Boeing redesigns door plug after Alaska Airlines emergency prompts safety overhaul

In early 2024, a significant incident involving Alaska Airlines Flight 1282 brought attention to Boeing's manufacturing processes. The flight, operated by a Boeing 737 MAX 9, experienced an emergency when a mid-exit door plug detached shortly after takeoff from Portland International Airport. This resulted in rapid cabin decompression and minor injuries to seven passengers and one flight attendant.

The National Transportation Safety Board (NTSB) found that the absence of four critical bolts led to the door plug's failure. These bolts were removed during maintenance months prior and not reinstalled, highlighting human error and organizational issues at Boeing’s Renton factory. NTSB Chair Jennifer Homendy described it as a "failure of multiple layers of safety."

Following this event, Boeing and Spirit AeroSystems redesigned the door plug assembly. By June 2025, they introduced secondary retention arms and bolt lanyards to enhance mechanical integrity even if bolts are missing. Retention arms act as internal backup latches, while bolt lanyards provide visual confirmation of hardware presence.