Boeing Whistleblower Suggests Manufacturing Flaws May Have Contributed to Air India Crash

The recent crash of Air India flight AI171 in Ahmedabad, which claimed the lives of more than 270 people, has drawn renewed scrutiny toward Boeing’s manufacturing practices. Among the voices raising alarms is Ed Pierson, a former Boeing executive turned whistleblower, who suggests systemic issues at the aircraft maker could have played a role in the tragedy.

The Boeing 787-8 Dreamliner, en route to London Gatwick, plunged into a residential area shortly after takeoff, ultimately coming to rest inside a college dining hall filled with medical students. Miraculously, one passenger survived. The incident has prompted an international investigation, with authorities from India, the UK, and the US analyzing black box and cockpit recordings to determine the cause.

Initial theories have centered on mechanical failures, including possible issues with engine thrust, wing flaps, and landing gear. Aviation expert Dr. Sonya Brown suggested the crash may have resulted from a stall due to significant thrust loss during ascent.

Whistleblower raises manufacturing red flags

Ed Pierson, who once held a senior management role at Boeing, spoke to NDTV about the 787’s production process, which he described as “chaotic and dangerous.” He recalled rushed timelines, overworked staff, and the forced fitting of parts—practices he believes may have compromised aircraft integrity.

“We were rushing to build planes,” Pierson said. “There were parts issues, aircraft systems issues, functional system testing and electrical system testing problems. I remember being very concerned that we were taking unnecessary risks.”

Now serving as the executive director of the Foundation for Aviation Safety, Pierson stressed that although it’s too early to determine the exact cause of the crash, the persistent pattern of unaddressed safety issues in Boeing’s manufacturing remains deeply troubling.

Warning signs before takeoff?

Adding another layer of concern, Pierson referenced a passenger account from an earlier flight on the same aircraft, who reported that several onboard systems—including air conditioning—were not functioning properly. “That’s a little bit of a concern,” Pierson said, noting that critical backups should have prevented such issues.

As investigators continue to analyze the black box data, Pierson and other experts urge caution in drawing conclusions—but insist that Boeing’s production process must be scrutinized.

“There is a lot of information we don’t know,” Pierson said. “But what we do know is that safety lapses in manufacturing have long been flagged, and they must be taken seriously.”

As families mourn an unimaginable loss, voices like Pierson’s remind us that aviation safety doesn’t end on the runway—it begins on the factory floor.