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Root Cause Analysis (RCA) of Boeing 737 Max Crashes

RCA of Boeing 737 Max Crashes

The Boeing 737 Max crashes refer to two tragic incidents involving the Boeing 737 Max aircraft, leading to a global grounding of this model's entire fleet. Leveraging tools like ProSolvr for Visual Root Cause Analysis can help dissect and address the causes of these crashes. Using Root Cause Analysis (RCA) techniques such as the Fishbone Diagram (Ishikawa diagram) is crucial for thoroughly understanding the contributing factors and ensuring robust safety improvements.

The first incident involved Lion Air Flight 610 (JT610), which occurred on the 29th of October, 2018, over the Java Sea near Jakarta, Indonesia. All 189 passengers and crew members on board lost their lives. The crash was primarily attributed to a malfunction in the Maneuvering Characteristics Augmentation System (MCAS), which repeatedly pushed the plane's nose down due to erroneous readings from a single angle of attack (AOA) sensor. The pilots struggled to regain control but were unable to counteract the MCAS inputs.

The second incident involved Ethiopian Airlines Flight 302 (ET302), which occurred on the 10th of March, 2019, near Bishoftu, Ethiopia. 157 passengers and crew members lost their lives. Similar to the Lion Air crash, this incident was also caused by issues with the MCAS system, which was erroneously activated due to faulty AOA sensor inputs, leading to repeated nose-down commands that the pilots struggled to overcome.

Following the Ethiopian Airlines crash, aviation authorities worldwide grounded the Boeing 737 Max fleet. Investigations revealed significant flaws in the MCAS system design and inadequate pilot training to handle a malfunction of this system. Boeing faced intense scrutiny and was required to make extensive software updates to the MCAS system, improve pilot training, and address other safety concerns. The 737 Max was eventually cleared to return to service in late 2020 and early 2021 after regulatory authorities approved the changes.

Boeing 737 Max Crashes

  • Mechanical Failure
    • Faulty AOA sensor
      • Susceptible to damage and malfunction
      • Single point of failure
    • MCAS Activation
      • Difficulty in overriding MCAS
      • Automated nose-down commands
  • Design Flaws
    • Design assumptions
      • Minimal change in training requirements
      • Assumed pilots would recognize and correct MCAS activation
    • MCAS single sensor dependency
      • No cross-checking with other sensors
    • Design redundancy
      • Insufficient redundancy
      • Overreliance on software to correct mechanical issues
      • Lack of backup systems for critical functions
  • Pilot Training
    • Inadequate training on MCAS
      • Insufficient time spent on MCAS in training programs
      • Lack of information on MCAS in manuals
      • Lack of simulator training
    • Rushed transition training for pilots from 737 NG to MAX
      • No realistic scenario simulations of MCAS malfunctions
  • Regulatory Oversight
    • Regulatory gaps
      • Lack of international coordination on safety standards
      • Inconsistent standards across different aviation authorities
    • FAA certification process
      • Insufficient scrutiny of new systems like MCAS
      • Delegated authority to Boeing (ODA)
    • Boeing self-certification
      • Pressure to expedite approval processes
      • Conflict of interest in self-assessment
  • Corporate Decisions
    • Management and communication
      • Underestimating pilot and airline feedback on aircraft handling
      • Poor internal communication of safety concerns
    • Pressure to compete with Airbus
      • Emphasis on market competitiveness over safety enhancements
      • Aggressive timelines for development and certification
    • Cost-cutting measures
      • Prioritizing profit margins over comprehensive safety evaluations
      • Reduction in budget for R&D and testing

The crashes severely damaged Boeing's reputation, leading to financial losses, legal settlements, and a loss of public trust. Boeing also had to provide compensation to the victims' families and to airlines affected by the grounding. These crashes underscore the importance of rigorous safety standards and thorough pilot training and awareness of new aircraft systems. ProSolvr, an AI-powered root cause analysis tool that uses fishbone templates, can visually map out the different causes that contributed to the problem effectively and efficiently.

Who should use the Boeing 737 Max Crashes template?

  • The Boeing 737 Max crashes provide critical lessons for a wide range of stakeholders in the aviation industry. Aircraft manufacturers like Boeing and its competitors can ensure robust design and testing of new systems like the MCAS. Regulatory bodies like the FAA and global equivalents can learn from these incidents to enhance aviation safety standards. Pilots and flight crew can receive better training to handle such contingencies. Software developers can implement rigorous testing protocols for critical systems, ensuring reliability under all conditions. Governments and policymakers can develop and enforce stringent regulations to ensure aviation safety and corporate accountability with the help of visual root cause analysis.
  • Why use the Boeing 737 Max Crashes template?

  • RCA, with the help of a Fishbone template, can visually map out the different causes that contributed to the problem. Tools like ProSolvr by smartQED, based on Six Sigma principles, can help analyze these causes effectively.

    By using a reliability tool like ProSolvr, stakeholders can gain a comprehensive understanding of the multifaceted causes of the Boeing 737 Max crashes. Authorities can systematically identify and address the root causes, leading to improved safety and prevention of similar incidents in the future. It can help them take preventive measures and work on corrective actions as well.


  • Create or customize your templates for problem analysis in ProSolvr by smartQED.

    Curated from community experience and public sources:

  • https://www.bbc.com/news/articles/cv2x2rxdlvdo
  • https://www.npr.org/2024/04/25/1247123011/boeing-crash-737-max-doj