Boeing's Fatal Flaw (full documentary) | FRONTLINE

The script opens with the shocking news of the Lion Air Flight 610 crash on October 29th, involving a Boeing 737 MAX 8 aircraft. The narrator describes the confusion and disbelief among aviation professionals, given the plane's new status. The company responsible for air data in Jakarta confirms irregular flight patterns, including rapid altitude changes and a sudden dive, leading to the crash. The tragedy results in 189 fatalities. The Boeing 737 MAX 8, touted as Boeing's fastest-selling jet, is scrutinized, and the flight data recorder reveals a glitch in the plane's tail control system. The script introduces the Maneuvering Characteristics Augmentation System (MCAS), a software system that Boeing had not disclosed to airlines or pilots, which played a critical role in the crash. Boeing's internal response and the subsequent global grounding of the 737 MAX fleet are discussed, highlighting the company's initial reluctance to acknowledge the problem and its impact on Boeing's reputation.

The second paragraph delves into the Ethiopian Airlines Flight 302 disaster, another Boeing 737 MAX 8 crash that killed all 157 people on board. The emotional impact on the victims' families is highlighted, with personal accounts of their experiences at the crash site. The script connects the two MAX crashes, suggesting a systemic issue with the aircraft. The New York Times' investigative efforts reveal that Boeing was aware of the MCAS system's potential risks but kept it undisclosed from pilots. The narrative also touches on the competitive pressure Boeing faced from Airbus and the rushed development of the MAX, which may have contributed to the oversights in safety.

This section traces the origins of the Boeing 737 MAX, set against the backdrop of Boeing's rivalry with Airbus. The Airbus A320neo's success spurs Boeing to respond with the MAX, leading to a rushed development process. The 737, a staple in Boeing's lineup, faces an upgrade to maintain its competitive edge. The script highlights the financial stakes for Boeing, with the 737 contributing significantly to the company's profits. The pressure to quickly launch the MAX, coupled with cost-cutting measures, sets the stage for the subsequent safety issues.

The focus shifts to the MCAS system, designed to prevent stalls by automatically pushing the plane's nose down. The script reveals that Boeing test pilots had concerns about MCAS during simulator tests, fearing a catastrophic event. Despite these early warnings, Boeing chose not to disclose MCAS to pilots or the FAA, potentially to avoid costly simulator training. The decision to keep MCAS hidden from pilots is shown as a critical misstep, with implications for the safety of the aircraft.

This paragraph examines the relationship between Boeing and the FAA, particularly the delegation of regulatory tasks to Boeing employees. The arrangement, intended to streamline certification processes, raises questions about oversight and accountability. The script introduces Ali Bahrami, a key FAA figure who had previously lobbied for greater industry involvement in FAA processes. The delegation of MCAS oversight to Boeing is highlighted, suggesting a lack of independent scrutiny that may have contributed to the MAX's safety issues.

The narrative continues with the revelation that Boeing engineers expanded the MCAS system, making it more aggressive and risky. The decision to apply MCAS to low-speed situations, such as just after takeoff, is criticized. The script also introduces Mark Forkner, a Boeing pilot who played a key role in minimizing pilot training for the MAX. His actions in downplaying the significance of MCAS and ensuring it was omitted from pilot manuals are highlighted, underscoring the corporate culture that prioritized cost and speed over safety.

The script delves into the technical details of the MCAS system, focusing on the angle of attack (AOA) sensor that triggers MCAS. The potential for a single faulty sensor to cause repeated nose-down commands is discussed, revealing a significant design flaw. Boeing engineers' concerns about this issue are noted, but their warnings were apparently dismissed, leading to a critical safety risk that played a role in the MAX crashes.

Following the crashes, investigations reveal that the AOA sensor was miscalibrated in the Lion Air crash, leading to erroneous MCAS activation. The script details the similarities between the Lion Air and Ethiopian Airlines crashes, both linked to the malfunctioning AOA sensor. Boeing's initial response, blaming pilot error, is criticized, highlighting the company's reluctance to accept responsibility for the flawed MCAS system.

This paragraph recounts the final moments of Ethiopian Airlines Flight 302, detailing the cockpit's struggle with MCAS. The script describes the pilots' attempts to regain control, following Boeing's directives, but ultimately failing due to the system's aggressive design. The emotional impact on the victims' families is emphasized, highlighting the human cost of the MAX's safety issues.

The script moves to the political and regulatory aftermath, focusing on congressional hearings and the FAA's involvement. The FAA's Ali Bahrami is questioned about the agency's knowledge of MCAS risks and its decision not to ground the MAX. The FAA's gamble with passenger safety is criticized, with internal communications revealing a lack of urgency in addressing the MCAS issues. The narrative underscores the regulatory failures that contributed to the MAX tragedies.

The final paragraph discusses the release of internal Boeing communications, revealing the company's awareness of MCAS issues prior to the crashes. Boeing CEO Dennis Muilenburg's testimony before Congress is highlighted, with the committee confronting him with evidence of Boeing's negligence. The script ends with the new Boeing CEO, David Calhoun, acknowledging the company's mistakes and the need for simulator training, suggesting a shift in Boeing's approach to safety.

The script concludes with the second anniversary of the Ethiopian Airlines crash and Boeing's settlement with the Department of Justice. Boeing admits to misleading statements about MCAS and agrees to pay $2.5 billion, with compensation for the victims' families and airlines. The FAA reapproves the 737 MAX, allowing it to return to service, but the script suggests that Boeing has yet to fully accept responsibility for the crashes.