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Boeing faces challenges after redesigning 737 MAX for larger engines

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Boeing faces challenges after redesigning 737 MAX for larger engines
Policy
Webp aenguskelly
Aengus Kelly CEO of AerCap | AerCap Holdings

Boeing's 737 MAX aircraft faced significant challenges following its design modifications to accommodate larger engines. The company's decision to retrofit the 737 with CFM International LEAP-1B engines on an airframe originally designed in the 1960s has been linked to two fatal crashes in 2018 and 2019. These incidents highlighted engineering and organizational issues within Boeing.

The Boeing 737, a staple of the company's commercial fleet since its first flight in 1967, was initially designed for smaller Pratt & Whitney JT8D turbofans. Over time, as engine technology advanced, Boeing adapted by re-engining the aircraft with progressively larger engines without altering the landing gear or other structural elements. This approach allowed Boeing to maintain its original type certification but led to complications when integrating the LEAP-1B engines.

In contrast, Airbus's A320 family, developed in the 1980s, was designed for larger engines from inception, easing transitions to newer models like the CFM International LEAP-1A engine.

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The Harvard Business School has suggested that cultural shifts following Boeing's merger with McDonnell Douglas in 1997 contributed significantly to these problems. The merger introduced a focus on cost-cutting over engineering innovation. Former McDonnell Douglas executive Harry Stonecipher became CEO of Boeing and emphasized running the company "like a business rather than a great engineering firm."

Despite these setbacks, there are signs of improvement at Boeing. Increased scrutiny from regulatory bodies like the FAA has prompted changes aimed at enhancing safety and quality control. The FAA continues to limit production of certain models while withholding type certificates for others.

Aer Cap's CEO noted improvements in Boeing's product quality during a CNBC interview in March 2025. However, Harvard critiques remain that leadership failures and cultural drift have undermined Boeing’s historical reputation for engineering excellence.

Organizations Included in this History
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