NTSB blames systemic failures for Alaska Airlines flight door plug blowout

In January 2024, an incident occurred aboard an Alaska Airlines Boeing 737 Max 9 shortly after takeoff from Portland, Oregon, when the door plug panel blew out mid-flight. As a result, a vacuum was created that sucked objects from the cabin out into the outside, leading to the deployment of oxygen masks while the 171 passengers struggled against the wind and noise. Remarkably, there were no major injuries after the crew successfully managed an emergency landing back at the airport. The door plug had been tampered with for repairs at ZBoeing's factory two months prior, but during the process, four bolts securing the plug were improperly handled and never replaced. NTSB investigations indicated numerous systemic failures contributing to this mishap, implicating Boeing’s lack of safety protocols and inadequacies in the FAA’s oversight practices. Several months into the investigation, many findings pointed to Boeing's production quality issues and the inexperience of factory workers. NTSB chair Jennifer Homendy highlighted that less experienced workers were pressured into executing unfamiliar tasks, which ultimately undermined safety. As inquiries continued over the months, the NTSB scheduled a public meeting to discuss findings and recommendations to prevent similar incidents in the future. New safety measures and leadership changes had been initiated at Boeing in response, but the NTSB insisted that major improvements were still required for both Boeing and the FAA.