Assignment2_DhruvDave_8799461
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School
Conestoga College *
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Course
101
Subject
Industrial Engineering
Date
Dec 6, 2023
Type
Pages
9
Uploaded by Mayaruthodi9008
Student
Name:
Dhruv Dave Girinbhai (8799461)
Deliverable:
Boeing 737 MAX, Exercise # 2B
Course Name:
Qual8000
Date
Assigned:
2022-02-10
Date Due:
2022-02-27
Rules:
1)
This assignment will be completed individually
2)
You will use the Word, PowerPoint, and other tools
you feel appropriate for this exercise
3)
Your work must be your own
4)
Copying/plagiarism/cheating is not allowed
5)
Each deliverable should be clear and simple to read
Executive summary
The Boeing 737 max plane crash, it is still the worst case of failure for the Boeing and more
than 340 people died during the plane crash. The first Boeing plane crashed was from
Indonesia, and second incident happened with Ethiopian airline. The report made after this,
and which
developed by Indonesia’s aviation safety agency. They told there was a problem
in sensor and there was a technical error by air agency. The second case is still not known
properly. After the speculation company made several changes to fix the problems. The
company told to take back their plane and they were not allowed to fly until 2020. After this
the CEO of company changed and the new CEO was David Calhoun he was appointed on
January 13, after that whole staff was changed including board of directors. Company made
so much of loss because of it. Airbus took the advantage of the situation, and they capture
the market. Boeing did not lose their hope and they came with new airplane with highest
capacity and fuel cost-effective. Company launched their new jet engine, and they were
passed through all the certifications process they gave training to new pilots. Federal
Aviation Administration (FAA) were going to help the company who is struggling with its
rival. Boeing came with a decision on both the cases, and they said that it was their worst
decision install Maneuvering Characteristics Augmentation System (MCAS). Once the firm
constructed 737 MAX aircrafts, the engines were made larger and to decrease the fuel
capacity company changed their position of placing engine and this resulted into
aerodynamics change. The MCAS was the problem for both crashes as it generated the
problem for pilots as they were not able to control or manage the flight. So, the report will
be evaluating four types of cost of quality namely, Appraisal cost, Prevention cost, Internal
failure cost and External failure cost.
Cost of Quality:
Appraiser cost:
Boeing made new modification for the plane they did not make the new. They knew that
the if they construct the new lineup of plane, it will cost them huge sum of money in making
and certification process. During the entire process
appraisers’
qualities cost came ahead
which include cost for inspection. During the process there was so much pressure on the
company to as the company values were going down, and the competitors were taking
advantage of that. FAA helped Boeing in certification process as it was truly brief period of
20 months. The company did not do inspection completely and it resulted in loss of lives and
company lost money.
Prevention Cost:
According to Boeing constructing a new plane it would add cost such designing process,
manufacturing material cost, quality inspection, certification process for saving the
prevention cost Boeing did not make new plane. Boeing did not take efforts on training the
pilots and they neglected the testing of MCAS. Flying Boeing 737 max is like flying the last
plane. According to the guidelines if the new plane is manufacturing there is a training
period for the pilots as to take the experience of the plane. The cost they saved from
training they used them in making new engines which has low fuel capacity. The first crash
did not wake up their eyes they were still on the same path. FAA did not raise any voice on
giving training to pilots. Both crashes happened because of sensors were not equipped. At
that time an engineer from the company tweeted that, for cutting the cost down, company
rejected safety system because of that it caused fatal crash.
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Internal Failure cost:
According to report new planes with higher fuel saving engines were fitted to the Boeing
body this switched its whole aerodynamic and this resulted in to controlling and handling
problems at higher altitude. Engineers suggested MCAS should be used for this but for
saving money they spend that money on different software fix. The company was struggling
with MCAS issues as it was giving the difficult to pilots as they were not able to control the
plane properly at higher altitude. Proper attention is not given on this, and company
resulted in paying huge sum of money on quality. In 2016 few engineers noticed the issue
with MCAS, but proper consideration was not done on this, and failures were not delivered.
External failure cost:
When the two crashes happened, company lost more than more than $30 billion. Their
valuation decreased day by day and stock market also affected. The crisis affected them
very badly as they charged with lawsuits, moreover they were spending money on
manufacturing sector. No company came forward to help them in crisis as their status was
going down day by day as new and new frauds were coming ahead. In
today’s
date company
is fixing the issues in Boeing 737 max. The company made losses in replacement of planes,
and they also paid more money on parking as they were not having place to keep the
aircrafts. The company made loss of more than 600 million dollars.
Root cause for the issue:
LION Air flight 610 issue:
The day before the crash there was a maintenance work done on deck on October 28 it was
reported that the there was some fault in sensor, and it must be replaced or to be assessed.
The maintenance team used refurbished sensors. The reports indicates that the sensor was
not properly calibrated. There was some error in 2 sensors it was showing faulty readings at
the time of landing. The pilots were unaware as the AOA lights were not working properly.
After some time when they reached at higher altitude the problem started with flaps, this
was the same thing happened on the day of crash. The problem came out that MCAS was
activated, and it took control and started forcing jet nose in downward direction. Pilots
managed these things by stopping the electric supply to MCAS. Pilots reported the problem
but because of carelessness of maintenance team the problem was not solved, and they
mentioned that issue was resolved. On the next day, the same plane took off and the
problem occurred was the same MCAS gave false readings. To counter this situation as
MCAS was forcing jet nose in downward direction pilots dragged the nose of the jet in
upward direction. Captain struggled with it as he was unaware about the problem, and he
was not able to control the plane and it got crashed in the sea with having speed of 500
miles per hour. Total 189 peoples killed in this incident.
Ethiopian Airlines Flight 302 issue:
According to the reports, MCAS was working properly after take-off, after some time it
suddenly change the degrees. Pilots were bit confused as it is not possible to fly at that
angle, they thought that it would be some bird hit and the vane got damaged. Suddenly
after this MCAS got triggered and to counter these crew just blocked the power supply to
the MCAS. Pilots tried to regain the speed and try to balance the trim wheel, but they were
not able move it. The stabilizer was also not working properly and continuously speed was
increasing and there was so much pressure on tail, it resulted into the crash. In that aircraft
there were 157 people, and it was a fatal accident.
Why was the MCAS system added to the Max 8?
Boeing invented the new system for handling the larger engines as it were used for
increasing the fuel efficiency. The system helps them to control the flight and it can improve
handling qualities and it help in decreasing pitch-up tendency at elevated angle of attack
(AOA). It is applied on 737 max to enhance it stability quality. Working of MCAS is like it
gives commands to nose stabilizer for improving its pitch quality during sharp turns as there
is so much load it activated automatically. MCAS gets active when the AOA exceeds its
altitude and airspeed.
How did a company that had a reputation for quality and safety find itself in
this situation?
The company situation was becoming worse because issue with the money and the cost
cutting in the quality. There is a report which tells that there was wreckage found in jack
screw which moves horizontal tail. The tail was also found to be in downward position at the
time of crash it was because of MCAS, and it got activated because of AOA failure. The
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company was neglecting the safety issues and their priority was money this affected them in
the worst situation.
How did the Boeing leadership manage this crisis?
After the 2
nd
crash and failure of aircraft CEO was changed on January 13. After the
company changed their board of directors and the regulatory step were taken against
them. All the aircrafts were grounded, and all the safety instructions were given to the
different team. Inspection work was conducted and main aim was to check the quality
of aircrafts. They took responsible decisions on quality, and they increased their cost
for all the resources which were needed. Newly appointed CEO gave instruction to
manufacture MCAS and this will help them to find AOA value. MCAS will also respond
less with slightly moving in downward direction. MCAS will start automatically but it
will be controllable by pilot. Company made huge loses but they also stated that they
will recover it. The new law was also made for the training of the pilots, and they were
taught all the things related to safety. They build their private cockpit for the trainee
pilots which is like the actual aircraft and works as the same. Certification process for
the Boeing 737 max was done properly and all the necessary steps were taken for
relaunching the Boeing 737 max. after 20 months it was relaunched with the proper
documentation and according to the FAA guidelines. The bare more than 20 billion
dollar loses, till now they are recovering from it. The company gave money 500 million
dollars to the families and relatives who were died in both the crashes.
References
1.
“
What are the 737 Max jets? Why did two of them crash within five months
of each other? And what is MCAS?
”
By Andrew J. Hawkins, MAR 22, 2019,
https://www.theverge.com/2019/3/22/18275736/boeing-737-max-plane-
crashes-grounded-problems-info-details-explained-reasons
2.
“
The timeline history
”
by David slotnick, Oct 29, 2020
https://www.businessinsider.com/boeing-737-max-timeline-history-full-
details-2019-9
3.
“
What lead to boeing 737 Max crisis
”
By Domnic Gates, Nov 18, 2020
https://www.seattletimes.com/business/boeing-aerospace/what-led-to-
boeings-737-max-crisis-a-
qa/#:~:text=Two%20crashes%20of%20virtually%20new,jet%20into%20a%2
0nose%20dive
.
4.
“
Boeing To Pay $2.5 Billion Settlement Over Deadly 737 Max Crashes
”
by
David Schaper, Jan 18, 2021
https://www.npr.org/2021/01/08/954782512/boeing-to-pay-2-5-billion-
settlement-over-deadly-737-max-crashes
5.
“
How Boeing 737 MAX's flawed flight control system led to 2 crashes that
killed 346 Watch the full story on "20/20"
”
, ByJoseph Rhee,Gerry Wagschal,
andJinsol Jung, 27 November 2020
https://abcnews.go.com/US/boeing-737-maxs-flawed-flight-control-
system-led/story?id=74321424
6.
“
Boeing 737: How world's most successful airplane became its most
troubled
”
By Jacopo Prisco , 25th December 2020
https://www.cnn.com/travel/article/boeing-737-story-behind-the-
troubled-aircraft/index.html
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