complaint with the Federal Aviation Administration (FAA) in January 2024, alleging that Boeing took shortcuts in the manufacturing of the 787 Dreamliner and 777 aircraft. He claimed improper assembly practices, such as misaligned fuselage sections and unfilled microscopic gaps (shimming issues), could lead to structural fatigue and potential catastrophic failure over time. Salehpour reported witnessing workers physically forcing parts into alignment, including “jumping on fuselage sections,” describing it as not how airplanes should be built.
- Retaliation: Salehpour also alleged that Boeing retaliated against him by transferring him to the 777 program after he raised concerns, and he claimed the company prioritized production speed over safety.
- FAA Investigation: The FAA launched an investigation into Salehpour’s claims, which remains ongoing. Boeing denied the allegations, asserting confidence in the 787’s safety and stating that extensive testing showed no fatigue issues in the composite fuselage.
- John Barnett’s Allegations:
- Defective Parts and Quality Control: John Barnett, a former Boeing quality manager who worked at the company for over 30 years, claimed in 2019 that Boeing pressured workers to install substandard or defective parts to meet production deadlines. He alleged that defective parts were retrieved from scrap bins and fitted onto 787s, and that testing showed a 25% failure rate in emergency oxygen systems.
- Suspicious Death: Barnett was found dead in March 2024 from a self-inflicted gunshot wound, ruled a suicide, just before a scheduled deposition in his whistleblower lawsuit against Boeing. His death raised suspicions due to its timing, though authorities found no evidence of foul play. A note found in his vehicle reportedly expressed frustration with Boeing.
- Claims About Air India Planes: Barnett’s allegations included concerns about the North Charleston plant, where some 787s were assembled, though the plane involved in the Ahmedabad crash was built in Seattle in 2013, predating some of his specific claims.
- Cynthia Kitchens’ Allegations:
- Overlooked Flaws: Cynthia Kitchens, a former Boeing quality manager from 2009 to 2016, claimed she flagged numerous flaws in 787s but was told by a supervisor to overlook them, as the planes were destined for overseas clients, including Air India. She noted specific concerns about three 787s delivered to Air India in early 2014, around the time the crashed plane (delivered January 2014) was sent.
- Documented Evidence: Kitchens maintained detailed records, including a list of 11 planes delivered between 2012 and 2013, raising concerns about systemic quality control issues.
Context of the Air India Crash
- Flight Details: Air India Flight AI171, a Boeing 787-8 Dreamliner (registration VT-ANB), crashed shortly after takeoff from Ahmedabad’s Sardar Vallabhbhai Patel International Airport, en route to London Gatwick. The plane, carrying 230 passengers and 12 crew, reached a maximum altitude of 625 feet before crashing into a residential area, including a medical college hostel, within 30 seconds of takeoff. A mayday call was issued, but the pilots became non-responsive.
- Sole Survivor: Ramesh Viswashkumar, a British national seated near an emergency exit (seat 11A), survived by jumping out after the crash.
- Preliminary Observations: Videos show the plane struggling to gain altitude, with some experts noting that the wing flaps appeared not to be properly deployed, potentially reducing lift. Other possible causes under investigation include bird strikes (common at Ahmedabad airport), engine failure, or fuel system issues, though no definitive cause has been established.
- Aircraft History: The plane, delivered in January 2014, had logged over 41,000 flight hours and nearly 8,000 takeoffs and landings, which is typical for its age. It was powered by GE GEnx engines and had no reported issues in the week prior, having flown 11 international trips.
Relevance to Whistleblower Claims
- No Direct Link Yet: The cause of the crash remains under investigation by India’s Aircraft Accident Investigation Bureau, with assistance from the US National Transportation Safety Board, UK Air Accidents Investigation Branch, Boeing, and GE Aerospace. There is no conclusive evidence yet linking the crash to the manufacturing flaws alleged by Salehpour, Barnett, or Kitchens. Experts note that the plane’s age and extensive flight history might align with Salehpour’s warnings about long-term fatigue, but this is speculative until black box data (flight data and cockpit voice recorders) is analyzed.
- Past 787 Issues: The 787 Dreamliner has faced prior scrutiny, including:
- Grounding in 2013 due to lithium-ion battery fires, resolved with a containment solution.
- Delivery halts in 2021–2022 due to fuselage assembly issues, though Boeing claimed these were addressed.
- Incidents like a 2024 Latam Airlines mid-air dive due to a cockpit seat issue, prompting FAA inspections.
- Four emergency landings by an American Airlines 787 earlier in 2025, linked to wing flap issues, which are now under scrutiny.
- Boeing’s Response: Boeing has denied the whistleblowers’ allegations, emphasizing the 787’s safety record and extensive testing. The company issued a statement expressing condolences and offering support to Air India and the investigation.
Broader Implications
- Boeing’s Safety Culture: The crash has reignited public and regulatory scrutiny of Boeing’s manufacturing practices, already strained by the 737 MAX crises (2018–2019) and a 2024 Alaska Airlines door plug incident. Whistleblower claims, including those from Salehpour and Barnett, highlight alleged systemic issues, such as prioritizing production over quality and retaliating against dissenters.
- Public Sentiment: Posts on X reflect heightened concern, with users referencing Barnett’s and Salehpour’s warnings and questioning Boeing’s accountability. Some posts note Barnett’s death and allege a cover-up, though these claims remain unverified.
- Market Impact: Boeing’s shares dropped nearly 5% on June 12, 2025, reflecting investor concerns about the company’s ongoing safety and financial challenges.
Conclusion
The whistleblower claims from Sam Salehpour, John Barnett, and Cynthia Kitchens have gained renewed attention following the Air India crash, raising questions about the Boeing 787 Dreamliner’s manufacturing integrity. While Salehpour warned of long-term structural risks, Barnett alleged defective parts, and Kitchens flagged specific issues with planes delivered to Air India, no direct connection to the crash has been confirmed. The investigation will focus on multiple factors, including mechanical issues, human error, and environmental conditions like bird strikes. Until the black box data is analyzed, the cause remains uncertain, but the tragedy underscores ongoing concerns about Boeing’s safety culture and manufacturing practices.