The Air India Boeing 787-8 Dreamliner crashed shortly after takeoff in Ahmedabad on Thursday, killing 241 of 242 people on board. The aircraft was flying to London Gatwick from Ahmedabad. The crash is the first fatal accident involving a Boeing 787 since it entered service in 2009, and one of the worst tragedies in India’s aviation history.
Multiple whistleblowers have come forward with serious allegations about the safety of Boeing aircraft, specifically the 787 and 777 models. Sam Salehpour, a Boeing quality engineer, testified before the Senate Homeland Security & Governmental Affairs Permanent Subcommittee on Investigations, outlining safety concerns and detailing retaliatory actions he faced after raising these issues internally. Salehpour claimed that Boeing rushed production, overlooked safety standards, and failed to adequately address potential issues with the 787 and 777 aircraft. He specifically mentioned concerns about gaps in the 787 Dreamliner that were not properly shimmed, potentially leading to premature fatigue failure. Another whistleblower, Richard Cuevas, a mechanic at Strom, a contractor for Boeing manufacturing partner Spirit Aerosystems, alleged that holes were improperly drilled into the forward pressure bulkheads of 787 planes, which could lead to “devastating consequences.” Sam Mohawk, a current Boeing employee, alleged that damaged or out-of-specification parts were “likely being installed” on planes, potentially leading to a “catastrophic event.”
The recent Air India crash in Ahmedabad, involving a Boeing 787-8 Dreamliner, has triggered a comprehensive investigation, focusing on multiple potential factors. The crash, which occurred shortly after takeoff on June 12, 2025, resulted in at least 270 fatalities, making it the worst aviation disaster in a decade. The investigation is being led by India’s Aircraft Accident Investigation Bureau, with support from the U.S. National Transportation Safety Board (NTSB) and the Federal Aviation Administration (FAA).
Following the crash, India’s aviation minister announced urgent inspections of all Boeing 787s in the Indian fleet. This includes the 33 Boeing 787s operated by Air India and one operated by IndiGo. Additional maintenance checks have been ordered, focusing on GEnx engines, take-off parameters, electronic engine control tests, and fuel-related checks. While the planes have not been grounded, the government considered this option. The investigation will examine all potential causes, including engine thrust, flap issues, and the landing gear’s position during takeoff. A government panel is expected to issue a report within three months.
Whistleblower Concerns and Manufacturing Practices
Sam Salehpour, a Boeing engineer, came forward in 2024 with serious allegations regarding the assembly of the 787 Dreamliner. He claimed to have witnessed and reported potential defects related to the joining of the aircraft’s fuselage sections. Salehpour alleged that these sections were not properly aligned during assembly, potentially leading to premature fatigue and structural failure. He further accused Boeing of ignoring his concerns and retaliating against him for raising safety issues, suggesting that the company prioritized profits over safety.
The crash has brought renewed scrutiny to the Boeing 787 Dreamliner, which has been in service since 2011. The aircraft involved in the crash was delivered to Air India in January 2014 and had accumulated over 41,000 flight hours and nearly 8,000 takeoffs and landings . While the 787 has generally had a good safety record, this incident marks the first fatal crash of a 787-8 Dreamliner.
The investigation is also examining past safety concerns and allegations regarding Boeing’s manufacturing practices. Several sources highlight potential issues raised by whistleblowers about the 787 Dreamliner. These concerns include:
- Structural Defects: Allegations of improper connections in the fuselage, potentially leading to structural failures .
- Manufacturing Lapses: Claims of shortcuts, overlooked faults, and the use of substandard parts during the assembly process, particularly at the Charleston, South Carolina, facility.
- Quality Control: Concerns about the pressure to meet production targets, which may have compromised quality control measures.
- Whistleblower Retaliation: Allegations that Boeing retaliated against employees who raised safety concerns.
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Attorneys for Boeing whistleblower Sam Salehpour have urged the FAA to release its findings on structural defects related to the 787, citing the Air India crash. Salehpour had previously raised concerns about the “structural integrity” of the 787 and Boeing’s manufacturing processes.
The investigation into the Air India crash is multifaceted, encompassing immediate safety checks, a review of the aircraft’s history, and an examination of past safety concerns and manufacturing practices. The findings of the investigation will be crucial in determining the cause of the crash and preventing future incidents.
The crash comes after a series of safety issues for Boeing, including the 737 MAX crashes and other incidents . Boeing has faced scrutiny over its safety culture and internal practices. The company has stated its commitment to safety and is cooperating with the investigation. Boeing CEO Kelly Ortberg has offered full support to Air India and stated that a Boeing team is ready to assist the investigation.
A former Boeing whistleblower, who sadly took his own life, had warned about serious problems with the Air India Boeing 787 before it tragically crashed
Just before “committing suicide”, Boeing whistleblower John Barnett warned of major quality issues in the company’s 787 aircraft that could lead to a fatal crash.
John Barnett, another whistleblower, raised concerns about the 787 production process well before his death in March 2024. Barnett, a former Boeing quality control engineer, alleged that Boeing had removed quality checks at its 787 production facilities. He claimed that this action compromised the safety of the aircraft. Barnett’s allegations included claims of defective parts being installed in the aircraft and a culture within Boeing that discouraged reporting safety concerns.
A former quality manager at Boeing, John Barnett, raised concerns about shoddy work practices and poor oversight in the manufacturing of the 787 Dreamliner, citing sub-standard parts and safety risks.
The 787 Dreamliner faced criticism for its complicated assembly process, outsourcing of parts to multiple contractors, and immediate technical problems upon launch, including battery-related fires and software bugs.
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A video suggests the Air India plane had power issues hours before its crash: ‘Nothing is working.’
A traveler filmed a video showing ‘nothing working’ on an Air India plane shortly before it crashed. Akash Vatsa, who was on the flight from Dehli to Ahmedabad, posted clips on X revealing that the air conditioning and media system were inoperable. Tragically, just hours later, 241 of the 242 passengers on the flight from Ahmedabad to London Gatwick lost their lives, with the sole survivor being British man Vishwash Kumar Ramesh.
I was in the same damn flight 2 hours before it took off from AMD. I came in this from DEL-AMD. Noticed unusual things in the place.Made a video to tweet to @airindia i would want to give more details. Please contact me. @flyingbeast320 @aajtak @ndtv @Boeing_In #planecrash #AI171 pic.twitter.com/TymtFSFqJo
— Akash Vatsa (@akku92) June 12, 2025
“I was in the same damn flight two hours before it took off from Ahmedabad,” social media user Akash Vatsa wrote on X.
“I came in this from Delhi to Ahmedabad. Noticed unusual things in the place,” he went on, adding that he had filmed the apparently malfunctioning aircraft so that he could share the footage with Air India later.
“The AC is not working at all. And, as usual, your TV screens are also not working, neither is this button for calling the cabin crew,” Vatsa can be heard saying in the video.
He also complained of “sweating like hell” due to a lack of AC, adding that this was why “Air India is considered one of the worst airlines in the world.”
Other apparent faults, such as loose parts under the seats, broken fittings, and potential signs of a lack of maintenance, are also visible in the videos.
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Boeing CEO David Calhoun acknowledged whistleblowers at the company sometimes face blowback from superiors
Ref:
- India’s government is urgently inspecting all Boeing 787s after a devastating Air India crash that claimed at least 270 lives this week, the aviation minister said on Saturday, adding that the authorities were investigating all possible causes. [https://www.cnn.com/2025/06/14/india/air-india-crash-being-inspection-intl]
- Authorities survey for more bodies after Air India crash that killed over 240 people. [https://www.npr.org/2025/06/12/nx-s1-5431419/air-india-crash-787-boeing-ahmedabad]
- From Dreamliner to nightmare: The warnings Boeing may have missed as Air India crash rekindles old fears. [https://m.economictimes.com/industry/transportation/airlines-/-aviation/from-dreamliner-to-nightmare-the-warnings-boeing-may-have-missed-as-air-india-crash-rekindles-old-fears/articleshow/121846337.cms]
- The odds were in your favor if you were one of the 242 people who boarded Air India flight 171 in Ahmedabad, India, bound for London on June 12. [https://time.com/7293945/boeing-787-dreamliner-long-history-safety-concerns/]
- Air India plane crash: Publish Boeing report immediately, says whistleblower’s lawyer to US Federal Aviation Administration. [https://timesofindia.indiatimes.com/india/air-india-plane-crash-publish-boeing-report-immediately-says-whistleblowers-lawyer-to-us-federal-aviation-administration/articleshow/121838842.cms]
- Air India crash puts spotlight on Boeing 787-8 Dreamliner safety and the company’s recent troubles. [https://www.cbsnews.com/news/air-india-boeing-787-8-dreamliner-safety-what-to-know/]
- https://nypost.com/2025/06/12/world-news/shocking-video-reportedly-shows-power-failures-inside-air-india-plane-hours-before-it-crashed/
- https://www.dailymail.co.uk/news/article-14806149/Boeing-whistleblower-died-safety-fears-Dreamliner-factory.html
- New Boeing whistleblower alleges faulty parts ‘likely installed’ on planes, risking ‘catastrophic event’. [https://www.foxbusiness.com/economy/new-boeing-whistleblower-alleges-faulty-parts-likely-installed-planes-risking-catastrophic-event]
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