The aviation industry is in shock following the death of former Boeing employee, John Barnett, a prominent whistleblower who bravely spoke out against the aerospace giant’s production standards. Barnett, who spent over three decades at Boeing as a quality control manager, was found dead in the US while actively involved in a lawsuit against his former employer.
John Barnett, a former quality control manager at Boeing, had raised significant concerns about the company’s safety standards prior to his death.
Barnett’s death on March 9th, reportedly from a self-inflicted wound as confirmed by the Charleston County coroner, has sent ripples through the industry, particularly given the timing. He was in Charleston, South Carolina, engaged in legal depositions related to his whistleblower lawsuit against Boeing. Just days before his untimely passing, Barnett had been providing evidence, alleging that Boeing prioritized speed and profits over safety, potentially compromising the quality and integrity of their aircraft.
John Barnett’s Allegations of Compromised Safety at Boeing’s 787 Dreamliner Plant
John Barnett’s career at Boeing spanned 30 years, culminating in a quality manager role at the North Charleston facility from 2010 until his retirement in 2017, citing health reasons. This plant is crucial for Boeing as it is responsible for manufacturing the 787 Dreamliner, a flagship aircraft renowned for its fuel efficiency and long-haul capabilities.
It was during his tenure at the North Charleston plant that Barnett witnessed and reported alarming practices that he believed jeopardized aircraft safety. In a 2019 interview with the BBC, Barnett detailed how workers, under immense pressure to meet production targets, were allegedly resorting to installing substandard parts on aircraft. He further claimed to have discovered critical issues with the oxygen systems on the 787 Dreamliner, suggesting a concerning failure rate where as many as one in four emergency oxygen masks might not function correctly during an emergency.
Barnett asserted that the relentless drive to accelerate aircraft production led to a compromised assembly process where safety protocols were overlooked. He revealed instances where procedures designed to track components were deliberately bypassed, leading to defective parts being untraceable. Shockingly, he alleged that in some cases, to avoid production delays, substandard components were even retrieved from scrap bins and fitted onto aircraft destined for flight.
His accusations extended to the critical emergency oxygen systems of the 787. Barnett stated that tests indicated a 25% failure rate in deployment, a potentially catastrophic flaw in a real emergency situation where passengers rely on these systems.
FAA Investigation and Boeing’s Denials
Despite Barnett’s repeated attempts to raise these concerns with Boeing management, he claimed that no meaningful action was taken to rectify the issues. Boeing vehemently denied Barnett’s allegations. However, a 2017 review conducted by the Federal Aviation Administration (FAA), the US aviation regulator, partially substantiated Barnett’s claims.
The FAA investigation confirmed that at least 53 “non-conforming” parts within the North Charleston factory were unaccounted for, deemed “lost”. The regulator mandated Boeing to implement corrective measures to address these lapses in quality control.
Regarding the oxygen cylinder concerns, Boeing acknowledged in 2017 the identification of some faulty oxygen bottles from a supplier that did not deploy correctly. However, the company maintained that none of these defective units were installed on operational aircraft.
Legal Battle and Tragic Death Amidst Scrutiny
Following his retirement, John Barnett initiated a protracted legal battle against Boeing. He accused the company of damaging his reputation and hindering his career progression as a direct consequence of his whistleblowing activities – accusations that Boeing refuted.
At the time of his death, Barnett was actively pursuing this lawsuit in Charleston. He had recently undergone formal depositions, being questioned by Boeing’s legal team and subsequently cross-examined by his own lawyers. Further questioning was scheduled for Saturday, March 9th. When he failed to appear, inquiries were made at his hotel, leading to the discovery of his body in his truck in the hotel parking area.
Barnett’s lawyer described his death as a “tragedy,” highlighting the immense pressure and stress Barnett was under while pursuing his case. Boeing issued a statement expressing sadness at Mr. Barnett’s passing and extending condolences to his family and friends.
John Barnett’s death occurs at a critical juncture for Boeing, as the company and its key supplier, Spirit AeroSystems, are facing intense scrutiny over their production standards. This heightened attention is largely due to a recent alarming incident in early January, where an emergency exit door detached from a brand-new Boeing 737 Max shortly after takeoff. A preliminary report from the National Transportation Safety Board (NTSB) indicated that critical bolts meant to secure the door were missing.
Adding to Boeing’s woes, the FAA recently announced the findings of a six-week audit, revealing “multiple instances where the company allegedly failed to comply with manufacturing quality control requirements.” The circumstances surrounding John Barnett’s death, coupled with ongoing safety concerns, have placed Boeing under unprecedented pressure to demonstrate its commitment to safety and quality above all else.
