Barnett worked his way into a lead position Barnett blamed a culture shift between the Everett and South Carolina plants on the latter's management being from the military, where he said he was pressured not to document defects and to follow non-Boeing procedures. He characterized the defense-based management's motto as "we’re in Charleston and we can do anything we want" and their wishes to, "...push planes out the door and make the cash register ring." He later said of the factory and its management, "...the whole place smelled of French fries," In 2017, Barnett filed an FAA AIR 21 whistleblower complaint against Boeing with OSHA.
Documentation and process procedures In 2013, a senior manager downgraded Barnett's employment level for "using email to express process violations" in place of face-to-face communication, which Barnett "took to mean he shouldn't put problems in writing." The manager also pushed Barnett to get better at "working in the gray areas and help find a way while maintaining compliance." Also in April 2024,
quality engineer Sam Salehpour reported similar issues after a 2021 delay of the 787 due to unacceptable fuselage gaps. Salehpour claimed that to address the flaws the company took "shortcuts" that forced the gaps closed, instead of engineering new parts. Salehpour has also filed a whistleblower complaint with the FAA against Boeing. A former Boeing mechanic, Davin Fischer, reported similar issues working on the 737. Boeing's
chief financial officer, Brian West, stated at a March 2024 investor conference, "For years, we prioritized the movement of the airplane through the factory over getting it done right. And that's got to change."
Use of defective parts and emergency oxygen equipment failure Barnett claimed that, in 2016, a
senior manager installed a scrapped, dented hydraulic tube in a plane. He filed a complaint with human resources. Boeing stated that they had investigated and did not substantiate those claims. In 2017, Barnett's team found that 25% of the oxygen systems for the 787 would fail to send oxygen through the cylinders to passengers in the case of an emergency. Barnett said that his report to management was stonewalled, so he alerted the FAA. Boeing's internal investigation found malfunctioning oxygen masks. A 2017 FAA report determined that at least 53 "non-conforming" parts were missing, and ordered Boeing to take remedial action.
Debris Barnett said that he was getting complaints about debris and various items being left inside of their planes, including tools, drawings, and fasteners. On a test flight of a 787, a ladder was found inside a horizontal stabilizer. Barnett said if it had not been found, the ladder could have fallen and caused the plane to malfunction.
Metal shavings Barnett reported that he had discovered "clusters of metal shavings", due to the process of securing titanium e-nuts, left near electrical systems for flight controls, which could have "catastrophic" results if the shavings were able to penetrate the wiring. He stated that he repeatedly urged his bosses to take action, but they instead transferred him to another part of the plant. In 2017, the FAA issued a directive mandating removal of shavings pre-delivery. Boeing claimed they were complying and working to improve the design to avoid the issue, but determined that the issue was not a flight safety issue.
Retaliation Barnett alleged that he was denied a promotion he said he was the most qualified applicant for, demoted, transferred out of his position in quality inspection into an undesirable department, and blocked from a job at
Michoud Assembly Facility, a NASA center in
New Orleans that manufactures rocket parts. == Retirement ==