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DannyB [soylentnews.org] writes:

From Ars Technica:
A new report finds Boeing’s rockets are built with an unqualified work force [arstechnica.com]

NASA declines to penalize Boeing for the deficiencies.

The NASA program to develop a new upper stage for the Space Launch System rocket is seven years behind schedule and significantly over budget, a new report [nasa.gov] from the space agency's inspector general finds. [Here is direct link to PDF of NASA report [nasa.gov]] However, beyond these headline numbers, there is also some eye-opening information about the project's prime contractor, Boeing, and its poor quality control practices.

[....] "We found an array of issues that could hinder SLS Block 1B’s readiness for Artemis IV including Boeing’s inadequate quality management system, escalating costs and schedules, and inadequate visibility into the Block 1B’s projected costs," [...]

[....] Boeing’s quality control issues are largely caused by its workforce having insufficient aerospace production experience," the report states. "The lack of a trained and qualified workforce increases the risk that the contractor will continue to manufacture parts and components that do not adhere to NASA requirements and industry standards. [...]

From the NASA report linked above . . .

[....] we found Boeing’s quality management system at Michoud does
not adhere to these standards or NASA requirements. NASA engages DCMA to conduct surveillance of Boeing’s core and upper stage manufacturing efforts at Michoud, and when deficiencies in quality are found, DCMA issues Corrective Action Requests (CAR) to the contractor. CARs are labeled Level I through IV, with Level I the least serious deficiency. From September 2021 to September 2023, DCMA issued Boeing 71 Level I and II CARs, as well as a draft Level III CAR. According to DCMA officials, this is a high number of CARs for a space flight system at this stage in development and reflects a recurring and degraded state of product quality control. Boeing’s process to address deficiencies to date has been ineffective, and the company has generally been nonresponsive in taking corrective actions when the same quality control issues reoccur.

Quality control issues at Michoud are largely due to the lack of a sufficient number of trained and experienced aerospace workers at Boeing. To mitigate these challenges, Boeing provides training and work orders to its employees. Considering the significant quality control deficiencies at Michoud, we found these efforts to be inadequate. For example, during our visit to Michoud in April 2023, we observed a liquid oxygen fuel tank dome—a critical component of the SLS Core Stage 3—segregated and pending disposition on whether and how it can safely be used going forward due to welds that did not meet NASA specifications. According to NASA officials, the welding issues arose due to Boeing’s inexperienced technicians and inadequate work order planning and supervision. The lack of a trained and qualified workforce increases the risk that Boeing will continue to manufacture parts and components that do not adhere to
NASA requirements and industry standards,

No government project is so broken that it can't be fixed by throwing more money and decades of additional time at it.

Original Submission