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FAA Proposes Requiring Four Key Boeing 737 MAX Design Changes (aljazeera.com) 178

The Federal Aviation Administration said on Monday that it is proposing requiring four key Boeing 737 MAX design changes to address safety issues seen in two crashes that killed 346 people and led to the plane's grounding in March 2019. Al Jazeera reports: The agency is issuing a proposed airworthiness directive to require updated flight-control software, revised display-processing software to generate alerts, revising certain flight-crew operating procedures, and changing the routing of some wiring bundles. The announcement is significant, but there are still other major steps, including finalizing pilot-training procedures, that must be completed before the 737 MAX can resume flights. The public has 45 days to comment on the changes, and it is still unclear if flights will resume before the end of 2020.

The FAA said in a separate 96-page report released on Monday that it "has preliminarily determined that Boeing's proposed changes to the 737 MAX design, flight crew procedures and maintenance procedures effectively mitigate the airplane-related safety issues" in the two fatal crashes. The airworthiness directive seeks to require Boeing changes. The FAA said the changes minimize "dependence on pilot action and the effect of any potential single failure."

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FAA Proposes Requiring Four Key Boeing 737 MAX Design Changes

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  • by ELCouz ( 1338259 ) on Monday August 03, 2020 @09:07PM (#60363095)
    From a regulation standpoint, it's a joke. Who on earth allow plane maker to self-certificate their products? They failed to listen and prevent crash even with warnings all over the sky.
    • https://www.cnbc.com/2019/10/3... [cnbc.com] https://www.nytimes.com/2019/1... [nytimes.com] They didn't even listen to their own people, before the damned thing ever entered service.
    • by bobbied ( 2522392 ) on Tuesday August 04, 2020 @07:09AM (#60364369)

      From a regulation standpoint, it's a joke. Who on earth allow plane maker to self-certificate their products? They failed to listen and prevent crash even with warnings all over the sky.

      Just in case you've not been paying attention... Boeing LOST the right to self certify. That's what this whole effort has been about since the groundings, the FAA going through the 737 MAX (and other aircraft)'s certifications to make sure all the rules where followed and everything is in order.

      So it's no joke and Boeing doesn't currently have self-certification authority. They are subject to rigorous oversight by the FAA right now, something that is going to cost Boeing a lot of money to keep up and is unlikely to change anytime soon.

      In fact, they've been going through the certification paper trails for a lot of Boeing aircraft, and have found a number of deficiencies in other aircraft's designs which are also being addressed.

      So where I agree, Boeing dropped the ball here, I also see that the FAA did as well. Now everybody has "got religion" on this and for a while at least, things will be better. Eventually, the process will get corrupted again, people will get hurt and we will ask ourselves why we forgot the lessons we learned and why the decades of success lulled us into a false sense of security. It is the way of things.

  • by thegreatbob ( 693104 ) on Monday August 03, 2020 @09:08PM (#60363101) Journal
    Would've been expensive to retrofit a third AoA vane, but to me, it feels like the most reliable solution to the problem of sensor agreement.
    • by rtb61 ( 674572 ) on Monday August 03, 2020 @11:15PM (#60363411) Homepage

      You design new taller landing gear, a new longer engine mount and fit the engines properly, anything else is just corrupt bullshit. A plane engineered to crash, that needs software to stop if from crashing, utter insanity.

      • It would probably be fine with an addition of strakes under the tail, Kevin Lear style and fixing the botched software. They limit themselves to fixing the botched software, which BTW was messed up beyond imagination. Who approved it!?
      • Also perfectly sensible suggestions... they do have a telescoping landing gear design for the MAX 10 that seems pretty sound, but I'm sure there are limits to what can be done with a system like that. Unfortunately, the landing gear bays are integral to the wing box, and the hinges to the wing structure... I really wish they had continued the developments they had originally pursued with the 757 (keep the 707-sized upper fuselage frames, trash pretty much everything else) in a single-aisle plane, but that s
      • You design new taller landing gear, a new longer engine mount and fit the engines properly, anything else is just corrupt bullshit. A plane engineered to crash, that needs software to stop if from crashing, utter insanity.

        Wow, way to mischaracterize the problem here.

        This whole system was a stall avoidance thing and there are multiple bits of software and hardware designed to remind the pilots not to stall the aircraft. It was NOT a critical bit of software and hardware or wasn't supposed to be. It was to augment the handling characteristics of the aircraft, keep pilots out of trouble because their stick and rudder skills may not be up to par when flying low and slow.

        The PROBLEM was that there was this one failure mode th

        • by sjames ( 1099 )

          I would argue that there is an additional few problems. First, MCAS only uses one of the two AOA sensors. That's how it got into the bad corner case in the first place. Second, there is no way to disengage MCAS without disengaging all electrical trim. Finally, the manual trim requires the strength of a gorilla to operate in some circumstances.

          So, MCAS needs to check BOTH AOA sensors and disengage with a warning if they disagree. The pilot needs to be able to disengage MCAS while leaving the electrical trim

          • All excellent ideas.. Especially the manual trim being with normal human strength for all situations. However, this manual trim requiring super human strength problem isn't unique to the 737Max.

            I'd really like to see the manual trim forces be evaluated for certification from now on. Unless you can manually adjust the trim throughout the full flight envelope (in terms of speed and AOA) regardless of the trim setting you go back to the drawing board...

            And no, the MCAS is required for the 737Max certifica

            • by sjames ( 1099 )

              The ability to disable all automatic inputs to the electrical trim leaving the thumb switches active should be acceptable. At worst, that should leave the pilots able to safely land at a nearby airport.

      • 1. Taller landing gear
        2. New fuselage to support taller landing gear.
        3. Lower the wings relative to the fesallage Center of mass/thrust
        4. and while were at it new airspeed detectors, and new software.
        5. oh and new engines.

        Simple.

    • Re: (Score:3, Informative)

      If they would have just used the available data from the two existing AoA vanes, that would have made a big difference already. Inexplicably, they based the MCAS interventions on the data from a single sensor even though two were available, which displays a level of stupidity unheard of in civil aviation.

      Even using two sensors is not a perfect solution yet, as both can ice up simultaneously in certain conditions (which actually happened to several Airbus airplanes, causing them to pitch down violently but r

    • It says that one change is that the software must rely on 2 sensors now. I’m guessing the plane has 2 but the software on relied on one of them.
    • by ceoyoyo ( 59147 )

      They don't need a third one, they need to use the second one, which is already there. Angle of attack sensors aren't flight critical instruments unless you've got a computer depending on them. If the two indicators disagree you tell the pilot the system is broken and they need to get it fixed before they fly, or, if in the air, they're restricted to a safer flight envelope until they land.

  • But how about gears instead? Like maybe a safe landing gear?

  • by klipclop ( 6724090 ) on Monday August 03, 2020 @09:14PM (#60363121)
    Hopefully they consulted with the pilots union before the recommendations and the FAA isn't expecting them to provide feedback during the comment period. :/
    • Re: (Score:2, Insightful)

      by Anonymous Coward

      The only consultations that are happening here are between Boeing managers and their FAA farm team future hires. The sons and daughters and other relations of FAA officials are finding cushy jobs at Boeing funded non-profits and Boeing managers make sure they mention the retirement packages that Boeing hires can expect when they hit 52 and on and on.

      It's a racket. There are no pilots or engineers involved.

    • Hopefully they consulted with the pilots union before the recommendations and the FAA isn't expecting them to provide feedback during the comment period. :/

      How about consulting with the passengers union instead . . . ?

      I'm thinking a lot of passengers will comment with their wallets in their choice to not fly on a 737 MAX, whether it is safe or not.

      The brand is now toxic. Boeing's only option would be to rename it.

      Maybe . . . 737 NG . . . ?

  • by schwit1 ( 797399 ) on Monday August 03, 2020 @10:00PM (#60363223)

    This was not an accident. The crashes were clearly foreseeable given the shoddy technological design and lack of pilot training.

    This FAA stuff is fixing the technology and training moving forward. BUT, when will we see indictments of Boeing decision makers that put $$$ ahead of basic passenger safety and indictments of the FAA people that signed off on this death-trap?

    My $0.02 is that if Boeing's people are not going to be held accountable then the FAA ought to refuse to recertify the plane.

    • by gweihir ( 88907 ) on Monday August 03, 2020 @10:08PM (#60363249)

      If you are big enough, you can kill people on mass-scale and not receive any punishment.

      • by ELCouz ( 1338259 )
        You remind me of the Pinto memo... when you are big enough you do a cost–benefit analysis. Do we continue to give checks to the family of the deceased or we do a recall? Twisted!
        • by Kiuas ( 1084567 )

          I agree that it is indeed twisted but it's a feature, not a bug, of modern capitalism. Corporations are neither moral nor immoral, they are amoral by design, guided by profit and profit alone. They'll even knowingly break laws and circumvent regulations if they know that the resulting fines are less than the profit made in doing so. This has caused massive economic crashes at times around the world, not to mention the massive suffering and environmental damage going on out of sight in the developing world w

    • the FAA ought to refuse to recertify the plane.

      The recertification process is not a mechanism for punishing past sins.

      If the plane is safe to fly, it should be certified as such.

      • by HiThere ( 15173 )

        I think the question is "With the same management in place, how can you trust their next version?". If there's no accountability, then you can expect corners to be cut where they shouldn't be. Possibly not the same corners, if people are not looking where they abused the process last time, but somewhere.

      • by ELCouz ( 1338259 )
        Million dollars question: Does the FAA is still competent, after all warnings ignored to do a certification on planes?
    • by Cylix ( 55374 )

      I’m not flying on that death trap.

      They are going to spend millions on propaganda to convince people it is a safe plane.

      At least it will have the net effect of cleaning the gene pool.

      • Iâ(TM)m not flying on that death trap.

        Good news! No one is flying!

        Though, if you're really trying to say you're not going to fly in any plane with issues, you're not going to fly at all - every major model of plane has had some serious problem or other.

        After all, the 787 had exploding batteries back when it was a new plane (when exploding batteries was a trendy thing among consumer elexctronics). Airbus has had issues with their fly-by-wire systems on many models. The Bombardier CSeries (now Airbus A220 series) has had exploding engine issues.

        The 777 had mysterious engine power loss issues as well.

        A lot of it is down to training - yes there was a line about the system but it was easily missed. The same kind of line missed that lead to SpaceShipOne (Virgin Galactic) going down a few years ago, except this time by skilled test pilots who also missed a single comment in a document that lead to the tragedy. (Yes,a simple software change would've fixed the issue too).

        Heck, the plane I flew, a simple little Cessna 172 has had MANY issues over the years, I even experienced one that lead to a airworthiness directive in flight. (The biggest one was the seat rail locks - it was possible to adjust the seat but not have the locking pin go into the hole, resulting in the seat sliding all the way back during say, takeoff). My issue was related to the autopilot - it was possible to enable it accidentally and not know about it causing control issues. An AD was issued where the autopilot was fixed to sound when it's activated so accidentally turning it on wouldn't be a surprise (you can override the autopilot - that's how I kept going while I had someone else see what's wrong - the plane was flying, just the controls felt funny). And yes, I thought I broke something.

        (And if you must know, the Cessna 172 is the most popular GA aircraft out there. Heck, during the pandemic, at one point there were more Cessna 172s in the air than 737s, realizing the 737 is the world's most popular aircraft).

    • when will we see indictments of Boeing decision makers that put $$$ ahead of basic passenger safety and indictments of the FAA people that signed off on this death-trap?

      You want an American government to anihilate an American Federal organization working hand in hand with the American flagship plane manufacturer selling expensive stuff worldwide? Will never happen.

  • by gweihir ( 88907 ) on Monday August 03, 2020 @10:07PM (#60363245)

    In production. The whole issue shows deep flaws in the design processes used, the errors that killed these two planes are just the end-result. Will be interesting to see what kills the next one.

  • Well at least they're being more consistent now, which is an improvement from the days of "Let's let Boeing make their own rules for a huge flying bomb of an airplane that flies over peoples' houses, while we simultaneously make rules to outlaw Timmy's 500 gram model airplane flying out in an empty field."

  • by FeelGood314 ( 2516288 ) on Monday August 03, 2020 @10:19PM (#60363273)
    I can't see any manager signing off on the purchase of a 737 MAX. The personal risk is too high. Boeing could prove the plane was half as likely to crash as a competitors but if there is a single issue that doesn't even injure anyone but hurts profits the person who approved the purchase can kiss their career good bye. Boeing has to get a fix in for the planes they sold but I can't see them selling anymore.
    • I cannot see anyone buying tickets to fly on them either.
      • by HiThere ( 15173 )

        Expect not to know until it's time to board that the flight's been switched to another plane.

    • I can't see any manager signing off on the purchase of a 737 MAX.

      You're in an industry with razor thin margins. Managers have their hands on their pens just waiting to sign off purchases for replacement fleets which minimise the cost of retraining pilots. It costs a *LOT* to change a fleet significantly.

      The personal risk is too high.

      The personal risk is precisely zero. There are certification agencies like the FAA that make the purchasing decision a zero liability.

    • Some airlines already have them and have signed contracts to buy them. There are provisions in the contracts for delays and cancellations but some airlines are already on the hook to receive them. Right now buying additional planes beyond the contract terms is not a good idea for other reasons.
  • by swell ( 195815 ) <jabberwock@poetic.com> on Monday August 03, 2020 @10:20PM (#60363275)

    New management. Dump the marketing people and return the engineers to top management. Assign personal responsibility to every engineer for their part in design and execution of components. Reward innovation and efficiency. Encourage workers' pride in their part in making a better, safer product.

    • by Zuriel ( 1760072 )

      Assigning responsibility to engineers is pointless unless you also assign authority to engineers.

      Assigning responsibility just means you continue to ignore engineers who report issues and fire the engineer 'responsible' every time there's a crash.

    • Comment removed based on user account deletion
  • by ugen ( 93902 ) on Monday August 03, 2020 @11:10PM (#60363397)

    Based on the description of the actual required changes, they seem like minor software fixes, rather than a key architectural change required to make 737MAX airworthy. My guess is - FAA is putting on a show of taking this seriously, while trying to save Boeing's business.

    The core issue is un-airworthy physical design of 737MAX's engine nacelles and wing (as a result of the overall airframe outliving its initial constraints). Reengineering that is the only way to ensure a well designed and safe aircraft. Anything else is a bandaid and a public relations campaign.

  • by 6Yankee ( 597075 ) on Tuesday August 04, 2020 @04:23AM (#60364079)

    One of the things to come out of the Kegworth crash [wikipedia.org] was that a theory-based differences course wasn't enough, and simulator time was needed. How quickly we forget.

  • 1. You have 30 minutes to move your plane
    2. Your plane has been impounded

    That already happened, so all that has to be added at this point would just be

    3. Your plane has been crushed into a cube
    4. You have 30 minutes to move your cube

    • And all the airlines that have already purchased 737 MAX planes would like to thank you for your shortsighted solution to their problem. After all every airline can write off $121M per plane quite easily.
  • by Eravnrekaree ( 467752 ) on Tuesday August 04, 2020 @08:57AM (#60364705)

    Boeing is a good example of how Wall Street sociopathy, commoditization of workers, treating workers as expendable, and the obsession with shareholder profits destroys companies. Boeing gained its reputation through a culture of engineer focused excellence, building well designed products, high employee morale, and people who were proud of their company and felt a part of the family and highly valued. What has destroyed Boeing is very low morale, people feeling underappreciated, overworked and undervalued, and the overriding focus on short term profits. People no longer care about the company, its just a job, and therefore do not care as much about their work and do only as much as necessary.

    This is a total rebuke of the "wall street way" of outsourcing, commoditization of people, profit obsession, greed, and basically what an=mounts to sociopathic, abusive behavior.

  • https://www.nytimes.com/2019/0... [nytimes.com]

    https://projects.seattletimes.... [seattletimes.com]

    https://aviation.stackexchange... [stackexchange.com]

    https://www.youtube.com/watch?... [youtube.com]

    https://www.youtube.com/watch?... [youtube.com]

    MCAS crashed the planes, but all they had to do to save themselves was lower the slats and keep them lowered to disable MCAS.

    Or they could probably have fought against the MCAS nose downs with electric trim nose ups as the Lion Air pilot managed to do for a while and then cutoff the auto trim switches during level flight and neutral trim before

  • by tiqui ( 1024021 ) on Tuesday August 04, 2020 @11:02AM (#60365155)

    The 737Max is a fine aircraft and will be perfectly safe - after Boeing is forced to make the single change that they avoided in the first place and which lead to the disaster..... fix the paperwork. Stay with me a moment on this:

    The 737Max is not actually a 737. Boeing wanted to offer a newer plane for the 737 market with more efficiency, so they needed a bigger engine. The 737 is so low to the ground however that they had no room to simply sling a bigger one, and they could not lengthen the landing gear because then it would not retract the same way into the same spaces (driving major airframe changes in vital structures). They had to move the newer bigger engines, which shifted both the center-of-mass of the engines and the thrust lines (and had other rippling effects). The result makes the plane unstable in a way the government regs frown upon, but still perfectly flyable - plenty of military aircraft have related issues. The Max could be operated safely by properly trained pilots but is essentially NOT a 737 anymore - the raw handling characteristics are different, particularly at high angles of attack and high engine power settings. They key point is that they needed to avoid the time and money to get it approved as a NEW design, they wanted the FAA to quickly approve it as a modification of the 737, and they also wanted to sell it to airlines as a "better 737" that pilots would not need training and additional certifications to fly. If you tell the airlines "your pilots will all need training and certifications on this new type", the airlines will say "well, then I should consider your competitor's planes too since that's what was keeping me from considering them". THAT is why they had to simultaneously add the MCAS system to make the plane seem to handle like a 737, AND downplay the system to the point that many people barely knew it was there. Normally a company does not practically hide such a supposed new wonderful high tech upgrade like MCAS. Had MCAS been an honest upgrade, one would have expected Boeing to publicize it and market it, and everybody would have been aware of it. There would have been brochures saying things like "that Airbus plane doesn't have the revolutionary new safety-enhancing patented MCAS system!"

    Doing a bunch of new "fixes" to try to keep pretending this thing is a 737 will only be a bandage on a puss-filled wound. The real fix that is needed is to require Boeing to no longer call it a 737. Boeing needs to be forced to being honest about this plane; it will be very expensive but doing the right thing after first doing the wrong thing for the wrong reasons usually is. Everybody, including regulators, needs to admit is is a different plane with different handling qualities, it needs certification as a new design, and all pilots who fly it need to be qualified in this new type. The FAA also needs to come clean and admit that they have failed in their most basic duties of oversight. They've been doing hyper-regulation of everything from homebuilt 2-seater planes to the drones kids fly in their back yards while failing to properly oversee airliners that haul tons of cargo and hundreds of civilians at hundreds of mile per hour miles above the ground. Oh, and as a minor quick fix, MCAS needs to be relegated to advisory, so it warns pilots they are nearing the borders of the plane's performance envelope, and it should not be allowed to take over and prevent pilots from doing something (this MCAS behavior was a thing one used to encounter on Airbus planes but never on Boeing, so it would certainly have baffled any Boeing-certified pilot in an emergency particularly if he'd never been trained for it or advised of it).

    This was all about money: Boeing did not want to spend the money and time (more money) to cert a NEW plane. Boeing's customers did not want to spend the money getting pilots and ground crews trained and certified on a new type. Boeing did not want to risk losing money by risking long-time 737 buyers and operators looking at other planes to replace their agein

    • Humm

      The FAA had just as many yes men along for the ride as Boeing. All aircraft in the future will be designed with more natural run away trim overrides in the future. The sim time spent on it will be mininal, software will kick end users back into the middle of the flight envelope with a bit more force. It was just a clasic failure chain that can be ascribed a cost savings to pick on Boeing on. If it was a ton and half in airframe weight in a some green effort causing a problem this inquiry would

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