Air India’s fleet has included the Boeing 787-8 Dreamliner since 2011. This aircraft, measuring 186 feet in length with a 197-foot wingspan, can accommodate 248 passengers. Powered by either a General Electric GEnx-1B or Rolls-Royce Trent 100 engine, it boasts an impressive range of 13,530 km. Boeing highlights the Dreamliner’s 25% reduction in fuel consumption, noting its role in transporting over one billion passengers and enabling 425 new nonstop global routes over the past 14 years.
Between 2015 and 2024, Air India’s Boeing 787 Dreamliner flights experienced 32 incidents, including engine shutdowns, flight control glitches, landing gear malfunctions, cabin smoke, communication loss, cracked windshields, cabin pressure problems, severe turbulence, altitude drops, slat malfunctions, tire bursts, and hydraulic leaks. While two of these technical issues led to accidents with passenger injuries, there were no fatalities until today’s Ahmedabad flight, which marks the first fatal crash for an Air India 787.
These incidents come amidst broader concerns about Boeing’s manufacturing practices. In January 2024, Boeing engineer Sam Salehpour, a whistleblower, filed a complaint with the Federal Aviation Administration (FAA), alleging that shortcuts were taken during the production of 777 and 787 Dreamliner jets. Salehpour claimed that crews failed to properly fill gaps when joining fuselage sections, potentially reducing the jets’ lifespan due to increased wear. He also alleged that engineers were pressured to approve work that had not been inspected. The FAA is currently investigating these serious claims.
Similar allegations regarding improper assembly prompted the FAA and Boeing to halt Dreamliner deliveries in 2021. Deliveries resumed only after an FAA inquiry and Boeing’s assurance of incorporating manufacturing process changes. Notably, no Dreamliners were grounded during that entire period.
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