Whistleblower Ed Pierson: Boeing's production pressure causes defects on 787

The tragic crash of Air India Flight AI171, a Boeing 787-8 Dreamliner, in Ahmedabad has renewed global focus on Boeing manufacturing culture and safety oversight. Former senior manager-turned-whistleblower Ed Pierson, now with the Foundation for Aviation Safety, has raised alarms. He argues that intense production pressure is creating serious defects in new aircraft.

Pressure and Fatigue on the Factory Floor

Pierson spent nearly a decade in senior roles on the 737 and 787 programs. He claims that while Boeing publicly touts safety, on the factory floor, "Schedule was king." This culture placed immense pressure on manufacturing, quality control, and supply-chain employees. Employees were asked to work excessively long hours, leading to fatigue and repeated mistakes. This is a key factor in production pressure defects.

• Human Factors: Exhausted workers made mistakes and suffered communication breakdowns.
• Out-of-Sequence Work: Supply-chain delays forced employees to rush installations, creating dangerous conditions.
• System Failures: Quality-control reports showed issues in flight-control, electrical, hydraulic, and pressurization systems.

Pierson pointed to similar patterns during the 787's early development. This period, called the “terrible teens,” saw dozens of aircraft needing extensive rework due to serious production defects.

The Ahmedabad Crash Investigation

The Air India Flight 171 crash on June 12, 2025, put the 787 Dreamliner under the safety spotlight. The Aircraft Accident Investigation Bureau (AAIB) preliminary report indicated a loss of engine thrust. This happened after the fuel cutoff switches transitioned to the "cutoff" position shortly after takeoff.

Pierson strongly rejected the narrative hinting at pilot error. He called the 787 an "electrical monster" due to its complexity. He raised grave concerns about the investigation's direction.

Concerns Over Omitted Data

Pierson described the AAIB preliminary report analysis as "horrible." He argued that it omitted crucial information that should be public. This included full sensor data, stabiliser details, and the complete cockpit voice recording (CVR). He suggested investigators must examine all possible faults before blaming the pilots. The preliminary report did not recommend immediate actions for 787 operators.

Pierson also noted a pattern in accident investigations. He claimed US authorities often prematurely blame pilots, overlooking mechanical or 737 MAX electrical failures and manufacturing issues. He applauded the Supreme Court’s intervention in the matter.

A Call for Cultural and Criminal Accountability

For the aviation whistleblower Ed Pierson, the problem is cultural, not just technical. He believes a Boeing manufacturing culture change is needed. He stated that the Federal Aviation Administration (FAA) is "failing" and "out of touch." He urged leadership to visit factories and talk to mechanics.

Pierson also called for criminal accountability to drive real change. He stated that pushing employees to meet schedules for public-relations announcements is "criminal behaviour." He believes leaders who knowingly made dangerous decisions must be held accountable. This is the only way to ensure lasting safety improvements for the Boeing 787 Dreamliner safety and the entire fleet.

• Immediate Action: Boeing must restart and quickly fix defects on the 737 and 787.
• Regulatory Oversight: The FAA must increase its oversight and engage with factory workers.
• Criminal Liability: The Department of Justice must step in to hold leaders accountable for gross negligence.

Pierson concluded that he would not fly on the 737 MAX or recommend the 787 until authorities "do their job." He noted that poor manufacturing processes seen on the MAX are also evident on the 787.