Discovery of the Issue
Richard Cuevas, an experienced mechanic, was contracted to work on the Boeing 787 Dreamliner at Spirit Aerosystems under Strom Aviation. In late September 2023, while working on the forward pressure bulkhead a crucial component of the aircraft’s airframe structure he observed a concerning alteration. Specifically, Cuevas noted that changes had been made to the fastener hole dimensions in the forward pressure bulkhead without Boeing’s knowledge.
The forward pressure bulkhead is vital for maintaining pressurized air within the aircraft. The integrity of this component is essential for the safety of the aircraft. The fasteners used to secure the bulkhead must fit tightly into the holes, known as an “interference fit,” ensuring the parts stay securely together during flight.
The Importance of the Interference Fit
Cuevas understood the significance of the “interference fit” in aerospace engineering. For the 787 Dreamliner forward pressure bulkhead, the fasteners must be 0.250 inches in diameter, while the holes they fit into measure 0.2475 inches. The critical three-thousandths difference allows the fastener to fit snugly into the hole, creating a secure connection. This interference fit is necessary to ensure that the bulkhead remains intact and can withstand the pressures of flight.
The interference fit is not just a matter of precision it’s a matter of life and death. The fasteners must be tight enough to hold the bulkhead and related components in place during flight. If the fasteners were loose, or if the holes were too big, the bulkhead could fail, compromising the integrity of the entire structure.
Identifying Unapproved Changes in Manufacturing
While working at Atlas, a supplier for Spirit, Cuevas observed several deviations from standard procedures. Typically, when constructing the forward pressure bulkhead, the metal parts (J and Y chords) are painted before drilling holes into them to prevent the paint from interfering with the fastener placement. However, at Atlas, the painted parts were drilled after painting. This required workers to re-drill the holes, wasting time and creating additional risks.
More alarmingly, Cuevas learned from an Atlas worker that Spirit’s Quality Manager, Michael Shellhammer, had directed them to use a .2495 reamer drill bit to clear out the holes making them slightly larger than necessary. This reaming process increased the risk that the fastener wouldn’t fit properly, especially if the drill was misused, which was common.
Additionally, Cuevas noted that Shellhammer instructed workers to use fewer fasteners than required to save costs. This decision was potentially dangerous, as fewer fasteners would result in a less secure attachment of the J and Y chords to the aircraft structure.
Realizing the Magnitude of the Issue
Cuevas’s concerns deepened once he moved back to Everett, Washington, to install the bulkheads onto the Dreamliners. After reassembling the J and Y chords into quarter-circles, Cuevas realized that some of the fasteners on Row 3 of the forward pressure bulkhead weren’t fitting properly. Fasteners were either falling out or missing entirely, suggesting that the fastener holes had been altered during the manufacturing process, likely due to the improper reaming.
This particular row Row 3 was crucial because it connected the bulkhead to the power ground feeders, which are responsible for distributing electrical power throughout the aircraft. Without the proper fit, the fasteners couldn’t securely attach the power feeders to the bulkhead, potentially causing loss of electrical power and even air pressure during flight.
Reporting the Issue to Spirit Management
Recognizing the severity of the issue, Cuevas discussed the problem with his Spirit supervisor, Angel Linares. Initially, Linares brushed off the concern, mentioning that Spirit had made some changes to the bulkhead. This response only increased Cuevas’s alarm. He then raised the issue with his quality contractor, Tony, who dismissed it with little concern, adding to Cuevas’s fears that Spirit was actively covering up the problem.
Filing an Official Ethics Complaint with Boeing
On October 20, 2023, after seeing that his concerns were being ignored, Cuevas filed an official complaint through Boeing’s ethics hotline. He explained the issues with the fasteners and the potential violations of FAA regulations. He also raised concerns about the lack of an interference fit in the bulkhead, which could lead to severe safety risks.
During the call, the ethics coordinator promised confidentiality, assuring Cuevas that his complaint would be investigated. However, despite this assurance, it would take weeks before any action was taken.
Retaliation and Escalation
In the weeks following his complaint, Cuevas noticed that his coworkers, including those who had expressed concerns about the fasteners, were being reassigned to other locations. Specifically, he learned that his colleagues Robbie and Barry, who had also raised concerns, had been transferred to Wichita. This signaled to Cuevas that Spirit was retaliating against anyone who escalated the safety issues.
Cuevas continued to push for answers and updates, but as the investigation seemed to stall, his concerns grew. During a meeting with Boeing’s ethics department, Cuevas reiterated the gravity of the situation, citing a tragic 1985 incident involving a Japan Airlines 747, which had crashed due to a ruptured pressure bulkhead.
The Abrupt Termination
On March 28, 2024, shortly after an FAA inspection at Boeing’s hangar, Cuevas was informed by his supervisor, Shellhammer, that his time at Spirit had come to an end. The reason given was vague: “a sign of the times.” Cuevas strongly suspected that his termination was a direct result of his whistleblowing activities, especially since he had been raising safety concerns for several months.
Legal Action and Retaliation Claims
Cuevas filed a formal legal complaint, asserting that Boeing, Spirit, and Strom had violated his rights under both the Wendell H. Ford Aviation Investment and Reform Act (AIR21) and the Sarbanes-Oxley Act (SOX). These laws protect whistleblowers who report safety violations and fraudulent activities. Cuevas’s case highlighted not only the engineering issues with the 787 Dreamliner but also the retaliatory actions he faced after raising his concerns.
Exposing the Cost of Cutting Corners
Cuevas’s whistleblowing case underscores the immense challenges faced by those who report safety violations in industries where cost-saving measures can take precedence over safety. Cuevas’s commitment to ensuring the safety of the 787 Dreamliner, despite facing retaliation and career setbacks, highlights the importance of safeguarding whistleblowers in high-risk industries.
While the legal battle is still ongoing, Cuevas’s actions have brought critical safety concerns into the spotlight, forcing Boeing, Spirit, and other stakeholders to reckon with their safety protocols and the consequences of cutting corners in aircraft manufacturing.
