Spirit plans investment in robotics to minimize Boeing 737 defects

Spirit AeroSystems’ interim CEO, Patrick Shanahan, has unveiled the company’s plan to invest in autonomous technology, aimed at minimizing defects in its production of Boeing 737 fuselages.

The move comes in response to a string of manufacturing challenges and the recent mid-air blowout incident involving a 737 MAX 9 aircraft.

Boeing and Spirit, responsible for constructing the complete 737 fuselage, are facing heightened scrutiny from investors, regulators, and lawmakers following an incident where a door plug detached from a MAX 9 aircraft mid-flight. Though no serious injuries were reported, the U.S. Federal Aviation Administration (FAA) has imposed restrictions on Boeing, preventing the planemaker from increasing production of the 737 MAX.

Quality issues

Spirit, already under scrutiny for a string of manufacturing challenges linked to the 737 MAX, recently detected a fresh quality concern regarding wrongly drilled holes on 737 window frames. This development may necessitate additional work on approximately 50 aircraft for both Spirit and Boeing.

Shanahan stated on Tuesday that Spirit anticipates having a repair plan established within 72 hours. He emphasized that Spirit will intensify training for mechanics and augment the number of inspections conducted by both Boeing and Spirit. Additionally, measures will be implemented to enhance the “mistake-proofing” of 737 MAX production processes.

“The mindset shift is to understand that the airplane is the boss. The airplane tells us what to do,” he said.

Also Read: U.S. regulators ground Boeing 737 MAX 9 flights

While full-scale robotics are “impractical” in Spirit’s Wichita, Kansas-based factory, Shanahan said the company is looking to accelerate technology that can make it easier for mechanics to build the front and rear portions of the 737 fuselage, which are the most confined and complex workspaces.

Shanahan said executive compensation would also be more heavily weighted toward quality in the future.

Spirit executives mentioned that they halted 737 production in the fourth quarter to stabilize operations, enabling the delivery of 104 fuselages to Boeing, marking the highest quarterly total for 2023.

The company is presently maintaining a production rate of 38 737 fuselages per month, with Shanahan noting that its supply chain is equipped to support up to 42 jets per month. In 2023, it successfully delivered 356,737 fuselages, meeting its adjusted target range of 345 to 360 units, which was revised in October from the initial goal of 370 to 390.