Boeing is once again under scrutiny after investigators discovered that nearly 500 Boeing 787 jets contain faulty parts that passed multiple audits.

This revelation comes at a time when the aerospace giant is still recovering from previous safety concerns and quality control issues. The investigation, which began as a pollution case in Italy, has now expanded into a major scandal involving substandard aircraft components.

How It All Started

In May 2020, Italian police in Brindisi caught two men pouring chemical waste into the sewers near a small aerospace factory. This routine pollution case led authorities to Manufacturing Process Specification (MPS), a small Italian aerospace company, and uncovered a much bigger problem—thousands of aircraft parts made from weaker metals had been supplied for Boeing 787 jets.

The Allegations Against MPS

Investigators found that MPS had replaced high-grade titanium and aluminum alloys with cheaper, weaker materials while still passing industry audits. These flawed parts, which include floor fittings that support the Boeing 787’s cabin structure, were supplied through Leonardo, an Italian aerospace company that manufactures fuselage sections for Boeing.

Prosecutors allege that for four years, these substandard components entered the aerospace supply chain, putting flight safety at risk. Although MPS executives deny any wrongdoing, police claim that whistleblowers and material inspections confirmed the use of lower-quality metals.

Boeing and Regulators Respond

Despite the serious nature of these findings, Boeing has maintained that there is no immediate safety risk. The U.S. Federal Aviation Administration (FAA) has not grounded any 787 jets but has issued guidance for airlines to inspect and replace faulty parts. While nearly 500 aircraft are potentially affected, the exact number of problematic components remains unknown until inspections are completed.

Leonardo and Boeing have been granted victim status in the case, arguing that they were misled by MPS. Leonardo stated that it was unaware of the issue until Boeing alerted them in late 2020.

Systemic Failures in Quality Control

One of the most alarming aspects of the case is how these faulty parts passed multiple industry audits between 2017 and 2021. Investigations revealed that certification bodies approved MPS without physically inspecting the structural components. Experts argue that this case exposes serious flaws in the aerospace industry’s voluntary audit system, which relies heavily on documentation rather than physical testing.

The Industry Aerospace Quality Group (IAQG), responsible for overseeing global aerospace standards, has acknowledged the need for updates in its auditing process. However, critics argue that stronger regulatory oversight is required to prevent similar incidents in the future.

A preliminary court hearing in Italy was scheduled for March 2024 but was postponed until May. Prosecutors have accused MPS executives of fraud and violating aircraft safety regulations. If convicted, they could face serious legal consequences.

Meanwhile, Boeing continues to work through its ongoing quality control challenges. With increasing scrutiny from regulators and customers, the company must address the weaknesses in its supply chain to restore confidence in its aircraft.