More on the Boeing 737 Max
Boeing Was 'Go, Go, Go' to Beat Airbus With the 737 MaxLong article but here are excerpts:
The competitive pressure to build the jet which permeated the entire design and development now threatens the reputation and profits of Boeing, after two deadly crashes of the 737 Max in less than five months. Prosecutors and regulators are investigating whether the effort to design, produce and certify the Max was rushed, leading Boeing to miss crucial safety risks and to underplay the need for pilot training.
One former designer on the team working on flight controls for the Max said the group had at times produced 16 technical drawings a week, double the normal rate. "They basically said, 'We need something now,'" the designer said.
A technician who assembles wiring on the Max said that in the first months of development, rushed designers were delivering sloppy blueprints to him. He was told that the instructions for the wiring would be cleaned up later in the process, he said.
His internal assembly designs for the Max, he said, still include omissions today, like not specifying which tools to use to install a certain wire, a situation that could lead to a faulty connection. Normally such blueprints include intricate instructions.
Despite the intense atmosphere, current and former employees said, they felt during the project that Boeing's internal quality checks ensured the aircraft was safe.
Rick Ludtke, an engineer who helped design the 737 Max cockpit and spent 19 years at Boeing, said the company had set a ground rule for engineers: Limit changes to hopefully avert a requirement that pilots spend time training in a flight simulator before flying the Max.
"Any designs we created could not drive any new training that required a simulator," Mr. Ludtke said.
But a main selling point of the new A320 was its fuel-efficient engines. To match Airbus, Boeing needed to mount the Max with its own larger and powerful new engines.
The bigger engines altered the aerodynamics of the plane, making it more likely to pitch up in some circumstances.
To offset that possibility, Boeing added the new software in the Max, known as MCAS, which would automatically push the nose down if it sensed the plane pointing up at a dangerous angle. The goal was to avoid a stall. Because the system was supposed to work in the background, Boeing believed it didn't need to brief pilots on it, and regulators agreed. Pilots weren't required to train in simulators.
The push for automation was a philosophical shift for Boeing, which for decades wanted to keep pilots in control of the planes as much as possible. Airbus, by comparison, tended to embrace technology, putting computers in control. Pilots who preferred the American manufacturer even had a saying: "If it's not Boeing, I'm not going."
The new software system is now a focus of investigators who are trying to determine what went wrong in the Ethiopian Airlines crash and the Lion Air tragedy in Indonesia. A leading theory in the Lion Air crash is that the system was receiving bad data from a faulty sensor, triggering an unrecoverable nose dive. All 737 Max jets around the world are grounded, and Boeing has given no estimate of when they might return to flight.