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Boeing has launched an in-depth investigation into a newly identified quality issue with its 787 Dreamliner aircraft, focusing on hundreds of incorrectly installed fasteners found on the fuselages of several undelivered jets. Sources familiar with the matter disclosed that this latest manufacturing setback involves more than 900 fasteners per plane, evenly distributed on both sides of the mid-body of the aircraft, and has been attributed to improper torquing procedures at a Boeing production facility.

Despite the significant number of affected fasteners, there are currently no immediate concerns regarding flight safety. However, Boeing is diligently working to determine the root cause of the problem. Once their investigation is complete, the company will decide on any necessary corrective actions. Sources, who spoke on condition of anonymity, indicated that Boeing has acknowledged the issue in response to inquiries from Reuters, reassuring stakeholders that it will not have a substantial impact on aircraft delivery schedules.

A spokesperson for Boeing stated, "Our 787 team is conducting thorough inspections of fasteners in the side-of-body area of some undelivered 787 Dreamliner airplanes to ensure they meet our stringent engineering specifications. The operational fleet can continue to safely operate.

"Throughout this process, Boeing remains in close collaboration with its customers and regulatory authorities, including the Federal Aviation Administration (FAA). The FAA has confirmed that Boeing reported potential issues with improperly installed fuselage fasteners and is actively working with the company to determine appropriate measures and implement immediate fixes within the production system.

FAA Administrator Mike Whitaker is planning to visit a Boeing 787 plant in South Carolina, where the latest manufacturing flaw was discovered. This incident specifically involves the attachment of the 787's lightweight carbon-composite skin to the fuselage's structural supports, known as longerons.

Boeing's recent challenges have intensified scrutiny on the company's manufacturing practices. This scrutiny was heightened following a January 5 incident involving an Alaska Airlines-operated 737 MAX, which was forced to make an emergency landing due to a fuselage panel issue during flight.

Despite these setbacks, Boeing continues its efforts to deliver 787 aircraft, albeit at a slower pace due to a previous, unrelated production slowdown. FlightRadar24 data confirms that a 787-10 model recently departed for a European customer, underscoring Boeing's commitment to fulfilling its delivery commitments.

However, airlines remain concerned about ongoing delays in receiving their ordered aircraft, with some customers estimating average delays extending over several months. These delays highlight the broader impact of Boeing's production challenges on its customers' operational planning and fleet management strategies.