Published by https://m10news.com | By Dayo Ade Olusola | Category: Aviation & Safety
Ryanair CEO Michael O’Leary has voiced renewed concerns over Boeing’s aircraft manufacturing practices following the recent crash of an Air India Boeing 787 Dreamliner in Ahmedabad, India.
Speaking to The Times, O’Leary revealed that Ryanair’s engineers have routinely discovered foreign tools—such as spanners—left beneath aircraft floorboards upon delivery of new jets from Boeing. While Ryanair’s fleet consists exclusively of Boeing aircraft, O’Leary criticised the oversight in Boeing’s production line, calling for improved supervision.
The safety comments come in the wake of the June 12 crash of Air India Flight 171, which plunged just seconds after taking off from Ahmedabad. The Boeing 787 aircraft was carrying 242 passengers and crew members when it experienced a catastrophic failure roughly 30 seconds into flight.
Although investigators have yet to determine the cause of the incident, and there is currently no official indication that Boeing is at fault, the crash has rekindled global scrutiny around the aerospace giant’s quality control protocols.
The aircraft involved was delivered in 2014, making it a seasoned unit that had undergone multiple rounds of scheduled maintenance.
Nevertheless, O’Leary said his airline has remained cautious about new Boeing deliveries—particularly since recurring issues were first detected during Ryanair’s own inspections.
“We had planes being delivered, and when we got them back to Dublin, we found spanners and tools under the floorboards,” O’Leary stated. “What the factory in Seattle needs is someone overseeing the production line. At the moment, it’s just salesmen.”
To mitigate risk, Ryanair now deploys a dedicated team of 30 engineers to oversee inspections at Boeing’s U.S. production sites. Once aircraft are delivered to Dublin, a further 48-hour inspection is conducted by Ryanair’s internal safety team. “Only once we are completely happy does it go into operation,” O’Leary said during a prior interview in February 2023.
Meanwhile, fresh attention has been drawn to longstanding claims by Boeing whistleblower Sam Salehpour, a veteran engineer who previously alleged that shortcuts taken in manufacturing the 787 Dreamliner may compromise its long-term airworthiness.
Salehpour, who worked at Boeing for over a decade, accused the company of prioritising speed over precision in its wide-body jet assembly lines.
Specifically, he warned that parts of the fuselage were poorly aligned during production due to being sourced from multiple subcontractors, which could lead to catastrophic structural failures mid-flight after years of service.
“I have analysed Boeing’s own data to conclude that the company is taking manufacturing shortcuts on the 787 programme that may significantly reduce the airplane’s safety and lifecycle,” Salehpour told a U.S. Senate panel. He even claimed to have witnessed workers physically “jumping on the pieces” of aircraft sections to force alignment during assembly.
The U.S. Federal Aviation Administration (FAA) has launched an investigation into Salehpour’s allegations, though its final report has yet to be released to the public. Boeing, for its part, has admitted to implementing changes in the Dreamliner’s manufacturing process but maintains there is no imminent safety risk.
In a previous statement, Boeing affirmed its confidence in the 787’s structural integrity. “These claims about the structural integrity of the 787 are inaccurate and do not represent the comprehensive work Boeing has done to ensure the quality and long-term safety of the aircraft,” the company said.
Boeing has touted the Dreamliner—first delivered in 2011—as one of its most advanced and fuel-efficient aircraft. Its carbon-fibre and glass composite materials offer significant weight reduction compared to traditional metal-bodied aircraft, allowing for extended range and improved fuel economy.
To date, Boeing’s official safety record claims that no Dreamliner has been irreparably damaged or written off in a crash, according to its April 2025 incident summary.
In response to the recent tragedy in Ahmedabad, Boeing CEO Kelly Ortberg offered condolences to the victims and pledged full cooperation with the investigation led by India’s Aircraft Accident Investigation Bureau (AAIB).
“Our deepest condolences go out to the loved ones of the passengers and crew on board Air India Flight 171, as well as everyone affected in Ahmedabad,” Ortberg said. “I have spoken with Air India Chairman N. Chandrasekaran to offer our full support, and a Boeing team stands ready to assist the investigation.”
Boeing has yet to issue an updated statement following renewed scrutiny from airline executives and the media. Metro has contacted the company for comment.
