In the ongoing saga concerning Boeing’s 737 Max aircraft, a new obstacle has emerged during their production, leading to the need to adjust around 50 planes that have yet to be delivered.

This recent challenge came to light via a memo circulated to Boeing employees by Stan Deal, who heads the company’s commercial aircraft division. According to the memo, an employee at Spirit AeroSystems, a crucial supplier responsible for producing the fuselages of the 737 Max planes, flagged an issue with two holes potentially not drilled according to Boeing’s specifications.

While this issue doesn’t pose an immediate safety risk for flights, and all 737s can continue to operate safely, the memo anticipates the need for rework on approximately 50 undelivered aircraft.

Spirit AeroSystems confirmed the error, with spokesman Joe Buccino acknowledging, “A member of our team identified an issue that does not conform to engineering standards.” The company promptly took corrective action upon notification, collaborating closely with Boeing to resolve the matter.

This revelation compounds Boeing’s already troubled reputation, marked by a series of setbacks over the past few years, including a recent alarming incident aboard a 737 Max 9 flight on January 5. In response, the Federal Aviation Administration (FAA) announced intentions to overhaul its oversight of Boeing’s manufacturing processes.

The January 5 incident involved an Alaska Airlines flight experiencing a door plug blowout, resulting in a significant breach in the aircraft’s side. Although the exact cause is still under investigation, Boeing CEO David Calhoun accepted responsibility, stating, “We caused the problem, and we understand that.”

The memo from Deal outlined Boeing’s commitment to addressing the issue, with plans for the Renton, Washington 737 Max factory to dedicate several days to rectifying the problem, highlighting the company’s focus on quality, safety, and operational stability.

Boeing’s reliance on suppliers for critical components as a cost-saving measure has made it susceptible to lapses in quality control. Deal acknowledged that Spirit AeroSystems isn’t the only supplier failing to meet Boeing’s standards, as internal production facilities also face challenges.

During a recent production pause aimed at prioritizing quality control, Deal noted widespread employee frustration over incomplete tasks, whether from suppliers or within Boeing’s operations. Recognizing the need for improvement, Boeing mandated a major supplier to halt shipments until all work meets specifications, despite potential disruptions to the production schedule.

This isn’t the first instance of Boeing halting deliveries due to non-compliance with specifications, impacting airline customers and contributing to financial losses. Recent financial reports indicate substantial losses totaling billions of dollars over the past five years, prompting major customers like United Airlines and Southwest Airlines to reconsider their orders for new 737 Max variants.

United CEO Scott Kirby cited the Alaska Air incident as a turning point, leading the airline to reevaluate its plans for receiving the Max 10 later this year. The most significant setback for Boeing remains the design flaw in the 737 Max, implicated in two fatal crashes in 2018 and 2019, leading to an extended grounding of the aircraft.

The recent issue involving mis-drilled holes underscores the FAA’s heightened scrutiny of Boeing’s production processes. Jodi Baker, an FAA official, outlined plans for enhanced oversight, emphasizing a shift toward more direct observation and interaction to ensure compliance with safety standards.

With the FAA actively developing a strategy for “re-imagined oversight,” covering all US aircraft manufacturers, surveillance measures are being intensified. Meanwhile, thorough inspections are underway along Boeing’s 737 Max assembly line in Renton, Washington, to uphold safety standards.

While the majority of grounded 737 Max 9s have returned to service following the January 5 incident, continued vigilance and proactive measures are crucial to restoring confidence in Boeing’s operations and ensuring the safety of future flights.