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FAA audit faults Boeing for 'multiple instances' of quality control shortcomings

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FAA audit faults Boeing for 'multiple instances' of quality control shortcomings

Boeing workers at the Renton Municipal Airport in Washington finalize assembly of an Alaska Airlines Boeing 737 Max jet on Feb. 27. An FAA audit faulted Boeing for “multiple instances” of quality control shortcomings.

Jovelle Tamayo for NPR


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Boeing workers at the Renton Municipal Airport in Washington finalize assembly of an Alaska Airlines Boeing 737 Max jet on Feb. 27. An FAA audit faulted Boeing for “multiple instances” of quality control shortcomings.

Jovelle Tamayo for NPR

WASHINGTON — After a six-week audit of Boeing, federal regulators say they found quality control problems at Boeing and Spirit AeroSystems, one of its top suppliers.

The Federal Aviation Administration says it found “multiple instances” of Boeing and Spirit failing to “comply with manufacturing quality control requirements.”

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The FAA launched the audit of Boeing and Spirit AeroSystems, which builds the fuselage for the Boeing 737 Max, after a door plug panel blew out in midair during an Alaska Airlines flight on Jan. 5.

No one was seriously hurt when the plug came off as the new jet climbed through 14,000 feet after departing Portland, Ore. It returned to make an emergency landing as winds whipped through a hole in the fuselage.

A preliminary investigation by the National Transportation Safety Board determined that four key bolts that were supposed to hold the door plug in place were missing when the plane left Boeing’s factory.

The audit found problems in “Boeing’s manufacturing process control, parts handling and storage, and product control,” the FAA said in a statement.

The agency says FAA administrator Mike Whitaker discussed the findings with Boeing CEO Dave Calhoun last week, when the agency gave Boeing 90 days to come up with a plan of action to address its quality control problems.

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The FAA says it provided both companies with a summary of the audit findings. But the agency declined to share those details with NPR, citing its ongoing investigation.

Auditors visited Boeing’s factory in Renton, Wash., and Spirit’s plant in Wichita, Kan.

Boeing confirmed Friday that it is in talks to buy Spirit AeroSystems.

“We believe that the reintegration of Boeing and Spirit AeroSystems’ manufacturing operations would further strengthen aviation safety, improve quality and serve the interests of our customers, employees, and shareholders,” said Jessica Kowal, Boeing’s director of media relations, in a statement.

That would be a change of strategy for Boeing, which nearly two decades ago sold off the assets that are now part of Spirit.

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But the supplier has had several costly and embarrassing problems with quality control in recent years as it pushed to keep up with Boeing’s ambitious production schedule.

NPR’s Joel Rose reported from Washington, D.C., and Russell Lewis from Birmingham, Ala.

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Video: F.A.A. Ignored Safety Concerns Prior to Collision Over Potomac, N.T.S.B. Says

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Video: F.A.A. Ignored Safety Concerns Prior to Collision Over Potomac, N.T.S.B. Says

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F.A.A. Ignored Safety Concerns Prior to Collision Over Potomac, N.T.S.B. Says

The National Transportation Safety Board said that a “multitude of errors” led to the collision between a military helicopter and a commercial jet, killing 67 people last January.

“I imagine there will be some difficult moments today for all of us as we try to provide answers to how a multitude of errors led to this tragedy.” “We have an entire tower who took it upon themselves to try to raise concerns over and over and over and over again, only to get squashed by management and everybody above them within F.A.A. Were they set up for failure?” “They were not adequately prepared to do the jobs they were assigned to do.”

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The National Transportation Safety Board said that a “multitude of errors” led to the collision between a military helicopter and a commercial jet, killing 67 people last January.

By Meg Felling

January 27, 2026

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Families of killed men file first U.S. federal lawsuit over drug boat strikes

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Families of killed men file first U.S. federal lawsuit over drug boat strikes

President Trump speaks as U.S. Secretary of Defense Pete Hegseth looks on during a meeting of his Cabinet at the White House in December 2025.

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Relatives of two Trinidadian men killed in an airstrike last October are suing the U.S. government for wrongful death and for carrying out extrajudicial killings.

The case, filed in Massachusetts, is the first lawsuit over the strikes to land in a U.S. federal court since the Trump administration launched a campaign to target vessels off the coast of Venezuela. The American government has carried out three dozen such strikes since September, killing more than 100 people.

Among them are Chad Joseph, 26, and Rishi Samaroo, 41, who relatives say died in what President Trump described as “a lethal kinetic strike” on Oct. 14, 2025. The president posted a short video that day on social media that shows a missile targeting a ship, which erupts in flame.

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“This is killing for sport, it’s killing for theater and it’s utterly lawless,” said Baher Azmy, legal director of the Center for Constitutional Rights. “We need a court of law to rein in this administration and provide some accountability to the families.”

The White House and Pentagon justify the strikes as part of a broader push to stop the flow of illegal drugs into the U.S. The Pentagon declined to comment on the lawsuit, saying it doesn’t comment on ongoing litigation.

But the new lawsuit described Joseph and Samaroo as fishermen doing farm work in Venezuela, with no ties to the drug trade. Court papers said they were headed home to family members when the strike occurred and now are presumed dead.

Neither man “presented a concrete, specific, and imminent threat of death or serious physical injury to the United States or anyone at all, and means other than lethal force could have reasonably been employed to neutralize any lesser threat,” according to the lawsuit.

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Lenore Burnley, the mother of Chad Joseph, and Sallycar Korasingh, the sister of Rishi Samaroo, are the plaintiffs in the case.

Their court papers allege violations of the Death on the High Seas Act, a 1920 law that makes the U.S. government liable if its agents engage in negligence that results in wrongful death more than 3 miles off American shores. A second claim alleges violations of the Alien Tort Statute, which allows foreign citizens to sue over human rights violations such as deaths that occurred outside an armed conflict, with no judicial process.

The American Civil Liberties Union, the Center for Constitutional Rights, and Jonathan Hafetz at Seton Hall University School of Law are representing the plaintiffs.

“In seeking justice for the senseless killing of their loved ones, our clients are bravely demanding accountability for their devastating losses and standing up against the administration’s assault on the rule of law,” said Brett Max Kaufman, senior counsel at the ACLU.

U.S. lawmakers have raised questions about the legal basis for the strikes for months but the administration has persisted.

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—NPR’s Quil Lawrence contributed to this report.

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Video: New Video Analysis Reveals Flawed and Fatal Decisions in Shooting of Pretti

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Video: New Video Analysis Reveals Flawed and Fatal Decisions in Shooting of Pretti

new video loaded: New Video Analysis Reveals Flawed and Fatal Decisions in Shooting of Pretti

A frame-by-frame assessment of actions by Alex Pretti and the two officers who fired 10 times shows how lethal force came to be used against a target who didn’t pose a threat.

By Devon Lum, Haley Willis, Alexander Cardia, Dmitriy Khavin and Ainara Tiefenthäler

January 26, 2026

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